Abstract: A speed control and stall protection system 10 for an electric DC brush motor includes a DC brush motor M. At least one relay K3 is connected between the motor and a power supply. A speed sensing circuit 20 is constructed and arranged to generate a signal indicative of a speed of the motor. A motor control and protection circuit 116 is constructed and arranged to receive 1) the signal from the speed sensing circuit and 2) a control signal input for operating the at least one relay to control operation of the motor. When a stall condition is determined based on the signal from the speed sensing circuit, the motor control and protection circuit is constructed and arranged to control the at least one relay to disconnect power to the motor.

Abstract: A fan module assembly includes at least one a rotatable fan (38) having blades (39) with tips of blades being joined by an annular fan band (42). An electrically conductive squirrel cage (46) is associated with the fan band to rotate therewith. Flux receiving structure (48) is associated with the fan band. A shroud (40) has a shaft (54) with the fan being associated with the shaft so as to rotate about the shaft and with respect to the shroud. Control structure (52) is mounted stationary with respect to the shroud generally adjacent to a portion of the fan band. The control structure is constructed and arranged to generate a changing magnetic field, generally at the radius of the fan band, which interacts with the flux receiving structure and the squirrel cage to cause the fan to be driven by tangential force.

Abstract: A multi-speed permanent magnet D.C. electric motor system 10 includes at least one permanent magnet DC electric motor 11 configured to operate at at least one speed. A current limiting device R1 is constructed and arranged to lower electrical input power to the motor 11 so that a speed of the motor is reduced, when the motor is powered together with the current limiting device, as compared to a speed of the motor powered absent the current limiting device. Switching structure K1, K2, K3 is associated with the current limiting device to selectively operate the motor at at least three discrete speeds, even though the motor is configured for at least one-speed operation.

Abstract: A cooling module includes a shroud (38) having an integral cover (42). The cover receives bearing structure (40). A fan (36) is provided for moving air. A rotor and stator assembly (30) has an opened end and includes a stator (29) having permanent magnets. A rotor (31) includes a lamination stack (16), windings (21), a commutator (20); and a shaft (18). The rotor is associated with the stator so as to rotate with respect thereto. One end (34) of the shaft is coupled with the fan and another end (39) of the shaft is received by the bearing structure. A brush and connector unit (52) is associated with the cover of the shroud and includes brushes (58) associated with the commutator, and an electrical connector (62). The cover covers the opened end of the rotor and stator assembly and covers at least a portion of a brush and connector unit.

Abstract: A method of assembling a cooling module with the module having a shroud (38) having a cover (42) receiving bearing structure (40). The cover has an opening (68) therein. A fan (36) is provided for moving air. A rotor and stator assembly (30) has an opened end and includes a stator, including permanent magnet structure (14), and a rotor having laminations (16), windings (21), a shaft (18) and a commutator (20). A brush and connector unit (52?) including brushes. The method mounts the fan to a first end of the shaft. The rotor and stator assembly is coupled to the cover to substantially close the opened end, with a second end of the shaft being received by the bearing structure. The brush and connector unit is inserted through the opening such that the brushes are associated with the commutator. The brush and connector unit is secured to the cover.

Abstract: A multi-powered electric motor system (21) is provided for a vehicle. The system includes first and second direct current motors (12, 14), each constructed and arranged to operate at a single speed. Current limiting structure (R1) is constructed and arranged to lower electrical input power to the motors so that a speed of the motors is reduced when the motors are powered together with the current limiting structure, as compared to a speed of the motors powered absent the current limiting structure. Switching structure (K1, K2, K3) is selectively operable to cause the motors to operate at various speeds resulting in three discrete power levels of the system.

Abstract: A method of providing RFI suppression in a DC motor provides a universal terminal bar structure 70 including a positive terminal bar 72 and a negative terminal bar 76, a first choke 80 electrically connected with the positive terminal bar, a second choke 82 electrically connected with the negative terminal bar, a first ground connection 86 constructed and arranged to electrically connect the positive terminal bar to ground, a first breakable section A between the first ground connection and the positive terminal bar, a second ground connection 88 constructed and arranged to electrically connect the negative terminal bar to ground, and a second breakable section B between the second ground connection and the negative terminal bar. Capacitor structure 90 is attached to the terminal bar structure, and the first breakable section is selectively broken, alone or in combination with the second breakable section to provide versatile RFI suppression.

