Abstract: In accordance with one embodiment, the present technique provides a bushing that is configured to electrically and mechanically couple a conductor bar of a rotor assembly to an end ring of the rotor assembly. The exemplary bushing has an interior surface that is configured to abut against the conductor bar and an exterior surface that is configured to abut the perimetric surface of an end slot. Advantageously, the bushing, because of a good fit in the end slot and around the conductor bar, provides a good electrical connection between the conductor bar and the end ring. Moreover, the exemplary bushing also provides interferences fits that at least partially secure the end ring to the rotor core.

Abstract: A method is provided for testing an electrical characteristic of a rotor. In one embodiment, the method may include applying current to the rotor, measuring voltage drop between first and second positions on the rotor, and evaluating the electrical characteristic of the rotor based at least on the voltage drop and the current. In another embodiment, the method may include coupling a first set of leads to a first end portion of the rotor at a first set of angular positions about an axis of the rotor. The method also may include coupling a second set of leads to a second end portion of the rotor at a second set of angular positions about the axis of the rotor. In addition, the method may include coupling the first and second sets of leads to a current source to provide a current flow through the rotor from the first end portion to the second end portion. Furthermore, the method may include engaging a first probe to the first end portion and a second probe to the second end portion to measure voltage drop.

Abstract: An integrated motor and drive assembly includes a motor, a fan, and a drive unit. The motor is responsive to at least one drive signal. The fan is axially aligned with the motor and operable to generate a cooling flow. The drive unit is axially aligned with the fan and operable to generate the drive signal. The cooling flow traverses the motor and the drive unit.

Abstract: In accordance with exemplary embodiments, the present invention provides a transient power source that includes a flywheel that stores kinetic energy. In the event of a loss of main or operating power, the kinetic energy stored in the flywheel is converted into electrical energy. As one example, the rotation of the flywheel drives a generator that converts this mechanical (i.e., kinetic energy) into electrical energy. Additionally, the exemplary flywheel, as one embodiment, generates a cooling airflow for various components of the electrical machine. Thus, the rotation of the flywheel not only generates power, but also cools the various components of the transient power source as well.

Abstract: In accordance with one embodiment, the present technique provides a bushing that is configured to electrically and mechanically couple a conductor bar of a rotor assembly to an end ring of the rotor assembly. The exemplary bushing has an interior surface that is configured to abut against the conductor bar and an exterior surface that is configured to abut the perimetric surface of an end slot. Advantageously, the bushing, because of a good fit in the end slot and around the conductor bar, provides a good electrical connection between the conductor bar and the end ring. Moreover, the exemplary bushing also provides interferences fits that at least partially secure the end ring to the rotor core.

Abstract: A system is provided for securing two ends of a rotating member, such as a shaft, with respect to a non-rotating member, such as a mounting hub. Inner and outer sleeves have tapered surfaces and are positioned about the rotating member and provided within a bore of the non-rotating member. The tapered surfaces of the inner and outer sleeves cooperate in securing the shaft within the bore. The one or more inner sleeves collectively provide two threaded extensions for engagement with two nuts. Further, the one or more outer sleeves aggregately include two extensions, each having an annular groove to accommodate a lip formed in the nut. The system is engaged and disengaged through the interaction of the various tapered surfaces and the nuts, caused by the directional rotation of the nuts.

Abstract: A system is provided for securing a rotating member with respect to a non-rotating member. A hollow member, such as a mounting hub or an inner ring of a bearing assembly, includes an extension having an annular outer groove. One or more tapered sleeves serve to lock the hollow member about a mechanical component, such as a shaft. A nut engageable on a sleeve includes an eccentric front aperture adjacent to a concentric groove, thereby forming a lip of varying depth The system is engaged by rotation of the nut on the sleeve in one direction, and disassembled by counterrotation of the nut such that a portion of the varying depth lip co-acts with a lip formed by a groove on an outer sleeve or on the hollow member.

Abstract: The present technique, in accordance with one exemplary embodiment, relates to a motorized pulley. The exemplary motorized pulley includes a rim or housing inside of which are disposed an electric motor and a gear assembly, which is configured to transfer torque of the electric motor to the housing. Thus, during operation of the motor, the exemplary pulley rotates the housing in relation to a support structure to which the motorized pulley is mounted. To improve the dissipation of heat generated during operation of the motor, the motor is thermally coupled to the frame. Additionally, the rotor shaft of the exemplary motorized pulley extends into the external environment surrounding the pulley, thereby facilitating the operation of a machine element located externally with respect to the pulley via the electric motor disposed within the pulley.

Abstract: The present invention relates to systems and methods for a synchronous motor/generator including at least one back iron element which is rotated along with a rotor of the motor/generator. Rotation of the back iron(s) mitigates eddy current losses and improves efficiency in the motor/generator. The motor/generator also includes at least one stator winding supported in a non-conductive structure attached to the machine frame. The motor/generator of the present invention can also include at least one permanent magnet located in the rotor. The permanent magnet(s) cooperates with rotor windings to generate a DC magnetic field for the rotor. The components of the motor/generator can be configured in an axial gap topology, radial gap topology, or any other suitable topology.

