Abstract: A system and method for controlling a speed of a permanent magnet AC motor (38) based on a delay angle of a triac-controlled AC voltage signal (66) from a triac (34). A simulated load (54) connected to the triac (34) enables a load current and creates the signal (66). A first detector (48) detects a zero-crossing point of the AC voltage signal, and a second detector (50) detects a subsequent turn-on instance of the triac (34). A speed command generator (52) measures an interval between the zero-crossing point and the subsequent turn-on instance, and converts the delay angle to a speed command for controlling the speed of the motor (38). The simulated load (54) may include resistors (70) having a resistance which causes the load current to be below a holding current rating of the triac (34), thereby causing the triac (34) to turn off after the interval has been measured.

Abstract: An electric motor comprising a rotor rotatable about a rotor axis and a stator at least substantially circumscribing the rotor is provided. The stator includes a generally toroidal core including a plurality of arcuately spaced apart, radially inwardly extending teeth. Each of the teeth presents a radially innermost face that extends along a curved contour. A portion of the contour has a radius of curvature that corresponds to a circle having a center. The center is radially offset from the rotor axis. Furthermore, each of the teeth includes a radially extending arm having an end and a crown extending relative to the end. The crown presents a pair of arcuately spaced apart endmost tips, each of which has a rotor-facing side. The rotor-facing side includes a tapered portion that turns away from the rotor.

Abstract: A method of estimating an input power of a motor comprises determining an output power of the motor; determining a speed of the motor; calculating a scaling factor as a function of the speed of the motor; and estimating the input power as a function of the scaling factor and the output power.

Abstract: A system and computer-implemented method for reducing an angle error in an estimated position of a rotor over various loads on an electric motor or type of electric motor. Electrical parameters of an electric motor are measured, a true rotor position is found, and sensorless gains based on the measured parameters are generated, including determining a sensorless angle. Data is gathered at multiple torque levels for at least one speed of the motor, including for each torque level, trying different inductance values, and determining an inductance value that results in an angle error of zero. The angle error is the difference between the true rotor position and the sensorless angle. The inductance value that results in an angle error of zero for each speed may be saved in an electronic memory and used to better control the motor or other motors of the same type.

Abstract: A stator of an electric motor includes a core and a covering overmolded on the core. The mold for overmolding the covering on the core includes first and second cavity-defining portions and pluralities of first and second pins extending at least generally toward opposite ones of the cavity-defining portions. The cavity is configured to receive the core therein. The first pins and the second pins are configured to extend into the cavity when the mold is in the closed position to cooperatively at least in part secure the core in the cavity.

Abstract: A system in which the operation of an electric motor is controlled by electronically controlled switches. The system includes the motor having a run winding and a start winding, a heating component, and a motor control subsystem. A control unit closes a first switch to energize the run winding, closes a second switch to energize the start winding, determines based on an amplitude and a lag time of a current flowing through the motor whether the motor has started and is running normally, and if so, opens the second switch to de-energize the start winding and closes a third switch to activate the heating component. The control unit determines whether the motor has started and is running normally by comparing the real time amplitude and lag time of the current to a plurality of stored amplitudes and lag times associated with different operating conditions.

Abstract: A motor includes a housing, a shaft, a bearing, a bearing plate, and a seal. The housing includes first and second housing components directly engaging one another along a housing interface. The housing at least in part defines a sealed chamber. The shaft is at least in part received in the chamber. The bearing rotatably supports the shaft. The bearing plate defines a bearing housing at least substantially receiving the bearing. The housing circumscribes the bearing plate such that the bearing plate is enclosed within the housing. The bearing plate is fixed to a supporting one of the housing components and directly engages the supporting one of the housing components along a bearing plate interface. The seal is disposed along at least one of the interfaces.

Abstract: An electric motor assembly includes a rotor, a stator, and a gear assembly. The gear assembly includes a drive gear, a ring gear, and an intermediate gear disposed between and engaging each of the drive gear and the ring gear. The gear assembly further includes a carrier supporting the intermediate gear and being fixed relative to the stator so as to be stationary relative thereto. The ring gear is rotatable relative to the carrier and the stator.

Abstract: Electric motors are disclosed. The motors are preferably for use in an automated vehicle, although any one or more of a variety of motor uses are suitable. The motors include lift, turntable, and locomotion motors.

