Abstract: A motor includes a shaft rotatable about an axis, an engaged component engaged by the shaft, a sleeve fixed to the shaft to rotate therewith, and a seal at least partly circumscribing the shaft. The shaft includes an engagement region presenting a substantially variable outer shaft surface that at least in part engages the engaged component. The sleeve includes a first section that at least partly circumscribes and engages the engagement region of the shaft. The first section of the sleeve presents an outer seal-engaging surface and an outer bearing-engaging surface. The seal and the bearing each at least partly circumscribe the engagement region of the shaft and the first section of the sleeve to engage the seal-engaging surface and the bearing-engaging surfaces, respectively, of the sleeve.

Abstract: A gearmotor assembly includes a housing, a rotatable shaft, a bearing, a retaining member, and a seal. The housing defines a gear chamber configured to contain a lubricant. The bearing rotatably supports the shaft. The bearing is disposed between the housing and the shaft. The retaining member at least in part restricts axial shifting of the bearing. The retaining member presents a plurality of retaining member threads. The housing defines a plurality of housing threads threadably engaging the retaining member threads. The retaining member and the housing cooperatively at least in part define an interface. The interface includes a threaded portion and an additional portion. The threaded portion is cooperatively defined by the retaining member threads and the housing threads. The additional portion is fluidly interconnected to the threaded portion.

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: A stator for use in an electric motor is disclosed. The stator comprises an annular core, a plurality of wedges, and a plurality of wedge-retaining structures. The core includes a plurality of arcuately spaced apart teeth. Each of the teeth includes a generally radial leg and a head projecting from the leg to present a pair of arcuately spaced apart head ends. A slot opening is defined between the opposed head ends of each adjacent pair of teeth. Each of the wedges is received within a corresponding slot opening. Each wedge-retaining structure is at least in part fixed relative to the core and cooperates with a respective one of the wedges to compressibly retain the respective wedge between the head ends.

Abstract: A motor controller for an electric motor having a stator and a rotor. The motor controller includes a power input for receiving AC power from a power source; a control input for receiving a control signal from a control; and circuitry for switching power from the power source to the electric motor in response to the control signal. The circuitry is operable to: apply a driving waveform to the stator to cause rotation of the rotor; remove the driving waveform from the stator to cause the rotor to coast and eventually stop; apply a stop detection waveform to the stator while the rotor is coasting, wherein the stop detection waveform induces a waveform on the rotor which in turn induces a waveform back to the stator while the rotor is rotating; and monitor the stator to detect a characteristic of the waveform induced back to the stator to detect when the rotor has substantially stopped rotating.

Abstract: A system for protecting an inrush resistor by determining whether an inrush relay connected in parallel with the resistor properly closes. A differential amplifier connected across the resistor produces an output signal that is proportional to the differential voltage. A control circuit determines whether the relay is open based on the output signal, and if the relay is open and the motor is running, takes remedial action to protect the inrush resistor. Alternatively, the amplifier is replaced with a slow response filter that produces an output signal that is a delayed version of a bus voltage. The control circuit determines the difference between the bus voltage and the output signal, and if it exceeds a predetermined value and the motor is running, takes remedial action to protect the inrush resistor. Remedial action may include shutting off the motor or restarting the motor to confirm improper behavior of the relay.

Abstract: An electric motor is provided. The electric motor comprises a stator and a rotor rotatable about an axis and spaced at least in part radially outside the stator. The rotor includes a plurality of arcuately spaced apart pole segments, a plurality of arcuately spaced apart magnets alternately arranged with the pole segments such that each of the pole segments is positioned between an adjacent pair of the magnets, a rotor can at least in part supporting the pole segments and the magnets, and a plurality of pegs. Each of the pole segments defines an opening therethrough and includes a generally arcuately extending wall structure positioned radially outside of and at least in part defining the opening. Each of the pegs extends through a corresponding one of the openings to secure a corresponding one of the pole segments relative to the can.

Abstract: A motor is cooled with a coolant. The motor includes a rotor rotatable about an axis, a stator including a stator core and windings wound about the stator core, a housing enclosing at least a portion of the stator, and a resiliently deflectable spray ring extending circumferentially relative to the axis. The spray ring defines at least one orifice configured to direct coolant on the stator. The spray ring presents first and second arcuately spaced apart ends defining a gap therebetween.

