Abstract: A drive circuit for an electric motor includes a first filter, a rectifier, an inverter, and a line contactor. The first filter is configured to be coupled to an AC source and produces a filtered line frequency AC signal. The rectifier is coupled to the filter and produces a DC signal from the filtered line frequency AC signal. The inverter is coupled to the rectifier and produces an AC signal on an output node of the inverter. The AC signal is supplied to the electric motor to energize its stator windings. The line contactor is coupled between an output node of the first filter and the output node of the inverter. The line contactor supplies the output node of the inverter directly with the filtered line frequency AC signal to energize the stator windings when the inverter is disabled.

Abstract: An electric motor assembly includes a stator assembly and a rotor assembly positioned adjacent the stator assembly to define an axial gap therebetween. The stator assembly is configured to induce a first axial force on the rotor assembly. The electric motor assembly also includes an impeller directly coupled to the rotor assembly opposite the stator assembly such that the rotor assembly and the impeller are configured to rotate about an axis. A fluid channeled by the impeller induces a second axial force on the impeller. The electric motor assembly further includes a hydrodynamic bearing assembly including a rotating member coupled to the rotor assembly and stationary member at least partially circumscribing the rotating member such that rotation of the rotating member with respect to the stationary member is configured to induce a third axial force on the rotor assembly.

Abstract: In one embodiment, a permanent magnet rotor is provided. The permanent magnet rotor includes at least one permanent magnet and a substantially cylindrical rotor core including an outer edge and an inner edge defining a central opening. The rotor core includes a radius R, at least one pole, and at least one radial aperture extending radially though the rotor core from the outer edge to a predetermined depth less than the radius. The at least one radial aperture is configured to receive the at least one permanent magnet. The rotor further includes at least one protrusion extending into the at least one radial aperture, the at least one protrusion positioned substantially along a bottom of the at least one radial aperture and configured to facilitate retention of the at least one permanent magnet within the at least one radial aperture.

Abstract: A bearing retainer for use in a bearing is provided. The bearing includes an inner ring, rolling elements and an outer ring. The bearing retainer includes a body. The body defines an inner periphery and an outer periphery of the body. The body further defines a plurality of inner walls. Each inner wall defines an opening extending from the inner periphery to the outer periphery of the body. The plurality of openings is adapted to receive one of the rolling elements. The inner walls are adapted to keep the rolling elements in a spaced apart relationship. Ribs extend inwardly from the inner periphery of the body.

Abstract: An end cap for use with a stator assembly is provided. The end cap includes a tooth portion, a yoke portion, and a lip. The tooth portion includes a first end and an opposite second end and the yoke portion is formed at the first end of the tooth portion. The yoke portion includes at least one arm that extends from the tooth portion. The lip is defined along at least one of the tooth portion and the at least one arm portion.

Abstract: An air blower includes a blower housing, impeller fan, and pressure tap. The blower housing defines a blower housing interior and includes a housing wall portion, an air inlet and an air outlet. The impeller fan is positioned within the blower housing interior. A first end of the pressure tap is outside the blower housing interior and a second end is inside the blower housing interior. A through passage extends through a body portion and a base portion. The base portion includes a radius portion extending both from the body portion towards the second end and radially outward from the body portion. The second end of the pressure tap is positioned closer to the impeller fan than the housing wall portion.

Abstract: A rotor for an electric machine includes a circular rotor base having a first surface, a second surface, and a circumferential outer edge extending from the first surface to the second surface, a plurality of magnets disposed proximate the circumferential outer edge of the circular rotor base, and a plurality of flux guides. Each magnet has a first surface and a second surface. The first surface of each magnet is attached to the first surface of the circular rotor base, and the second surface of each magnet defines a first shape. Each flux guide is attached to the second surface of a different magnet and has a first surface attached to the second surface of a first respective magnet and a second surface opposite the first surface. The second surface of each flux guide defines a second shape different than the first shape of the magnets.

Abstract: A hydrodynamic bearing assembly includes a first stationary component, a shaft coupled to the first stationary component, and a second stationary component coupled to the shaft opposite the first stationary component. The hydrodynamic bearing assembly also includes a rotating component coupled to the shaft between the first stationary component and the second stationary component. The rotating component includes a first end surface including a first diameter and an opposing second end surface including a second diameter that is greater than the first diameter.

Abstract: A centrifugal blower assembly comprises a scroll wall and a pair of opposing sidewalls. The scroll wall is positioned between the pair of opposing sidewalls such that the scroll wall and opposing sidewalls together define a blower chamber and a blower outlet. A baffle element is positioned within the blower chamber and adjacent the blower outlet such that the baffle element is configured to facilitate uniform distribution of airflow downstream of the blower assembly. An air stream splitter is coupled to the scroll wall. The air stream splitter includes a spline member extending a varying distance from the scroll wall. The air stream splitter is positioned within the blower chamber to facilitate uniform airflow distribution within the blower assembly.