Abstract: A method of providing RFI suppression in a DC motor provides a universal terminal bar structure 70 including a positive terminal bar 72 and a negative terminal bar 76, a first choke 80 electrically connected with the positive terminal bar, a second choke 82 electrically connected with the negative terminal bar, a first ground connection 86 constructed and arranged to electrically connect the positive terminal bar to ground, a first breakable section A between the first ground connection and the positive terminal bar, a second ground connection 88 constructed and arranged to electrically connect the negative terminal bar to ground, and a second breakable section B between the second ground connection and the negative terminal bar. Capacitor structure 90 is attached to the terminal bar structure, and the first breakable section is selectively broken, alone or in combination with the second breakable section to provide versatile RFI suppression.

Abstract: A cooling module 67 includes a motor assembly 42 having a motor case 24 having at least one open end and including mounting brackets 30 integral therewith. Each bracket has only a bottom portion 32 connected with the motor case. An armature assembly is disposed in the motor case and includes a rotatable shaft 46. A brush card assembly 56 is associated with the armature assembly, and an end cap 60 is disposed over the brush card assembly and partially covers the open end of the motor case and thereby defining a non end cap covered motor portion 63. A fan 64 is coupled to an end of the shaft and has a hub substantially covering one end of the motor assembly. A shroud 74 has a motor cover 76. Fastening structure 78 is associated with the shroud and engaged with the brackets thereby mounting the motor assembly to the shroud, with the motor cover substantially covering the end cap and the non end cap covered motor portion.

Abstract: A brush card assembly 30 is provided for a permanent magnet brush motor 50. The motor includes a link wound, high speed side commutator 46 and an associated high speed side armature winding 44, and a link wound low speed side commutator 54 and an associated low speed side armature winding 52. The brush card assembly includes a brush card 31 including a high speed side having a positive brush 32 and a negative brush 32? constructed and arranged to be operatively associated with the high speed side commutator 46, and a low speed side opposite the high speed side. The low speed side has a positive brush 33 and a negative brush 33? constructed and arranged to be operatively associated with the low speed side commutator 54. The brushes are constructed and arranged with respect to the commutators to provide at least two different operating speeds of the motor.

Abstract: A stator and armature assembly 12 is provided for a permanent magnet DC motor. The assembly includes an armature 13 having a lamination core 14 and windings 15, and a stator structure 16 associated with the armature. The armature is constructed and arranged to rotate with respect to the stator structure. The stator structure includes at least one permanent magnet 22 providing a certain flux, and at least one wound core structure 17 having a core 18 and a coil 19 wound about the core so as to define an alternate pole with respect to the permanent magnet. When current to the coil is controlled, flux of the stator structure 16 can be increased or decreased relative to the certain flux. In this way a motor can operate at different speeds.

Abstract: A motor case assembly 20 a permanent magnet D.C. electric motor includes a motor case 24 having a generally cylindrical wall 25, a closed end 21, and an open end 23 opposite the closed end, defining an interior 27. Permanent magnet structure 26 is mounted to the wall 25 in the interior 27. A surface defines at least one hole 22 through the wall 25. The hole 22 is constructed and arranged to be employed in mounting the case 20 to a shroud to obtain a mass balance distribution of a motor shroud assembly.

Abstract: A permanent magnet D.C. electric motor includes a stator housing, permanent magnet structure, and an armature assembly. The armature assembly includes a shaft rotatably mounted in the stator housing, lamination structure, first and second coil windings associated with the lamination structure, a first commutator electrically connected with the first coil windings, and second commutator electrically connected with the second coil windings, each of the first and second commutators being generally cylindrical and having a plurality of commutator segments. Certain segments of the first commutator and certain segments of the second commutator are electrically connected. The motor also includes a brush card assembly including a high speed side having first brush structure associated with the first commutator, and a low speed side having a second brush structure associated with the second commutator, and switches for selectively connecting a D.C.