Abstract: A system is provided for securing two ends of a rotating member, such as a shaft, with respect to a non-rotating member, such as a mounting hub. Inner and outer sleeves have tapered surfaces and are positioned about the rotating member and provided within a bore of the non-rotating member. The tapered surfaces of the inner and outer sleeves cooperate in securing the shaft within the bore. The one or more inner sleeves collectively provide two threaded extensions for engagement with two nuts. Further, the one or more outer sleeves aggregately include two extensions, each having an annular groove to accommodate a lip formed in the nut. The system is engaged and disengaged through the interaction of the various tapered surfaces and the nuts, caused by the directional rotation of the nuts.

Abstract: According to one aspect, the present technique provides methods and apparatus for inserting coil windings into a stator. Advantageously, the windings may be wound in a vertical configuration to facilitate insertion of the windings into stator slots. Moreover, the exemplary embodiment provides a transfer tool that maintains the stepped and vertical configurations of the coil windings developed during winding upon separation of the wire from the winding form. Advantageously, the present technique may decrease motor fabrication times and improve motor performance.

Abstract: A coupling assembly having an integral flange hub configured to bear against a flexible coupling element, and an external flange element configured to engage the hub to exert compressive force on the flexible coupling element. The assembly further includes a nut having inner threads configured to mate with a threaded extension of the hub to urge the hub and the external flange element into engagement with the flexible coupling element. The assembly may also include a tapered sleeve and a sleeve nut having inner threads configured to mate with the threaded extension of the tapered sleeve to secure the hub with a shaft.

Abstract: A system is provided for securing two ends of a rotating member, such as a shaft, with respect to a non-rotating member, such as a mounting hub. Inner and outer sleeves have tapered surfaces and are positioned about the rotating member and provided within a bore of the non-rotating member. The tapered surfaces of the inner and outer sleeves cooperate in securing the shaft within the bore. The one or more inner sleeves collectively provide two threaded extensions for engagement with two nuts. Further, the one or more outer sleeves aggregately include two extensions, each having an annular groove to accommodate a lip formed in the nut. The system is engaged and disengaged through the interaction of the various tapered surfaces and the nuts, caused by the directional rotation of the nuts.

Abstract: A technique for separating the stator leads of an electric motor during the manufacturing process. The technique comprises a system having a lead gathering assembly, a lead separator, and a drive mechanism. The lead gathering assembly is adapted to gather together a plurality of stator windings extending from a stator. The lead separator having a plurality of teeth adapted to separate a stator winding from the plurality of stator windings gathered together by the lead gathering assembly. The drive mechanism is adapted to drive the lead separator into the plurality of stator windings. The lead separator has teeth to separate each of the stator windings gathered together by the lead gathering assembly.

Abstract: A system and method for establishing estimated values of electrical parameters of a motor. The electrical parameters may be established from motor databases, measured input electrical data, measured output data, and various estimations to account for unknown motor parameters. Compensations also may be provided for stator resistance, cable resistance, and other motor parameters. Based on the foregoing data, the system and method also may be used to estimate motor operating parameters, such as torque, efficiency, output power, output speed, and other performance criteria of the motor. The system and method also may establish energy and monetary comparison data between the motor and at least one alternative motor.

Abstract: A system and method for establishing a plurality of operating parameters of a multiphase motor. The plurality of electrical parameters may be established from stator resistance data and electrical input data. The system and method may be used to decompose the electrical input data into a positive sequence and a negative sequence. The positive sequence may be used to establish a plurality of electrical parameters of the motor. The plurality of electrical parameters may be used with the positive sequence and negative sequence to establish the output power of the motor.

Abstract: A multi-layer corrosion protection system and a method for applying the multi-layer corrosion protection system. The system comprises a corrosion-resistant layer plated onto a metallic substrate. The corrosion-resistant layer may be deposited using an autocatalytic (electroless) process. The corrosion-resistant layer may comprise phosphorous. The system comprises a stain-resistant layer deposited over the corrosion-resistant layer. The stain-resistant layer may be deposited using an autocatalytic (electroless) process. The stain-resistant layer may comprise nickel. The system may also comprise an inner layer plated onto the metallic substrate to prepare the metallic substrate for the application of the corrosion-resistant layer. The inner layer may comprise nickel and may be deposited using an autocatalytic (electroless) process.

Abstract: A technique for securing a conduit box to a housing of an electric motor is disclosed. The technique includes forming a hollow extension from a surface of the conduit box. The conduit box is placed on a motor frame so that the hollow extension is inserted into a hole in the motor frame that passes into the hollow interior of the motor frame. The hollow extension is plastically deformed inside the motor housing to a greater width than the diameter of the hole in the motor housing so that the conduit box cannot be removed from the motor housing. A stator is placed in the motor housing and wiring is routed from the stator to the interior of the wiring box through a passageway formed by the hollow extension.

Abstract: In accordance with certain embodiments, the present technique provides a reduced current field-oriented-control scheme. For example, the present technique provides a method of controlling an induction device in which a predetermined reduction factor is employed to reduce the flux-current vector of a field-oriented-control scheme. By reducing this vector, less current and less power are drawn by the induction device, in turn reducing resistive heating and stator core losses, for instance.

Abstract: A system and method for establishing estimated values of electrical parameters of a motor. The electrical parameters may be established from stator resistance data and motor data obtained at a single load on the motor. The electrical parameters also may be established without stator resistance data by using motor data at three load conditions of the motor. The electrical parameters also may be established from baseline motor data and motor data obtained at a desired operating load of the motor. Based on the estimated values, the system and method also may be used to estimate motor operating parameters, such as torque, efficiency, output power, output speed, and other performance criteria of the motor.