Abstract: An electric motor for a pump is provided. The electric motor includes a motor controller configured to convert alternating current (AC) power supplied to a variable frequency variable voltage power for driving the electric motor at a motor output according to a commanded motor output. The motor controller includes an inverter configured to generate the variable frequency variable voltage power according to the commanded motor output and a microcontroller coupled to the inverter. The microcontroller is configured to control the inverter to operate at a first switching frequency when the motor output is less than a threshold motor output and control the inverter to operate at a second switching frequency when the motor output is greater than the threshold motor output, wherein the second switching frequency is less than the first switching frequency.

Abstract: A blower comprising a blower housing, a blower wheel, and a motor. The blower wheel is within the blower housing and has a plurality of blades. The motor is operatively connected to the blower wheel to rotate the blower wheel about an axis of rotation. The blower housing comprises a wall perpendicular to the axis of rotation. The wall has a static tap hole having a leading edge and a trailing edge. The static tap hole is positioned near an axial side of the blower wheel such that as the blower wheel rotates, any of the blades of the blower wheel passes the leading edge of the static tap hole before passing the trailing edge of the static tap hole. The wall comprises a protrusion protruding axially from the wall and toward the blower wheel. The protrusion is located adjacent the trailing edge of the static tap hole.

Abstract: One aspect of the disclosure includes a fluid moving system. The fluid moving system includes a fluid moving apparatus configured to convey a fluid through a housing from an inlet to an outlet. The fluid moving system includes an active cleaning device configured to neutralize or remove at least a portion of an undesired matter from the fluid conveyed through the housing. The fluid moving system includes an electric motor including a rotor coupled to the fluid moving apparatus and configured to turn the fluid moving apparatus upon application of electric power to a stator of the electric motor. The fluid moving system includes a motor controller communicatively coupled to the electric motor and configured to control at least one of a speed output or a torque output thereof.

Abstract: A health monitor circuit for an electric machine includes a plurality of sensors, a rectifier, a memory device, and a microprocessor. The plurality of sensors includes a current transformer configured to be electromagnetically coupled to an electrical conductor that feeds a stator winding of the electric machine. The rectifier is coupled to the current transformer and is configured to convert an AC signal generated by the current transformer to a DC signal to supply power for the health monitor circuit. The microprocessor is coupled to the memory device and the plurality of sensors. The microprocessor is configured to periodically collect a stator current measurement from the current transformer and write the stator current measurement to the memory device.

Abstract: An electric machine assembly includes a housing defining an inner cavity, a rotatable shaft extending through the inner cavity, and at least one electrical component positioned within the cavity. The electric machine assembly also includes an internal fan coupled to the shaft and positioned within the inner cavity such that rotation of the fan provides a cooling airflow to the at least one electrical component.

Abstract: A motor controller for an electric motor is provided. The motor controller includes an inverter configured to supply current to stator windings of the electric motor. The motor controller further includes a plurality of sensors configured to generate a sensor signal in response to detecting a parameter. The sensor signal represents a measured parameter. The motor controller further includes a processor coupled in communication with the inverter and with the plurality of sensors. The processor is configured to, in a first mode, transmit a control signal to the inverter to operate the electric motor at a first frequency. The processor is further configured to receive the sensor signal from the plurality of sensors. The processor is further configured to determine a first fault condition is present at the electric motor based on the measured parameter represented by the sensor signal.

Abstract: A rotor assembly for use with an electric machine assembly includes a plurality of magnets and a rotor frame having a pair of opposing end plates and a plurality of circumferentially spaced longitudinal members extending between the opposing end plates. The opposing end plates and the plurality of longitudinal members combine to define a plurality of openings that are each configured to receive a magnet of the plurality of magnets. At least one of the opposing end plates includes a plurality of fins extending therefrom in a direction opposite the longitudinal members.

Abstract: An electric motor system is provided. The electric motor system includes a drive circuit including an inverter configured to supply variable frequency current over a first duration and a switch configured to supply line frequency current over a second duration. The electric motor system further includes an electric motor coupled to the drive circuit and a controller communicatively coupled to the drive circuit. The controller is configured to control the inverter to supply variable frequency current to the electric motor over the first duration, determine to control the drive circuit to transition from supplying variable frequency current to supplying line frequency current, measure at least one parameter of the inverter, compute, based on the at least one measured parameter, an adjustment to a default parameter to enable the inverter to reach a threshold output frequency, and operate the inverter based on the computed adjustment to the default parameter.

Abstract: A rotor assembly is disclosed, including a rotatable rotor shaft defining a central axis, the rotor shaft coupled to a rotor core, the rotor core including a plurality of rotor pole pieces circumferentially located about the central axis, each pair of adjacent pole pieces being separated by a space, said rotor core comprising a plurality of core magnets located in the spaces separating the adjacent pole pieces; at least one magnet retainer plate positioned adjacent the rotor core and connected to the rotatable rotor shaft, the at least one magnet retainer plate including a plurality of circumferentially spaced magnet slots and balancing slots located between adjacent magnet slots, the balancing slots configured to receive a balancing weight; and, compression springs located in the balancing slots, each compression spring located adjacent a respective core magnet when the at least one magnet retainer plate is located adjacent the rotor core.

Abstract: An electric motor system is described. The electric motor system includes a drive circuit configured to supply variable frequency current and a contactor configured to supply line frequency current, wherein the drive circuit includes a three-phase inverter and an H-bridge including two phases of the inverter. The electric motor system also includes an electric motor and a controller. The controller is configured to control the inverter to supply variable frequency current to the electric motor over a first duration and determine to control the drive circuit to transition from supplying variable frequency current to supplying line frequency current. The controller is also configured to determine a polarity of a sensed alternating current (AC) voltage, disable at least two switches of the H-bridge, and control the contactor to close, thereby preventing the contactor and the inverter from energizing the electric motor at the same time once the contactor is closed.

