Abstract: According to one embodiment, the present invention provides a rotor assembly. The exemplary rotor assembly includes a plurality of rotor laminations, which cooperate to form a rotor core, capped at each end by end members. Extending through the rotor core and the end members, a plurality of rotor channels is configured to receive electrically conductive members therethrough. Each of the electrically conductive members has external portions, which extend beyond the rotor channel, and an interior portion that is housed within the rotor channel. By flexing the external portions, a compression force that secures the laminations and the end members with respect to one another may be provided. Advantageously, the external portions may be fused to one another and/or to the end members. As one example, the external portions may be fused through the introduction of a molten metal into the end member.

Abstract: A resistance temperature detector device and system are provided for measuring the temperature adjacent to windings within a stator assembly. The resistance temperature detector comprises a resistive element enclosed within a plurality of insulative layers, including insulation panels and adhesive. These surrounding insulation layers are sufficient to prevent partial discharge within any air gaps or low dielectric materials adjacent to the resistive element when the resistance temperature detector is disposed within a motor. A method for detecting temperatures between windings of an electrical machine is also provided.

Abstract: The present invention relates to a manual brake release mechanism for an electromagnetic brake of an electronic motor. The manual brake release mechanism includes a cam and lever assembly operable to move an armature plate away from a friction disk, thereby, disengaging an electromagnetic brake. The cam and lever assembly is coupled to a field cup and provides an even pull over both sides of the armature plate.

Abstract: A system and method is provided for monitoring the operating condition of a pump by evaluating fault data encoded in the instantaneous current of the motor driving the pump. The data is converted to a frequency spectrum which is analyzed to create a fault signature having fault attributes relating to various fault conditions associated with the pump. The fault signature is then input to a neural network that operates in conjunction with a preprocessing and post processing module to perform decisions and output those decisions to a user interface. A stand alone module is also provided that includes an adaptive preprocessing module, a one-shot unsupervised neural network and a fuzzy based expert system to provide a decision making module that operates with limited human supervision.

Abstract: An extended stator core in a motor/generator can be utilized to mitigate losses in end regions of the core and a frame of the motor/generator. To mitigate the losses, the stator core can be extended to a length substantially equivalent to or greater than a length of a magnetically active portion in the rotor. Alternatively, a conventional length stator core can be utilized with a shortened magnetically active portion to mitigate losses in the motor/generator. To mitigate the losses in the core caused by stator winding, the core can be extended to a length substantially equivalent or greater than a length of stator winding.

Abstract: A machine diagnostic system for on-line diagnosis of a machine including a package for a machine diagnostic module that collects data relating to operation of the machine. The package is mounted to an outer mounting surface of the machine and includes a container which contains the machine diagnostic module. The package further includes a heat dissipation device between the container and the outer mounting surface of the machine which dissipates heat generated by the machine into surrounding air thereby minimizing heat transfer to the container.

Abstract: A system and method is provided for monitoring the operating condition of a pump by evaluating fault data encoded in the instantaneous current of the motor driving the pump. The data is converted to a frequency spectrum which is analyzed to create a fault signature having fault attributes relating to various fault conditions associated with the pump. The fault signature is then input to a neural network that operates in conjunction with a preprocessing and post processing module to perform decisions and output those decisions to a user interface. A stand alone module is also provided that includes an adaptive preprocessing module, a one-shot unsupervised neural network and a fuzzy based expert system to provide a decision making module that operates with limited human supervision.

Abstract: A system and method is provided to accommodate positional variations in a bearing assembly, which has a clearance adjustment assembly for setting the roller clearance therein. The bearing assembly has multiple rows of tapered rollers disposed circumferentially between an inner sleeve and the clearance adjustment assembly, which is secured by an outer retaining sleeve. The clearance adjustment assembly has at least one clearance adjustment ring disposed adjacent multiple tapered support rings, which extend circumferentially about the multiple rows of tapered rollers. In the bearing assembly, the at least one clearance adjustment ring forces the multiple tapered support rings against the multiple rows of tapered rollers to set the desired roller clearance. Accordingly, the bearing assembly can accommodate expansion, contraction, and angular variations in the system.

Abstract: A system for determining at least one condition of a seal including an optical fiber for transmitting light from a light source. The optical fiber is embedded in the seal and operatively coupled to an interferometric system. The interferometric system is operatively coupled to a processor. The interferometric system provides the processor with information relating to wear of the optical fiber, and the processor determines wear of the seal, rate of wear and remaining useful life of the seal based on the information relating to wear of the optical fiber.

Abstract: A method of constructing a segmented wound member of an N phase electromechanical device comprises winding N sets of segments and combining the N sets of segments in a common circular arrangement to form the wound member. The N sets of segments are wound with a single continuous length of wire for each set. Each of the N sets of segments is wound separately from the remaining sets of segments and then combined in the common circular arrangement with the remaining sets of segments to form the wound member.

