Abstract: An electric motor includes a controller. The controller includes a controller housing presenting a heat sink surface. The controller further includes a printed circuit board and a power module. The printed circuit board is at least substantially disposed within the housing. The power module thermally engages the heat sink surface and is mounted transverse to the printed circuit board.

Abstract: A motor control system providing at least seventeen speed settings using industry standard control signals and an industry standard five pin speed connector. One speed monitoring pin transmits an output signal for monitoring the speed of the motor, and four speed setting pins receive input signals for setting the speed. One of the speed setting pins receives and decodes two binary states and two frequency states, thereby providing a total of thirty-two speed settings. A non-regulated isolated winding is added to an internal transformer to provide an internal isolated flyback power supply for the motor, thereby liberating a pin on the industry standard five pin speed connector to provide the fourth speed setting input pin. Transmission circuitry is associated with the speed monitoring pin, and the non-regulated isolated winding is used to provide a direct current bias to the transmission circuitry.

Abstract: A motor control system providing at least seventeen speed settings using industry standard control signals and an industry standard five pin speed connector. One speed monitoring pin transmits an output signal for monitoring the speed of the motor, and four speed setting pins receive input signals for setting the speed. One of the speed setting pins receives and decodes two binary states and two frequency states, thereby providing a total of thirty-two speed settings. A non-regulated isolated winding is added to an internal transformer to provide an internal isolated flyback power supply for the motor, thereby liberating a pin on the industry standard five pin speed connector to provide the fourth speed setting input pin. Transmission circuitry is associated with the speed monitoring pin, and the non-regulated isolated winding is used to provide a direct current bias to the transmission circuitry.

Abstract: A motor controller assembly is configured for use with an electric motor and includes a controller and an absorbent pad. The controller includes a capacitor with a capacitor shell and a liquid electrolyte contained therein. The capacitor shell has a frangible rupture area that opens during a capacitor rupture event to permit the discharge of liquid electrolyte from the capacitor shell. The absorbent pad overlies the rupture area to collect discharged liquid electrolyte.

Abstract: A motor control system providing at least seventeen speed settings using industry standard control signals and an industry standard five pin speed connector. One speed monitoring pin transmits an output signal for monitoring the speed of the motor, and four speed setting pins receive input signals for setting the speed. One of the speed setting pins receives and decodes two binary states and two frequency states, thereby providing a total of thirty-two speed settings. A non-regulated isolated winding is added to an internal transformer to provide an internal isolated flyback power supply for the motor, thereby liberating a pin on the industry standard five pin speed connector to provide the fourth speed setting input pin. Transmission circuitry is associated with the speed monitoring pin, and the non-regulated isolated winding is used to provide a direct current bias to the transmission circuitry.

Abstract: A motor controller assembly is configured for use with an electric motor and includes a controller and an absorbent pad. The controller includes a capacitor with a capacitor shell and a liquid electrolyte contained therein. The capacitor shell has a frangible rupture area that opens during a capacitor rupture event to permit the discharge of liquid electrolyte from the capacitor shell. The absorbent pad overlies the rupture area to collect discharged liquid electrolyte.

Abstract: An electric motor including a rotor, a stator, a motor housing having a controller can, and a controller having an electronic component disposed within the controller can. The controller can includes an insert comprising thermally conductive metal for exchanging heat with an external heat sink space.

Abstract: A motor assembly includes a motor, a controller for controlling at least one aspect of operation of the motor, a housing, and an insulation system. The housing defines a motor chamber at least substantially receiving the motor and a controller chamber at least substantially receiving the controller. The housing includes a generally annular sidewall at least in part defining the controller chamber. The sidewall includes an electrically conductive portion adjacent the controller, such that a generally radially extending potentially electrical pathway is defined between the controller and the electrically conductive portion. The insulation system extends along the electrically conductive portion, in electrically insulative engagement therewith, to at least in part obstruct the pathway.

Abstract: A system-specific interface module for a motor control subassembly for controlling operation of an electric motor within a larger system which uses a particular system communication method. The motor control subassembly includes a standard power module and the interface module. The power module includes a controller processor configured to receive input for controlling and to generate output regarding operation of the motor. The interface module includes a communication interface hardware block configured to exchange input and output signals with the larger system, and an interface processor configured to translate the input and output signals between the particular system communication method used by the larger system and a standard internal communication method used by the power module. Thus, the motor control subassembly can be configured to accommodate any of a variety of different system communication methods and other input/output options by selecting and inserting the appropriate interface module.

Abstract: A tool for programming a controller of an electric motor by engaging a connection block of the motor and providing high voltage power and communicating programming signals to the controller. The tool includes a body having an interface for engaging the connection block, and internal wiring presenting tool terminals at the interface for making contact with corresponding motor terminals to allow for providing power and communicating signals between the tool and the controller. An energy-limited transformer having an isolated high impedance secondary winding provides both electrical isolation to protect against shock and low energy output to protect against arc flash. Redundant interlocks include a software interlock which allows the power to be present at the interface only during actual programming of the controller. A light ring encircling the body indicates the presence of high voltage and is visible from multiple directions.

