Abstract: A mounting system for mounting a pressure switch to a mounting body without using screws or brackets. The mounting system includes a support physically supporting the pressure switch on the mounting body, a conduit carrying a pressure signal from the mounting body to the pressure switch, and a connector extending between and connecting the support to the conduit. The support and conduit may have ends constructed of synthetic rubber to frictionally engage support and conduit mounts, and the support and conduit may have approximately the same length and/or the same cross-sectional shape. The mounting body may be a draft inducer, a condensate collector box, or a drain trap in a furnace.

Abstract: A motor controller assembly is configured for use with an electric motor and includes a controller and an absorbent pad. The controller includes a capacitor with a capacitor shell and a liquid electrolyte contained therein. The capacitor shell has a frangible rupture area that opens during a capacitor rupture event to permit the discharge of liquid electrolyte from the capacitor shell. The absorbent pad overlies the rupture area to collect discharged liquid electrolyte.

Abstract: A spoked rotor is rotatable about an axis. The rotor includes a core. The core includes a plurality of pole segments arranged arcuately about the axis. The rotor includes a plurality of arcuately arranged magnets alternating arcuately with the pole segments, such that each of the magnets is at least in part interposed between a pair of adjacent pole segments. Each of the magnets includes a curved section extending arcuately between radially inner and outer curved section ends. An effective rotor pole location is defined on each of the pole segments. Each of the pole segments has an end opposite the effective rotor pole location. A center point is defined at the pole segment end. Each of the effective rotor pole locations is arcuately offset from a corresponding one of the center points by between about five tenths (0.5) rotor poles and about two (2.0) rotor poles.

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 including a rotor, a stator, a motor housing having a controller can, and a controller having an electronic component disposed within the controller can. The controller can includes an insert comprising thermally conductive metal for exchanging heat with an external heat sink space.

Abstract: A conveyor assembly is provided for use with a mobile vehicle. The conveyor assembly includes a conveyor module. The conveyor module includes a first roller assembly. The first roller assembly includes a first rotatable roller body and a second rotatable roller body. The first and second roller bodies are interconnected to each other in such a manner as to share a first rotational axis yet be at least substantially rotationally independent of each other, such that each of the first and second roller bodies can rotate without causing or interfering with rotation of the other of the first and second roller bodies.

Abstract: A system and method for facilitating regenerative charging of a battery by a motor drive when the battery is properly physically connected to a drive circuitry and blocking current when the battery is improperly physically connected. The system includes drive circuitry, a battery and motor drive connected to the drive circuitry, an N-channel MOSFET connected to a high side of the drive circuitry, and a FET controller including a charge pump connected to a gate terminal of the N-channel MOSFET. When the battery is properly physically connected to the drive circuitry, the charge pump is switched on and the N-channel MOSFET allows reverse current to flow from the motor drive to recharge the battery. When the battery is improperly physically connected to the drive circuitry, the charge pump is switched off and the N-channel MOSFET blocks current from flowing and damaging the battery.

Abstract: A system and method for identifying and responding to a condition in which an electric motor fails to start. A rotor core includes slots in which magnets are received to produce an electrical reluctance. A motor controller determines a position of the rotor, uses the determined position to convert a torque demand to a demanded D-axis current value, and compares the demanded value to a supplied D-axis current value. If the demanded value differs from the supplied value by at least a pre-established threshold amount, then the motor is restarted. Otherwise, the difference between the torque demand and an actual current is used to drive a voltage applied to the motor. The controller may also implement a sensorless technology, and may restart the motor if the demanded value differs from the supplied value by at least the threshold amount even if the sensorless technology determines that the motor started.

Abstract: A rotor assembly for an electric machine includes a rotor core that is fabricated from a plurality of laminations stacked along a rotational axis of the electric machine. The rotor core has a plurality of arcuately arranged, axially extending magnet-receiving slots. The rotor core includes a plurality of magnets received in respective ones of the magnet-receiving slots. Each of the laminations includes opposed deflectable magnet-retaining prongs that extend into a corresponding one of the magnet-receiving slots. The magnet-retaining prongs are deflected by and engage the magnets to exert a reactive force against the magnets and hold them in place. Each of the laminations also includes respective support posts axially adjacent the magnet-retaining prongs. The support posts extend alongside and thereby limit the deflection of the magnet-retaining prongs when engaged with the corresponding one of the magnets.