Abstract: A motor includes a rotor rotatable about an axis, a housing defining a motor chamber receiving at least a portion of the rotor, and a bearing assembly rotatably supporting the rotor on the housing. The housing includes a pair of axially spaced apart endshields. The bearing assembly includes a bearing and lubricant collection structure associated with the bearing. The lubricant collection structure defines a collection chamber configured to collect lubricant from the motor chamber and direct the lubricant to the bearing.

Abstract: Methods and systems for replacing HVAC blower motors and other electric motors are disclosed including systems and methods for gathering and storing information about motors that may need to be replaced, systems and methods for selecting replacement motors, and systems and methods for programming the replacement motors. The systems and methods allow a select few replacement motors to be programmed to replace nearly any original motor.

Abstract: A location and retention component is provided for positively locating an overspeed guard and retaining a centrifugal actuator at an optimum positional relationship relative to each other. The system includes a first and second retention element removably engagable to the output shaft of a motor and axially fixable to the shaft at corresponding locations to maintain the optimum positional relationship. The first retention element serves as a positive stop for assembling the overspeed guard on the motor shaft, while the second retention element ensures that the centrifugal actuator is properly placed within the overspeed guard.

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: A motor controller for an electric motor having a stator and a rotor. The motor controller includes a power input for receiving AC power from a power source; a control input for receiving a control signal from a control; and circuitry for switching power from the power source to the electric motor in response to the control signal. The circuitry is operable to: apply a braking waveform to the stator while the rotor is rotating; monitor a reactive power of the stator; detect an increase in the reactive power of the stator to determine the rotor has substantially stopped rotating; and remove the braking waveform from the stator in response to detecting the increase in the reactive power.

Abstract: An electric motor is provided. The motor is mountable to a machine. The motor includes a rotor rotatable about an axis, a stator, a housing, and a fastener. The housing includes a first endshield and a controller can, with the stator being positioned axially between the endshield and the can. The fastener extends through and interconnects the first endshield, the stator, and the can. The fastener projects axially beyond at least one of the first endshield and the can for connection to the machine.

Abstract: A system for wirelessly programming and diagnosing a motor includes a server computer system, a portable electronic device, and a wireless communication device. The server computer system stores motor operating parameters and other motor data that can be accessed by the portable electronic device over a wireless communication network for identifying a suitable replacement motor for an unserviceable motor. The server computer system also generates motor programming instructions for programming the replacement motor to emulate the unserviceable motor. The portable electronic device wirelessly transmits the motor programming instructions to the wireless communication device for storing the motor programming instructions on a memory of a controller of the replacement motor so that the replacement motor will emulate the unserviceable motor.

Abstract: A method is provided for storing data from an external device in a dynamoelectric machine assembly (i.e., an electric motor or generator). The dynamoelectric machine assembly includes a memory device and a processor for controlling operation of the dynamoelectric machine assembly in response to commands from an external device. The method includes receiving a command from the external device to store data in the memory device of the dynamoelectric machine assembly, and storing the data in the memory device in response to the command. Dynamoelectric machine assemblies, external devices and systems suitable for use in the provided method are also disclosed.

Abstract: An electric motor system has a motor having motor windings and a motor housing. The motor is a variable speed permanent magnet motor configured to drive a load which is part of a residential or commercial machine. A motor control subsystem includes a power module electrically connected to the motor windings. A common mode inductor is electrically interposed between the motor control subsystem and the motor windings so as to present a high impedance obstacle to common mode transients and to reduce an electromagnetic interference effect of an inherent capacitance of each of the motor windings. The common mode inductor is an air core inductor located substantially within the motor housing, and takes the form of additional turns added to the end of each of the motor windings.

Abstract: Methods and systems for replacing HVAC blower motors and other electric motors are disclosed including systems and methods for gathering and storing information about motors that may need to be replaced, systems and methods for selecting replacement motors, and systems and methods for programming the replacement motors. The systems and methods allow a select few replacement motors to be programmed to replace nearly any original motor.

Abstract: A system and method of avoiding hunting behavior by a motor around disallowed speed ranges. A sensor or sensorless method determines the motor's actual speed. A memory contains lower and upper speed values that define a disallowed range. A control unit determines whether the motor is operating under a limiting condition and engaged in hunting behavior by determining whether the motor is repeatedly moving between an actual speed that is within the disallowed range and an actual speed that is at or below the lower speed value during a first period, and if so, sets a temporary speed limit for the motor at the lower speed value for a second period. The first period may be the time required for the motor to change its actual speed a few times and thereby confirm hunting behavior. The second period may be sufficiently long that the limiting condition may have changed.

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.