Abstract: A motor or generator assembly including a motor or generator machine and mounting structure supporting the machine on an appliance is provided. The machine presents an axially extending, radially outermost circumferential face and a pair of axially spaced apart, radially projecting axial margins. The mounting structure includes a pair of at least substantially radially extending plates and a base configured for connection to the appliance. The plates extend at least in part adjacent respective ones of the axial margins and at least in part define a machine-receiving space therebetween. The machine is mounted on the brackets so as to be positioned at least in part in the machine-receiving space. The base is positioned at least substantially radially outside the circumferential face of the machine and presents a pair of axially spaced apart side faces, with each of the plates being secured against a respective one of the side faces.

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 motor comprising a rotor, a stator, a motor shell, a pair of motor endshields, and a controller housing is provided. The rotor is rotatable about an axis. The stator presents opposite axial ends. The motor shell extends around the axis to at least partly circumscribe the rotor and stator. Each motor endshield is positioned adjacent a respective one of the stator ends and provides support for the rotor. The fastener extends through and interconnects the stator and endshields. The controller housing defines an electronics compartment positioned radially outside the motor shell. The controller housing includes a connector that receives the fastener so as to fix the controller housing to the stator and endshields.

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.

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: Various embodiments of an electric motor and electronic control for an electric motor are disclosed. An exemplary electric motor comprises a single-phase brushless permanent magnet electric motor. In exemplary embodiments, the electronic motor control is configured to commutate an electric motor at a frequency other than line frequency, perform pulse width modulation, and drive the electric motor with a drive waveform that approximates the counter-electromotive force of the 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: A motor assembly broadly includes a motor, a motor controller, and an interface controller having an integrated power supply. The integrated power supply includes an AC to DC power conversion and voltage reduction component. The motor controller and the interface controller receive line voltage electrical power without the need for an external transformer.

Abstract: An electric motor includes a stator and a rotor. The stator has a plurality of low speed windings and a plurality of separate high speed windings. A first type of thermal overload protector is coupled with at least one of the low speed windings and a second type of thermal overload protector is coupled with at least one of the high speed windings.

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: A method of assembling a motor for use in a machine is disclosed. The motor includes an axially extending rib protruding radially outwardly from the radially outer surface of the core. The motor further includes a groove-defining portion that defines an axially extending groove receding radially outwardly from the radially inner surface of the shell. The motor assembly method includes the steps of: (a) heating at least the groove-defining portion of the shell; (b) rotationally orienting the core and the shell so as to axially align the rib and the groove; (c) axially receiving the core within the shell such that the rib is received in the groove without interfering with the groove-defining portion; and (d) cooling at least the groove-defining portion so that the rib is fit within the groove via an interference fit.

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: An HVAC system includes a heating/cooling element; an electric motor; a speed sensor; and a control device. The heating/cooling element includes a heating element, a cooling element, and heat exchangers. The motor has a rotatable shaft coupled with a blower wheel. The speed sensor senses a rotational speed of the motor shaft and the blower wheel and includes a magnet coupled with the motor shaft for rotation therewith; and a coil assembly mounted concentrically over the magnet and operable to generate an alternating signal when the magnet rotates relative to the coil. The alternating signal has an electrical characteristic that is generally proportional to the rotational speed of the shaft. The control device determines a rotational speed of the motor shaft and disables operation of the heating/cooling element when the alternating signal indicates that the rotational speed of the shaft drops below a minimum threshold speed.

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 household appliance includes a tub, in which a liquid is at least temporarily contained, and a pump assembly for effecting liquid flow within the tub. The pump assembly includes a housing including an integrally formed flow path portion defining an inlet, an outlet, and a flow path extending between and interconnecting the inlet and the outlet. The flow path portion defines a turn, such that part of the flow path extends in a direction oriented at an angle relative to the inlet axis. The pump assembly includes a rotatable impeller. The impeller includes a plurality of blades extending at least substantially radially from the impeller axis and configured to propel a fluid at least substantially axially thereby. The impeller is positioned in the flow path adjacent the inlet such that the impeller axis and the inlet axis are at least substantially parallel or at least substantially aligned.

Abstract: An overmolded stator for use in an electric motor is disclosed. The stator core includes a yoke and a plurality of arcuately spaced apart teeth extending at least substantially radially from the yoke. Each of the teeth presents opposite axially spaced apart endmost surfaces, a leg extending generally radially from the yoke, and a head extending generally arcuately relative to the leg to present opposite head ends spaced from the leg. A pair of wire retention wings extend at least substantially circumferentially outwardly relative to each of the teeth.

Abstract: A power circuit is configured with mostly passive electrical components to connect a phase shift capacitor to a phase shift winding of a PSC motor selectively. The power circuit includes a timing circuit, a switching circuit, and a triac having a first anode connected to the second capacitor and a second anode connected to electrical ground. The timing circuit has a plurality of passive electrical components and a single active comparator configured to generate a signal indicative of an expiration of a predetermined time period after application of a line voltage to the motor. The switching circuit has a plurality of passive electrical components and a single active switch, which generates a signal to operate the triac to electrically connect the second capacitor to the second winding during the predetermined time period and to disconnect electrically the second capacitor from the second winding in response to a signal generated by the timing circuit indicating the predetermined time period has expired.

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 multiphase motor is provided. The motor includes a rotor rotatable about an axis and a sectioned stator. The sectioned stator includes one or more stator sections. Each stator section has a core section including a yoke and a plurality of arcuately spaced apart teeth that extend generally radially from the yoke. The stator includes a plurality of electrically conductive wire windings. Each of the windings corresponds with a respective power phase. Each stator section is wound with each of the windings such that each stator section includes windings for all of the power phases.