Abstract: A tool for programming a controller of an electric motor by engaging a connection block of the motor and providing high voltage power and communicating programming signals to the controller. The tool includes a body having an interface for engaging the connection block, and internal wiring presenting tool terminals at the interface for making contact with corresponding motor terminals to allow for providing power and communicating signals between the tool and the controller. An energy-limited transformer having an isolated high impedance secondary winding provides both electrical isolation to protect against shock and low energy output to protect against arc flash. Redundant interlocks include a software interlock which allows the power to be present at the interface only during actual programming of the controller. A light ring encircling the body indicates the presence of high voltage and is visible from multiple directions.

Abstract: A system-specific interface module for a motor control subassembly for controlling operation of an electric motor within a larger system which uses a particular system communication method. The motor control subassembly includes a standard power module and the interface module. The power module includes a controller processor configured to receive input for controlling and to generate output regarding operation of the motor. The interface module includes a communication interface hardware block configured to exchange input and output signals with the larger system, and an interface processor configured to translate the input and output signals between the particular system communication method used by the larger system and a standard internal communication method used by the power module. Thus, the motor control subassembly can be configured to accommodate any of a variety of different system communication methods and other input/output options by selecting and inserting the appropriate interface module.

Abstract: A tool for programming a controller of an electric motor by engaging a connection block of the motor and providing high voltage power and communicating programming signals to the controller. The tool includes a body having an interface for engaging the connection block, and internal wiring presenting tool terminals at the interface for making contact with corresponding motor terminals to allow for providing power and communicating signals between the tool and the controller. An energy-limited transformer having an isolated high impedance secondary winding provides both electrical isolation to protect against shock and low energy output to protect against arc flash. Redundant interlocks include a software interlock which allows the power to be present at the interface only during actual programming of the controller. A light ring encircling the body indicates the presence of high voltage and is visible from multiple directions.

Abstract: An electric motor including a rotor, a stator, a motor housing having a controller can, and a controller having an electronic component disposed within the controller can. The controller can includes an insert comprising thermally conductive metal for exchanging heat with an external heat sink space.

Abstract: A system-specific interface module for a motor control subassembly for controlling operation of an electric motor within a larger system which uses a particular system communication method. The motor control subassembly includes a standard power module and the interface module. The power module includes a controller processor configured to receive input for controlling and to generate output regarding operation of the motor. The interface module includes a communication interface hardware block configured to exchange input and output signals with the larger system, and an interface processor configured to translate the input and output signals between the particular system communication method used by the larger system and a standard internal communication method used by the power module. Thus, the motor control subassembly can be configured to accommodate any of a variety of different system communication methods and other input/output options by selecting and inserting the appropriate interface module.

Abstract: A motor assembly includes a motor, a controller for controlling at least one aspect of operation of the motor, a housing, and an insulation system. The housing defines a motor chamber at least substantially receiving the motor and a controller chamber at least substantially receiving the controller. The housing includes a generally annular sidewall at least in part defining the controller chamber. The sidewall includes an electrically conductive portion adjacent the controller, such that a generally radially extending potentially electrical pathway is defined between the controller and the electrically conductive portion. The insulation system extends along the electrically conductive portion, in electrically insulative engagement therewith, to at least in part obstruct the pathway.

Abstract: A motor control system for adjusting motor speed if a current overload condition occurs. The motor control system may include a motor, a power factor correction (PFC) circuit providing current to the motor, and a signal processor. The PFC circuit may limit current provided to the motor based on an output voltage sensed by the PFC circuit. The signal processor may sense input voltage of the PFC circuit to determine a power limit, then compare sensed or calculated drive power of the motor with the power limit. If the drive power sensed or calculated is greater than the power limit, the signal processor may output a signal for reducing the drive power to the power limit. Limiting the drive power provided to the motor limits or decreases a speed of the motor.

Abstract: An electric motor system having substantially independent hardware-based and software-based pathways for detecting and initiating responses to fault conditions, such as over-current conditions, in an electric motor which is powered by a power inverter which is controlled by a power module and a microprocessor. Each pathway involves comparing a voltage, which is representative of an electric current flowing to the motor, to a predetermined maximum voltage, and if the former exceeds the latter using hardware or software to initiate shutting off the motor, such as by shutting off the power inverter. When one pathway detects a fault condition it may notify the other pathway, and the notified pathway may also initiate shutting off the motor.

Abstract: A tool for programming a controller of an electric motor by engaging a connection block of the motor and providing high voltage power and communicating programming signals to the controller. The tool includes a body having an interface for engaging the connection block, and internal wiring presenting tool terminals at the interface for making contact with corresponding motor terminals to allow for providing power and communicating signals between the tool and the controller. An energy-limited transformer having an isolated high impedance secondary winding provides both electrical isolation to protect against shock and low energy output to protect against arc flash. Redundant interlocks include a software interlock which allows the power to be present at the interface only during actual programming of the controller. A light ring encircling the body indicates the presence of high voltage and is visible from multiple directions.

Abstract: A system for protecting an inrush resistor by determining whether an inrush relay connected in parallel with the resistor properly closes. A differential amplifier connected across the resistor produces an output signal that is proportional to the differential voltage. A control circuit determines whether the relay is open based on the output signal, and if the relay is open and the motor is running, takes remedial action to protect the inrush resistor. Alternatively, the amplifier is replaced with a slow response filter that produces an output signal that is a delayed version of a bus voltage. The control circuit determines the difference between the bus voltage and the output signal, and if it exceeds a predetermined value and the motor is running, takes remedial action to protect the inrush resistor. Remedial action may include shutting off the motor or restarting the motor to confirm improper behavior of the relay.