Abstract: A slinger for an electric motor broadly includes a hub and a wheel. The motor includes a housing in which a stator and rotor are at least partly housed. The motor also includes a rotatable output shaft projecting upwardly through a shaft opening in the housing. The hub is fixedly attachable to the output shaft of the motor so that the slinger rotates with the output shaft. The wheel is configured to divert liquid radially away from the shaft opening. The wheel includes a wheel plate and a plurality of radially extending blades cooperatively forming a series of passages extending radially outward relative to the shaft opening, when the hub is attached to the output shaft. The wheel plate is supported by the hub so as to be positioned above the housing when the hub is attached to the output shaft. The blades present radially inboard ends intersecting the hub.

Abstract: A gearmotor includes a motor assembly, a gear assembly, and an electronics assembly. The motor assembly includes a rotor including a rotor shaft; a stator; and a stator retention apparatus. The stator includes a core defining a core orientation feature, and a plurality of coils. The stator retention apparatus includes an apparatus orientation feature and an electronics assembly support structure. The gear assembly includes an output shaft. The electronics assembly includes a rotor shaft rotation sensor that is radially spaced from a rotor shaft position indicium, an output shaft rotation sensor that is radially spaced from an output shaft position indicium, and a magnetic sensor mounted to the electronics assembly support structure. The core orientation feature and the apparatus orientation feature engage one another to position the stator retention apparatus radially and arcuately relative to the core, such that the magnetic sensor is positioned adjacent an axial coil margin.

Abstract: An electric motor includes a stator assembly and a rotor assembly. The rotor assembly includes a rotor shaft that is rotatable relative to the stator assembly about a rotation axis. The motor also includes an endshield, a bearing assembly rotatably supporting the rotor shaft on the endshield, a shaft ground assembly electrically coupled to the rotor shaft, and a bearing lockplate. The bearing lockplate is fixedly coupled to the endshield. The shaft ground assembly is supported by the bearing lockplate on the endshield.

Abstract: A method and apparatus serve to mount a calibrated encoder assembly to an electric motor so that a sensor output signal waveform produced by the calibrated encoder assembly is aligned with a back electromotive force (BEMF) waveform of the electric motor. The calibrated encoder assembly is fixed to an alignment plate, which is attached to the electric motor. The electric motor is rotated using a servo driven functional tester and the BEMF waveform of the electric motor is measured. The sensor output signal waveform is measured, and the alignment plate is adjusted relative to the electric motor to align the sensor output signal waveform to the BEMF waveform. The alignment plate is secured to the electric motor in the adjusted orientation.

Abstract: A method of electrically grounding a rotor shaft of an electric motor includes removing a first lockplate fastener from a motor endshield and an internal bearing lockplate. A second lockplate fastener remains coupled to the motor endshield and internal bearing lockplate such that the internal bearing lockplate stays secured along an interior side of the motor endshield. A mounting plate of a shaft ground assembly is positioned along an exterior side of the motor endshield. The mounting plate supports a shaft ground that includes a conductive element configured to electrically couple to the rotor shaft. The first lockplate fastener is replaced with a first mounting plate fastener coupled to the mounting plate, motor endshield, and bearing lockplate to secure the mounting plate to the endshield and to secure the bearing lockplate along the interior side of the motor endshield.

Abstract: An electric motor assembly includes a stator, rotor, housing, rotatable shaft, and cooling fan. The stator and rotor are at least partly housed in the housing. The shaft is associated with the rotor to rotate about an axis. The cooling fan is fixed to and thereby rotates with the shaft to induce airflow within the housing. The cooling fan includes a wheel plate projecting radially relative to the shaft. The cooling fan further includes a plurality of radial blades that project axially from the wheel plate. The blades define a series of radial channels. The wheel plate defines an axial plate opening therethrough in alignment with a respective one of the channels.

Abstract: A rotor assembly for an electric machine includes a rotor core that is fabricated from a plurality of laminations stacked along a rotational axis of the electric machine. The rotor core has a plurality of arcuately arranged, axially extending magnet-receiving slots. The rotor core includes a plurality of magnets received in respective ones of the magnet-receiving slots. Each of the laminations includes opposed deflectable magnet-retaining prongs that extend into a corresponding one of the magnet-receiving slots. The magnet-retaining prongs are deflected by and engage the magnets to exert a reactive force against the magnets and hold them in place. Each of the laminations also includes respective support posts axially adjacent the magnet-retaining prongs. The support posts extend alongside and thereby limit the deflection of the magnet-retaining prongs when engaged with the corresponding one of the magnets.

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 endhsield. 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 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.