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 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 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 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 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 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 stator assembly 16 for a brush-type permanent magnet DC motor includes a or body 17 having a central axis A and an annular inner wall 20 disposed about the central axis. The inner wall has at least one raised portion 21 and at least one recess 22 adjacent to the at least one raised portion. The raised portion defines a flux recovery feature. At least one permanent magnet 18 is disposed within the recess 22 such that an inside radius IRM of the magnet is substantially the same as, and concentric with, an inside radius IRF of the raised portion as measured from the central axis, with the flux recovery feature 21 and magnet 18 defining a magnetic circuit. In section, the at least one raised portion is joined with a surface defining the at least one recess by a generally S-shaped structure thereby defining a curved transition there-between. Thus, in a motor having N poles, only N/2 magnets are required.

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.

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 system and method for protecting a motor from a stall condition includes a brush motor 11 having power brushes 14 and 16 that convey power to windings of the motor, and one sensing brush 20 constructed and arranged to sense a speed of rotation of an armature motor. A controller 23 is constructed and arranged to compare a sensed speed of rotation with a minimum speed value that is indicative of a stall condition. A relay 28 is constructed and arranged to disconnect power to the motor if the sensed speed is below the minimum speed value.

Abstract: A method of linking commutator bars of a commutator for a motor wherein N is the number of magnetic poles of the motor and N is an even integer greater than 2. The method include a) arranging a plurality of commutator bars to be generally equally spaced in a circular arrangement to define the commutator, each commutator bar having a tang extending therefrom, b) contacting an end of a continuous, insulated conductive member to a tang, c) moving the member to contact a second tang which is disposed at an angle of 720°/N from the previously contacted tang to form a link, and when N is greater than four, repeating this step until N/2−1 links are created, d) moving the member to contact a tang which is immediately adjacent to the second tang contacted in step (c) such that the member defines a bridging portion between the adjacent tangs, e) repeating steps (c) and (d) and until all tangs have been contacted by the member, and f) cutting the bridging portion between adjacent tangs.

Abstract: A resistor and stall protection assembly for a permanent magnet brush-type DC motor includes a first speed circuit for operating the motor at a first speed. The first speed circuit includes at least one resistor 12 for reducing voltage to the motor 14. A second speed circuit is provided for operating the motor at a speed greater than the first speed. A first connecting structure 16 is constructed and arranged to connect the assembly to a source of power 18. A second connecting structure 20 is constructed and arranged to connect the assembly to the motor 14. A sensing structure 22 is constructed and arranged to sense a motor stall condition, and a circuit protecting device 24 such as a relay or transistor is constructed and arranged to interrupt power to the motor 14 when the motor is in the stall condition.

Abstract: An engine cooling module 10 includes a shroud 12 having at least one fan opening 15 and at least one additional opening 18 in the wall generally adjacent to the fan opening to permit air to pass though the shroud 12. A fan 14 is coupled to the shroud to permit air moved by the fan to pass through the shroud 12. An electric motor drives the fan. Closure structure 20 is movable to prevent and permit air flow through the additional opening 18. An actuator 28 moves the closure structure 20 from a closed position, covering the additional opening 18, to an opened position, uncovering the additional opening 18. A sensor 34 detects ram air at the shroud 12. A controller 32 receives a signal from the sensor 34 indicating the initial presence of ram air and, in response thereto, sends a signal to the actuator 28 to move the closure structure 20 to the opened position.

Abstract: An engine cooling module 10 includes a shroud 12 having at least one fan opening 15 in a wall thereof, and at least one additional opening 18 in the wall generally adjacent to the fan opening to permit air to pass though the shroud 12. A fan 14 is coupled to the shroud so as to be adjacent to the fan opening to permit air moved by the fan to pass through the shroud 12. An electric motor drives the fan. Closure structure 20 is associated with the additional opening 18 and is movable to prevent and permit air flow through the additional opening 18. An actuator 28 is constructed and arranged to actuate the closure structure 20 to move the closure structure 20 from a closed position, covering the additional opening 18, to an opened position, substantially uncovering the additional opening 18. A sensor 34 is constructed and arranged to detect ram air at the shroud 12.