Abstract: According to another embodiment of the present invention, an electric machine is provided. The machine includes a housing and a stator. The stator is fixedly secured to the housing. The machine also includes a rotor. The rotor is rotatably secured to the housing. At least one of the housing, the stator and the rotor include an inner wall defining a passageway adapted for improved fluid flow therethrough.

Abstract: A method of operating a drive circuit for parallel electric motors is provided. The method includes receiving measurements of stator phase currents in the parallel electric motors. The method includes selecting a target PM motor, from among the parallel electric motors, that generates a largest torque output. The method includes executing a vector control algorithm to generate a complex command voltage vector for the target PM motor. The method includes generating and transmitting a pulse width modulation (PWM) signal based on the complex command voltage vector for controlling an inverter. The method includes operating the inverter according to the PWM signal to supply three-phase alternating current (AC) power to the parallel electric motors.

Abstract: A fan assembly includes an axis of rotation and a fan that includes an inlet ring and a rear plate that together define an inner fan chamber, wherein the fan is a backward curved plug fan. The fan assembly also includes an axial flux motor coupled to the rear plate such that the motor is positioned entirely outside the fan chamber to facilitate preventing interference between the motor and an airflow within the fan chamber.

Abstract: A blower assembly is configured for use with a gas-operated heater having a burner and an exhaust port. The blower assembly has a blower and a sensor. The blower is configured to operate at two or more speeds and is configured to operatively connect to the burner in a manner to facilitate flow of combustion air into the burner and to facilitate flow of exhaust through the exhaust port. The sensor is configured to be sensitive to pressure of exhaust downstream of the blower. The sensor is operatively connected to the blower in a manner such that the blower will change speeds if said pressure exceeds a threshold pressure.

Abstract: A modular transfer system with a primary flow system and a diverter system. The primary flow system includes a primary flow belt for conveying an article along a primary flow path from an infeed side of the modular transfer system to a pass-through side of the modular transfer system. The diverter system includes one or more diverter belts for diverting an article from the primary flow path towards a divert side of the modular transfer system. The primary flow belt includes multiple movable components contacting the diverter belt. The movable components can have one or more rotational degrees of freedom.

Abstract: An electric motor control system and methods of manufacture are provided. The system includes a power supply module including a printed circuit board (PCB) and a plurality of power processing components configured to convert an input voltage into an output voltage. The system also includes a motor management module including an encapsulated, heat-sharing package for housing a plurality of moisture-sensitive driver components configured to convert the output voltage from the power supply module and provide output voltages for application to windings of the electric motor.

Abstract: An electric motor includes a main winding coupled to a first line terminal, and first and second boost windings coupled in series to the main winding. A high-speed lead wire is coupled to a first tap between the main winding and the first boost winding, a medium-speed lead wire is coupled to a second tap between the first boost winding and the second boost winding, and a low-speed lead wire is coupled to a third tap after the second boost winding. A start winding has a first end coupled to the first line terminal and a second end. A capacitor has a first end series-coupled to the second end of the start winding and a second end coupled to the second tap. A switch coupled to a second line terminal is configured to couple the second line terminal to one of the high, medium, and low-speed lead wires.

Abstract: According to an embodiment of the invention, a pump motor controller for managing energy usage of a pump motor and for receiving signals from a signal sending device corresponding to the status of a climate control device is provided. The motor controller is adapted to receive the signal and to control the pump motor at least partially based on the signal.

Abstract: A motor controller and methods for operating a motor are described herein. The motor controller includes a high-frequency (HF) inverter having a direct current (DC) input stage and an alternating current (AC) output stage, the HF inverter operable at a switching frequency to generate a three-phase output having a fundamental frequency. The motor controller also includes a differential mode (DM) filter coupled in series with the output stage of the HF inverter and having a resonant frequency less than 10% of the switching frequency, the DM filter configured to reduce harmonic components of the three-phase output and generate a first filtered output. The motor controller further includes a common mode (CM) filter coupled in series with the DM filter, the CM filter configured to filter the first filtered output to generate a second filtered output having a reduced CM voltage to operate the electric motor with a reduced bearing current.

Abstract: A method for determining a direction of rotation for an electronically commutated motor (ECM) is described. The motor is configured to rotate a blower and the method comprises rotating the blower using the ECM and determining if the resulting blower rotation is indicative of the desired direction of rotation for the blower.

Abstract: A blower assembly kit for fabricating a plurality of blower assemblies is provided. A first of the plurality of blower assemblies is configured for use with a first motor having a rotor and a second of the plurality of blower assemblies is configured for use with a second motor having a shaft. The kit includes a body having a member for generating air flow, a first adapter having a first connection for connecting the first adapter to the body and a second connection for connecting the first adapter to the rotor of the first motor, and having a second adapter having a first connection connecting the second adapter to the body and a second connection connecting the second adapter to the shaft of the second motor. The body and the first adapter provide the first blower assembly and the body and the second adapter provide the second blower assembly.