Abstract: A motor is provided for use in a machine. The motor includes a segmented stator comprising magnetically isolated core segments.

Abstract: A system and method for dynamically optimizing flux levels in electric motors based on estimated torque. Motor parameters and motor equations are used to estimate operating characteristics and to set current and voltage limits which define an optimal flux operating range for a given speed and torque of the motor. A slope of a linear flux gain is determined within the defined operating range at different speeds of the motor. The determined slopes for the different speeds are saved in a memory element. A control element determines and achieves an optimal flux level for the motor by accessing the table to identify a specific slope which corresponds to an actual speed of the motor, multiplying the slope by the estimated torque and adding an offset value to determine a phase current component value associated with the optimal flux level, and applying the determined phase current component value to the motor.

Abstract: An electric motor is provided. The rotor includes a rotor shaft, with a bearing rotatably supporting the rotor shaft. A bearing housing is interposed between the bearing and the motor frame assembly. The bearing housing is releasably connected to the motor frame assembly so as to be selectively secured in supporting relationship with the bearing and thereby the rotor. The motor frame assembly includes a circumferentially extending support face. The bearing housing presents a circumferentially extending engagement face which engages the support face when the bearing housing is in the supporting relationship. At least one of the faces is axially tapered to facilitate axial movement of the bearing into the supporting relationship.

Abstract: A rotor for an outer rotor-type motor is provided. The rotor includes a metallic coupler and a polymeric frame molded over at least part of the metallic coupler.

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: Rotary switches and associated methods. A rotary switch can include one or more arcuate passages which are prone to ingress of particulate or liquid contaminants. A gasket, a rib, and/or a lubricant reservoir can be provided in the arcuate passages for blocking ingress of contaminants to an interior of the switch.

Abstract: A motor controller for providing a three-phase alternating current (AC) signal to a three-phase motor. The motor controller uses current feedback from a single shunt to monitor or control the three phase AC signal. The motor controller may include a three-phase DC to AC power inverter, a single-shunt current sensor, and a processor. During individual duty cycles when two or more phase signals are too close to each other, the processor may shift one of the phase signals in time so that its leading or trailing edges are a predetermined conflict time away from each other. Then, the processor may sample current from the single-shunt current sensor to determine currents of two of the three phase signals and then calculate current of a remaining one of the three phase signals. Sample times may depend on pulse widths and shifting of the phase signals.

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 antenna assembly comprises a substrate, an impedance matching network, and a driven antenna element. The substrate includes an insulating layer and a first electrically conductive layer disposed on a top surface of the insulating layer. The impedance matching network includes a balun, a first resistor, and a second resistor. The balun converts unbalanced signals to balanced signals and vice-versa. The first and second resistors are electrically connected to the balun. The driven antenna element is formed from the first electrically conductive layer and disposed on the top surface of the insulating layer. The driven antenna element includes a body, a first arm, and a second arm with the first and second arms spaced apart from another, parallel to one another, and physically connected to opposing ends of the body. The first arm is electrically connected to the first resistor. The second arm is electrically connected to the second resistor.

Abstract: An electrical device configuration enables heat to be dissipated from a multi-layer printed circuit board (PCB) while handling electrical currents in excess of 200 amps. The semiconductor devices that convert input DC current to output AC current are mounted to a side of the PCB that is opposite the side of the PCB that receives the input DC current. A base plate that acts as a heat sink includes recessed areas to receive the semiconductor devices and enable the PCB to be positioned close to the base plate. Thermal vias are provided in the PCB to conductive heat from the semiconductor devices to the side of the PCB that receives the input current. Also, the busbars for receiving the input current are positioned to provide short resistive paths to the current to reduce the generation of heat by the current flowing in the PCB.

Abstract: A data acquisition device that can be coupled with any motor, even those already in service, to automatically monitor the operation of the motor and provide alerts when the motor is in need of repair or replacement. The data acquisition device senses conditions of the motor and transmits sensor data to a computer system or other remote monitoring device so that the remote monitoring device can determine if the motor needs to be repaired or replaced. The data acquisition device also acquires location data and sends it to the remote monitoring device so that a technician or other person can quickly locate the motor.

Abstract: A motor includes a shaft presenting a shaft lead end, a switch assembly including a switch arm shiftable between a first position and a second position, and shield structure. The shaft lead end and the switch assembly are disposed axially outward of an endshield. The shield structure is disposed axially outward of the switch arm to at least substantially restrict direct tool access to the switch arm from an axially outward position relative to the switch arm. The shield structure at least in part defines first and second tool access channels each extending radially inwardly to the shaft lead end, such that the shield structure enables direct tool access to the shaft lead end via the tool access channels but prevents or at least substantially restricts direct tool access to the switch arm via the tool access channels.