Abstract: An electric motor 10 includes a motor housing 12 defining an internal cavity 15. A brush card assembly 24, a commutator 26 and an armature assembly 18 are provided in the cavity 15. The commutator 26 cooperates with the brush card assembly 24 to resupply electric current to the armature assembly 18. Permanent magnet structure 44 is provided in the housing 12 to generate a magnetic field to cause rotation of the armature assembly 18. A FET 52 is mounted with respect to the housing 16 so as to be in heat exchange relation therewith. A gate terminal G of the FET is constructed and arranged to receive pulse width modulation output from an electronic control unit 64 which is remote from the motor so as to enable able the motor to operate at more than one speed. A method of integrating a FET in a motor is also provided.

Abstract: A motor and fan structure 10 includes direct current motor assembly 18 having a stator assembly 20 including a flux plate 22 and permanent magnet structure 24 mounted on the flux plate 22. The flux plate 22 defines one end of the motor assembly and define a magnetic flux path of the motor assembly. The motor assembly also includes a generally cylindrical armature assembly 32 defining another end of the motor assembly. The armature assembly is radially wound with windings 40, and an outermost part of the armature assembly and at least a portion of the windings is exposed to the environment. The structure includes a fan 12 having a generally cylindrical hub 14 receiving and covering the outermost part and the portion of the windings of the armature assembly. The hub 14 has a plurality of blades 16 extending therefrom. Thus, the weight and axial length of the motor assembly can be reduced since no case is required to cover the armature assembly yet the armature assembly is protected by the fan hub.

Abstract: A motor and fan structure 10 includes direct current motor assembly 18 having a stator assembly 20 including a flux plate 22 and permanent magnet structure 24 mounted on the flux plate 22. The flux plate 22 defines one end of the motor assembly and define a magnetic flux path of the motor assembly. The motor assembly also includes a generally cylindrical armature assembly 32 defining another end of the motor assembly. The armature assembly is radially wound with windings 40, and an outermost part of the armature assembly and at least a portion of the windings is exposed to the environment. The structure includes a fan 12 having a generally cylindrical hub 14 receiving and covering the outermost part and the portion of the windings of the armature assembly. The hub 14 has a plurality of blades 16 extending therefrom. Thus, the weight and axial length of the motor assembly can be reduced since no case is required to cover the armature assembly yet the armature assembly is protected by the fan hub.

Abstract: A motor control circuit for use in a motor circuit includes a varying duty cycle pulse width modulation circuit and a switch. The varying duty cycle pulse width modulation circuit is operable to generate a PWM signal having a varying duty cycle, wherein an average of said varying duty cycle corresponds to a desired motor speed. The switch has a control input operably coupled to the pulse width modulation circuit to receive the PWM signal therefrom. The switch further includes first and second terminals, the first terminal adapted to be coupled to a coil of the motor circuit, the switch operable to selectively electrically connect and disconnect the first and second terminals based in part on the PWM signal received by the control input.

Abstract: A connector structure 10 is provided for powering an electric motor 19. The connector structure 10 includes a connector body 12; a low speed terminal 14 in the body; a high speed terminal 16 in the body; and a ground terminal 18 in the body. The ground terminal and the high-speed terminal are constructed and arranged to be coupled directly to the motor. The low speed terminal, the high speed terminal and the ground terminal are constructed and arranged to be coupled to a source of electrical power to power the motor. A resistive element 20 is coupled between the low speed terminal and the high-speed terminal. A shield member 26 houses the resistive element. The shield member is coupled directly to the connector body. Electrical power to the motor may be by controlled by selectively energizing the low speed terminal, the high speed terminal, or both the low speed terminal and high speed terminal so as to operate the motor at two different speeds.

Abstract: A vehicle engine cooling system includes a coupling assembly to be connected to and rotated by a vehicle engine output shaft. An electric motor includes a motor shaft having first and second ends. An impeller is coupled to the first end of the motor shaft. A clutch structure is integral with the electric motor and includes an input member carried by the second end of the motor shaft for rotation therewith. An end of the coupling structure is operatively associated with the input member to cause rotation of the input member upon rotation of the coupling assembly. An electro-magnet structure is disposed about the input member. The clutch structure also includes output structure having a mounting member fixed to the motor shaft. A movable element, including magnetically permeable material, is mounted with respect to the mounting member for rotational movement therewith and for movement between a non-engaging position and an engaging position. A spring biases the movable element towards the non-engaging position.