Abstract: A permanent magnet D.C. electric motor 100 includes a motor housing 118 having first and second ends and a generally cylindrical periphery between the ends. The first end 120 is substantially closed and has an end of a shaft 124 extending there from. The first end includes vent holes 16 therein. The second end 122 is substantially open and defines a plurality of ventilation holes 126 in the cylindrical periphery. An end cap 130 closes the second end and covers another end of the shaft. The end cap has a base 132 and a flange 134 extending transversely with respect to the base. The flange is disposed over a portion of the cylindrical periphery of the housing so as to define a gap G there-between such that air may pass through the gap and through the ventilation holes and vent holes to cool the motor, with the end cap inhibiting foreign material from entering the ventilation holes.

Abstract: A dual fan module system 28 includes a two-speed electric motor 12 for operating a first fan 36, a one-speed electric motor 14 for operating a second fan 38, and switching structure K1, K2, K3, and K4 constructed and arranged to operate the system at more than two different speeds.

Abstract: A permanent magnet D.C. electric motor 36 includes a motor housing 29 having first and second ends. The second end 42 is substantially closed and has an end of a shaft 35 extending there from. The second end includes vent holes 20 therein. The first end 27 is substantially open. An end cap 31 closes the first end of the housing. The end cap 31 has venting holes 34 therein for permitting air to pass there-through to cool the motor. A splash shield 32 is integral with the end cap 31 and covers the venting holes 34 in such a manner to limit foreign matter from entering the venting holes while permitting air to flow through the venting holes.

Abstract: A multi-speed permanent magnet D.C. electric motor system 10 includes at least one permanent magnet DC electric motor 11 configured to operate at at least one speed. A current limiting device R1 is constructed and arranged to lower electrical input power to the motor 11 so that a speed of the motor is reduced, when the motor is powered together with the current limiting device, as compared to a speed of the motor powered absent the current limiting device. Switching structure K1, K2, K3 is associated with the current limiting device to selectively operate the motor at at least three discrete speeds, even though the motor is configured for at least one-speed operation.

Abstract: A commutator bar (10) includes a body and first and second anchors disposed in spaced relation with each anchor and coupled to a proximal end of the body. A free end of the first anchor (13) extends in a direction towards the proximal end H of the body, and a free end of the second anchor (12) extends in a direction towards a distal end (0) of the body. Third and fourth anchors (17) and (18), are disposed in spaced relation and each have one end coupled to a distal end of the body and a free end extending in a direction towards the proximal end of the body. Fifth and sixth anchors (15) and (16) each have one end coupled to the body at a location between the proximal and distal ends. A free end of the fifth anchor extends toward one side of the body and a free end of the sixth anchor extends toward the other side of body.

Abstract: A stator and armature assembly 12 is provided for a permanent magnet DC motor. The assembly includes an armature 13 having a lamination core 14 and windings 15, and a stator structure 16 associated with the armature. The armature is constructed and arranged to rotate with respect to the stator structure. The stator structure includes at least one permanent magnet 22 providing a certain flux, and at least one wound core structure 17 having a core 18 and a coil 19 wound about the core so as to define an alternate pole with respect to the permanent magnet. When current to the coil is controlled, flux of the stator structure 16 can be increased or decreased relative to the certain flux. In this way a motor can operate at different speeds.

Abstract: A commutator 100 for an electric motor includes a body 112 having opposing ends. Commutator bars 118 are attached to a periphery of the body. Oil throw and recovery structure 122 is integral with the body and is disposed at one of the ends of the body. The oil throw and recovery structure 122 flares outwardly from the one end of the body and defines a continuously curved, annular surface 124 terminating in an annular tip 126. The commutator 100 is constructed and arranged to be mounted to a shaft 128 with the oil throw and recovery structure 122 being adjacent to a bearing 132. The oil throw and recovery structure is constructed and arranged to deflect oil, moving from the bearing and contacting the annular surface, in a direction away from the one end of the body with the annular tip directing the oil back to the bearing.