Abstract: A system is provided for securing a rotating member with respect to a non-rotating member. A hollow member, such as an inner ring of a bearing assembly, includes an extension having an annular outer groove. A tapered sleeve serves to lock the hollow member about a mechanical component, such as a shaft. A nut engageable on the 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 the groove of the hollow member.

Abstract: A method is disclosed for making an electric motor stator. In accordance with the method, coil groups are inserted for different electrical phases through a first and second ends of a stator core. An insertion tool is used for insertion of the coil groups independently. Coils for individual phases are inserted through the first and second ends, and leads for the coil groups may exit alternative ends as a result of the method.

Abstract: A technique is provided for manufacturing a stator of an electrical machine, such as a motor. The stator is formed by using thin end plates or laminations that are attached to each other by rods around a group of laminations. The end plates maintain pressure on the laminations. Within the laminations, slots extend thru the length of the stator. A slot liner is placed within each slot as an insulating layer between coils and the laminations. Furthermore, an insulating end piece or lamination is positioned within each end plate and adjacent to the laminations to provide support to the slot liners that extend beyond the laminations. The insulating end lamination supports the slot liners during the winding processes to prevent the slot liners from damage. In addition to providing support, the insulating end lamination is able to provide extra insulation between the coils, laminations, and the end plate.

Abstract: A worm shaft is provided with an intermediate worm thread section between first and second end structures, wherein at least one of the first and second end structures has a coupling structure for a desired extension of a plurality of modular worm shaft extensions. The desired extension and the intermediate worm thread section are both selectable based on the desired application, the desired gearing ratio, and other features. Accordingly, the multi-component worm shaft of the present technique increases flexibility, reduces manufacturing costs, and reduces inventory.

Abstract: A motor controller is provided including a synchronous motor, a feed back detector for detecting the position and velocity of the rotor of the synchronous motor, a detector for detecting a magnetic pole position of the rotor of the synchronous motor, an inverter for controlling an electric power to be supplied to the synchronous motor, an estimator for estimating the magnetic pole position of the rotor of the synchronous motor, and a detector for detecting the abnormality of the feed back detector.

Abstract: An extended stator core in a motor/generator can be utilized to mitigate losses in end regions of the core and a frame of the motor/generator. To mitigate the losses, the stator core can be extended to a length substantially equivalent to or greater than a length of a magnetically active portion in the rotor. Alternatively, a conventional length stator core can be utilized with a shortened magnetically active portion to mitigate losses in the motor/generator. To mitigate the losses in the core caused by stator winding, the core can be extended to a length substantially equivalent or greater than a length of stator winding.

Abstract: A temperature controlled bearing includes a bearing element disposed within a temperature conductive housing for receiving and facilitating the rotation of a shaft. An oil sump may be formed within the housing or bearing which contains a supply of lubricant for the bearing. At least one fan is mounted to the exterior of the bearing housing, such as adjacent an oil sump. The fan is adapted to transfer heat from the bearing housing to the atmosphere by forced convection. A temperature sensor may be disposed within the bearing housing and coupled to a logic controller. The logic controller operates the fan according the temperature of the bearing as detected by the sensor.

Abstract: A system and method for establishing estimated values of a plurality of electrical parameters of a motor. The plurality of electrical parameters may be established from stator resistance data and electrical input data obtained with no load on the motor. The plurality of electrical parameters may also be established from stator resistance data, electrical input data, and motor speed data obtained at at least two load conditions of the motor. The plurality of electrical parameters may comprise rotor resistance. The system and method may also be used to estimate a plurality of operating parameters of the motor based on the estimated values of a plurality of electrical parameters of the motor. The plurality of operating parameters of a motor may comprise rotor temperature, motor torque, and motor efficiency.

Abstract: A system and method is provided for setting the roller clearance of a multi-row tapered roller bearing assembly via a clearance adjustment assembly and an outer retaining sleeve. The bearing assembly has multiple rows of tapered rollers disposed circumferentially between an inner sleeve and the clearance adjustment assembly, which is secured by the outer retaining sleeve. The clearance adjustment assembly has at least one clearance adjustment ring disposed adjacent multiple tapered support rings, which extend circumferentially about the multiple rows of tapered rollers. In the bearing assembly, the at least one clearance adjustment ring forces the multiple tapered support rings against the multiple rows of tapered rollers to set the desired roller clearance.

Abstract: A technique for making a stator for an electric motor or similar machine includes disposing a plurality of concentric coils in a stator core such that leads exit both ends of the stator core. The coils are disposed in accordance with a winding pattern that is particularly suited for making four-pole, three-phase machines. Certain of the coils are disposed singularly within core slots, while other coils share slots with coils of other winding groups. The coils may be inserted by machine, and in several layers by rotating the stator core between each layer insertion.