Abstract: A blower motor is provided for use in a machine. The motor includes a stator and a rotor rotatable about an axis. The stator includes a generally toroidal core, a first-main winding, and an auxiliary winding that is electrically out of phase with the first-main winding. The first-main winding and the auxiliary winding are both full pitch windings.

Abstract: An electric motor is provided. The stator includes a core and a stator cage. The stator core is comprised of a plurality of axially stacked laminations. The stator cage includes a pair of end plates positioned adjacent the axial ends of the rotor core. The stator cage also includes at least one axially extending bar that interconnects the end plates. The stator core, the end plates, and the at least one bar are interconnected to form an integral body that is supported on the motor frame. The at least one bar presents opposite ends and includes a bore that projects axially from one of the ends. The bore is exposed to facilitate lifting of the stator.

Abstract: An electric motor is provided. The motor includes a motor frame assembly including a motor frame and a motor housing. A stator is fixed relative to the motor frame assembly. A rotor including a rotor shaft is mounted in the motor frame assembly for rotational movement relative to the motor frame assembly about an axis. A rotor jack is operable to selectively support the rotor shaft. The rotor jack is shiftably coupled relative to the motor frame assembly for movement between a support position, in which the jack is shifted into supporting contact with the rotor shaft, and a retracted position, in which the jack is spaced from the rotor shaft.

Abstract: An electric motor includes a stator, a rotor, and weights removably attached to the rotor shell for use in balancing the rotor. The removable weights may be integrally formed with a rotor shell such that the weights and the rotor shell form a unitary, one-piece construction. The removable weights may be substantially uniformly spaced apart around an entirety of the outer perimeter of the rotor shell. In a method of making an electric motor, the stator is coupled to the rotor such that the weights are accessible for selective removal during balancing of the rotor.

Abstract: An enclosure for a ground ring includes an enclosure housing configured to accept a ground ring and hold the ground ring in a predetermined position around a shaft that is electrically connected to a drive shaft of an electric motor. The ground ring having a first opening for the drive shaft and the enclosure housing has a second opening for the drive shaft. The enclosure includes an attachment configured to hold the enclosure housing around the shaft to dissipate an electrical charge and to form a cavity that contains the ground ring and includes a predetermined gap between a perimeter of the second opening of the enclosure and a surface of the drive shaft.

Abstract: An electric motor assembly including a stator having a stator core and windings around the stator core is disclosed. The stator core has opposing ends and an outer surface extending between the opposing ends. The electric motor assembly also includes a housing having an inner surface enclosing at least a portion of the stator, and at least one fluid passage between the outer surface of the stator core and the inner surface of the housing. The fluid passage permits a coolant in the fluid passage to contact one or more portions of the outer surface of the stator core to remove heat from the stator core during operation of the electric motor assembly. Additional motor assemblies including stator and/or rotor cooling features are disclosed.

Abstract: A system and method for limiting the vibration of an electric motor so as to avoid situations in which extreme vibration may result in damage to the motor or other equipment. A motor control subsystem runs the motor in accordance with a command specifying a speed or torque. A vibration sensor, such as a three-axis accelerometer, senses a vibration of the electric motor, or, alternatively, software indirectly detects the vibration based on phase or torque ripple. Such vibration may be caused by, e.g., a broken fan blade or an accumulation of snow or ice. A control element receives data regarding the vibration, determines whether the vibration exceeds a pre-determined limit, and if so, takes action to reduce the vibration of the electric motor below the pre-determined limit. Such action may involve slowing or stopping the motor, thereby avoiding damage, increasing reliability, and reducing cost.

Abstract: A system-specific interface module for a motor control subassembly for controlling operation of an electric motor within a larger system which uses a particular system communication method. The motor control subassembly includes a standard power module and the interface module. The power module includes a controller processor configured to receive input for controlling and to generate output regarding operation of the motor. The interface module includes a communication interface hardware block configured to exchange input and output signals with the larger system, and an interface processor configured to translate the input and output signals between the particular system communication method used by the larger system and a standard internal communication method used by the power module. Thus, the motor control subassembly can be configured to accommodate any of a variety of different system communication methods and other input/output options by selecting and inserting the appropriate interface module.