Abstract: An electric machine includes a housing having an air intake, an air outlet, and defining an air passage therein. The air passage includes a first channel extending from the air intake in a radial direction and a second channel extending in the radial direction to the outlet. The electric machine further includes a motor assembly positioned within the housing that includes a shaft that rotates about a rotational axis that is generally perpendicular to the radial direction. The electric machine further includes an electronics assembly within the housing interior and a heat sink positioned at least partially within the air passage and thermally connected to the electronics assembly. Operation of the motor assembly draws an ambient airflow into the air passage in the radial direction through the air intake, directs the airflow along the heat sink, and exhausts the airflow through the air outlet in the radial direction.

Abstract: A centrifugal blower assembly including a blower housing having a scroll wall defining a blower chamber, the scroll wall extending circumferentially between a cutoff point to an end point defining a blower circumference, the blower housing further having a surface adjacent to the cutoff point; and a modular cutoff configured to attach to the surface of the blower housing, the modular cutoff having an abutting surface and a cutoff surface configured to extend the cutoff point of the blower by the cutoff surface to an extended cutoff surface. The abutting surface of the modular cutoff further includes an attachment feature configured to mate to an attachment feature of the blower housing.

Abstract: An electrical machine assembly including a housing, a shroud, and a terminal box coupled to the housing. The terminal box includes a base having an outer wall extending therefrom, wherein the outer wall includes a distal edge that is correspondingly shaped with the housing such that the outer wall engages with the housing and with the shroud to form a seal.

Abstract: An HVAC system including a multi-capacity compressor, and a control system for the multi-capacity compressor are described herein. The control system includes an AC line voltage source, a variable-voltage variable-frequency drive, and a processor. The AC line voltage source is configured to operate the multi-capacity compressor. The variable-voltage variable-frequency drive is coupled to the AC line voltage source and is configured to operate the multi-capacity compressor at a variable speed. The processor is coupled to the AC line voltage source and the variable-voltage variable-frequency drive, and is configured to selectively couple the AC line voltage source and the variable-voltage variable-frequency drive to the multi-capacity compressor to operate the multi-capacity compressor. The processor is further configured to transmit a capacity control signal to the multi-capacity compressor.

Abstract: A fuse holder is disclosed. The fuse holder includes a housing having a fuse compartment and termination compartments, each termination compartment having a cable termination aperture for receiving a cable and a lock pin slot; a bus assembly disposed including current bars having a first end and a second end extending from the termination compartment to the termination compartment, the first end having fuse contacts extending from the first end, the second end including a barb extending from the second end; and, push-in clamps disposed within the termination compartment, the push-in clamps normally biased against the barbs; wherein insertion of an electrical cable into the cable termination aperture depresses and elastically deforms the push-in clamp such that a gap is formed between the barb and the push-in clamp, wherein the push-in clamp continuously applies a biasing force against the electrical cable non-removably clamping the cable into the termination aperture.

Abstract: A combustion air blower includes a blower housing, an impeller fan within the blower housing, and an embossment to restrict airflow from the combustion air blower. The blower housing has a discharge conduit defining a discharge passageway. The discharge conduit is adapted and configured to receive a baffle such that, when the baffle is received, the baffle extends inwardly into the discharge passageway from a first wall towards a second wall opposite the first wall. The baffle restricts airflow within the discharge passageway. The embossment is in the discharge passageway and in the second wall and extends towards the first wall such that the embossment restricts airflow within the discharge passageway. The embossment cooperates with a baffle to provide a reduced cross sectional area of the discharge passageway in comparison to an upstream portion.

Abstract: A motor controller for a pump motor is provided. The motor controller includes an input device and a memory configured to store a plurality of actuation sequences and a plurality of commands. Each actuation sequence is associated with a command. The motor controller further includes a processor coupled to the input device, the memory, and the pump motor. The processor is configured to detect at the input device, a first actuation sequence in response to the input device being actuated. The processor is further configured to perform a lookup in the memory to determine a first command corresponding to the first actuation sequence. The processor is further configured to operate the pump motor according to the first command.

Abstract: A motor controller for an electric motor is provided. The motor controller includes a voltage limiting circuit configured to be coupled to an alternating current (AC) source and is configured to limit a voltage at an output node of the AC source, a filter configured to be coupled to the AC source and is configured to produce a filtered line frequency AC signal, a rectifier coupled to the filter and configured to produce a direct current (DC) signal from the filtered line frequency AC signal, an inverter coupled to the rectifier and configured to produce an AC signal on an input node of the electric motor, and a line contactor coupled between the AC source and the input node of the electric motor and configured to supply the input node of the electric motor directly from the AC source to energize stator windings therewith when the inverter is disabled.

Abstract: An interface module and methods for controlling a motor in a heating, ventilation, and air conditioning (HVAC) system are provided. The interface module is configured to determine an operating mode selected from a plurality of operating modes of the HVAC system based on at least one signal received from at least one of a first device and a second device, determine a motor operating parameter at which to operate the motor based on the determined operating mode, and control the motor in accordance with the motor operating parameter.

Abstract: Methods and systems for controlling an electric motor using a motor controller including a processor are provided. The method includes transmitting, by the processor, a no-spin signal commanding the electric motor not to spin, receiving temperature information associated with a temperature of the electric motor, comparing the temperature information to a predetermined threshold temperature to determine whether the temperature is at a sufficient level to prevent icing, and adjusting current applied to the electric motor when the temperature measurement is below the predetermined threshold.