Abstract: A strategy to control and diagnose the operation of an electric motor using a sensorless control system augmented by feedback from a position and speed sensor is disclosed. The strategy can improve the robustness of operation and diagnose potential faults in electric motors. The present invention includes a method for diagnosing operation of an electric motor and a method and system for controlling an electric motor. In the diagnostic method, a sensorless system and a sensor based system are checked against each other to determine if either of the systems is faulted. In the control method, the sensor based control system is used when the motor speed is below a predetermined threshold and the sensorless system is used when the motor speed is above the predetermined threshold. The position sensor can be a low resolution position sensor, an engine crankshaft sensor, an engine camshaft sensor, or a transmission sensor.

Abstract: A strategy to control and diagnose the operation of an electric motor using a sensorless control system augmented by feedback from a position and speed sensor is disclosed. The strategy can improve the robustness of operation and diagnose potential faults in electric motors. The present invention includes a method for diagnosing operation of an electric motor and a method and system for controlling an electric motor. In the diagnostic method, a sensorless system and a sensor based system are checked against each other to determine if either of the systems is faulted. In the control method, the sensor based control system is used when the motor speed is below a predetermined threshold and the sensorless system is used when the motor speed is above the predetermined threshold. The position sensor can be a low resolution position sensor, an engine crankshaft sensor, an engine camshaft sensor, or a transmission sensor.

Abstract: A method of manufacturing electric machines comprised of geometrically patterned arrays of permanent magnets, soft magnetic materials, and electrical conductors deposited by kinetic spraying methods directly atop a carrier. The magnets and planar coils of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.

Abstract: A method of manufacturing electric machines comprised of geometrically patterned arrays of permanent magnets, soft magnetic materials, and electrical conductors deposited by kinetic spraying methods directly atop a carrier. The magnets and planar coils of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.

Abstract: A method of manufacturing electric machines comprised of geometrically patterned arrays of permanent magnets, soft magnetic materials, and electrical conductors deposited by kinetic spraying methods directly atop a carrier. The magnets and planar coils of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.

Abstract: A method of manufacturing a permanent magnet by the steps of preparing an admixture of magnetic material and binder material, the admixture material having a particle size of less than 325 mesh. Then heating a carrier gas to a temperature substantially below the melting point of either component of the admixture. The admixture is introduced into the carrier gas and the admixture is sprayed atop a ductile carrier. The admixture adheres to the carrier and forms a solid permanent magnet. An electric field is applied to the sprayed admixture to create a permanent magnetic moment.

Abstract: A method of manufacturing electric machines comprising the steps of kinetically spraying a powdered admixture of magnetic material and ductile binder material on to a substrate and applying a concentrated magnetic field to the sprayed admixture to cause magnetic dipole alignment in the sprayed admixture. The magnets of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.

Abstract: An electric machine made from kinetically sprayed permanent magnet material and a binder material form a composite admixture having microstructure of permanent magnet material embedded in the binder material. The admixture has a permanent magnetic moment. The magnets of the present invention may be integrally formed atop carriers to form electrical machines such as motors, generators, alternators, solenoids, and actuators. The manufacturing techniques used in this invention may produce highly defined articles that do not require additional shaping or attaching steps. Very high-purity permanent and soft magnetic materials, and conductors with low oxidation are produced.