Abstract: An electric fan includes a plurality of blades and an electric motor for rotating the blades. The electric motor includes a stator and a rotor rotatable relative to the stator about an axis. The rotor includes a backing ring and a diecast rotor can. The can includes a non-machined sidewall that is diecast integrally as part of the rotor can. The sidewall extends about the axis. The rotor can is diecast in an overlying relationship with at least part of the backing ring, with the sidewall and backing ring being securely interengaged so as to restrict relative shifting therebetween.

Abstract: A system and method for starting electric motors. A controller attempts to start a motor without applying a brake to the rotor. If the motor fails to start, the controller applies a strength of braking and then again attempts to start the motor. If the motor still fails to start, the controller iteratively increases the strength of braking and attempts to start the motor until a maximum strength of braking and/or a maximum number of attempts to start the motor is reached. Alternatively, a sensing system first determines whether the rotor is rotating. If the rotor is rotating, the sensing system determines the speed of rotation, the controller determines a strength of braking that will halt the rotation based on the speed of rotation, applies that strength of braking to halt the rotation of the rotor, and then attempts to start the motor.

Abstract: A power supply generates power factor corrected power from AC power having one or more phases and different levels of output voltages. The power supply includes a power factor correction circuit that charges a capacitor through at least one inductor. Each inductor of the at least one inductor is independently connected to the capacitor to charge the capacitor with rectified power.

Abstract: Indicator circuit having a backlight and an indicator light associated with a graphical element. The graphical element is adapted to be illuminated by the indicator light for indicating an active vehicle function as well as backlit by the backlight. A switch coupled to the backlight selectively turns OFF the backlight in response to a drive signal supplied by the indicator light. In this manner, the backlight is OFF when the graphical element is illuminated by the indicator light.

Abstract: A system and method for wirelessly communicating with an HVAC motor or other motor in order to manage the motor with regard to, e.g., identifying a suitable replacement for, programming, monitoring and/or diagnosing, and/or tuning or otherwise reprogramming the motor without physically connecting to the motor. A technician uses a software application on a smartphone, tablet, or other portable device to communicate with the motor controller via a wireless communication device incorporated into the motor assembly. The smartphone may receive relevant information, such as identification, programming, or diagnostic information, and process the information or wirelessly transmit the information to a server for processing. Based on the information, the smartphone may transmit programming instructions to the motor controller via the wireless communication device. Further, the wireless communication device may transmit sensor data associated with the motor to allow for monitoring the motor's performance.

Abstract: A motor assembly is provided for powering a blower operable to generate fluid flow. The motor assembly includes a motor, a controller assembly, and a flow director. The motor includes a rotor rotatable about an axis. The rotor includes a rotatable support body, a plurality of arcuately spaced apart magnets, and a magnet retention ring at least in part securing the magnets relative to the support body. The controller assembly includes a controller and a controller case at least substantially housing the controller. The controller extends lengthwise to present opposite first and second sides at least in part spaced from the controller case. The flow director and the controller case cooperatively direct fluid received from the blower along a flow path that at least in part extends along each of the first and second sides of the controller.

Abstract: Electric motors are disclosed. The motors are preferably for use in an automated vehicle, although any one or more of a variety of motor uses are suitable. The motors include lift, turntable, and locomotion motors.

Abstract: An electric motor having a rotor, a stator, a case at least partially enclosing the rotor and the stator, and a lead connector. The lead connector includes a body having a base, a terminal end, and an intermediate portion extending between the base and the terminal end. The lead connector also includes a first sealing interface extending substantially circumferentially about the intermediate portion and a second sealing interface abutting the case.

Abstract: A seal assembly for a longitudinally extending cable comprises a gland shiftable between an unsealed position and a sealed position, and a receiver including an inner portal-defining wall that defines a portal configured to receive at least a portion of the cable. The gland is at least in part received within the portal when in the sealed position. The receiver defines a radially extending, annular receiver face. The gland includes a tapered body configured to circumscribe the cable. The gland further includes a head including an outwardly extending flange. The flange presents a radially extending, annular seal face that engages the receiver face when the gland is in the sealed position. The tapered body presents an axially tapering outer wall that is spaced in its entirety radially inwardly from the portal-defining wall when the gland is in the sealed position, such that an annular buffer is defined therebetween.

Abstract: Electric motors are disclosed. The motors are preferably for use in an automated vehicle, although any one or more of a variety of motor uses are suitable. The motors include lift, turntable, and locomotion motors.

Abstract: Electric motors are disclosed. The motors are preferably for use in an automated vehicle, although any one or more of a variety of motor uses are suitable. The motors include lift, turntable, and locomotion motors.