Abstract: Methods and systems for controlling an electric motor are provided. An electric motor controller is configured to be coupled to an electric motor. The controller includes a rectifier, an inverter coupled to the rectifier, and a control unit coupled to the inverter. The rectifier is configured to rectify an alternating current (AC) input voltage to produce a pulsed direct current (DC) voltage that drops to approximately zero during each cycle when the AC input voltage transits zero. Energy is stored on a load coupled to the motor when AC input voltage is available. The inverter is configured to receive the DC voltage and to provide a conditioned output voltage to the motor. The control unit is configured to manage energy transfer between the motor and the load such that the motor generates positive torque when the DC voltage supplied to the inverter has approximately 100% voltage ripple.

Abstract: Methods and systems for controlling an electric motor are provided. An electric motor controller is configured to be coupled to an electric motor. The controller includes a rectifier, an inverter coupled to the rectifier, and a control unit coupled to the inverter. The rectifier is configured to rectify an alternating current (AC) input voltage to produce a pulsed direct current (DC) voltage that drops to approximately zero during each cycle when the AC input voltage transits zero. Energy is stored on a load coupled to the motor when AC input voltage is available. The inverter is configured to receive the DC voltage and to provide a conditioned output voltage to the motor. The control unit is configured to manage energy transfer between the motor and the load such that the motor generates positive torque when the DC voltage supplied to the inverter has approximately 100% voltage ripple.

Abstract: An electric motor controller is configured to be coupled to an electric motor. The controller includes an inverter and a control unit coupled to the inverter. The inverter is configured to receive an input voltage and to provide a conditioned output voltage to the electric motor. The control unit is configured to control the electric motor to produce positive torque when direct current (DC) link voltage has a 100% voltage ripple. Methods for controlling an electric motor using the electric motor controller are also provided.

Abstract: A control system for a motor includes an inverter coupled to the motor. The control system further includes a microcontroller coupled to the inverter. The microcontroller includes a processor programmed to measure an input voltage and acquire a back EMF voltage of the motor. The processor is also programmed to control the inverter to regulate the motor voltage based on the input voltage and the back EMF voltage to facilitate controlling the motor.

Abstract: A control system for a motor includes an inverter coupled to the motor. The control system further includes a microcontroller coupled to the inverter. The microcontroller includes a processor programmed to measure an input voltage and acquire a back EMF voltage of the motor. The processor is also programmed to control the inverter to regulate the motor voltage based on the input voltage and the back EMF voltage to facilitate controlling the motor.

Abstract: An electric motor controller is configured to be coupled to an electric motor. The controller includes an inverter and a control unit coupled to the inverter. The inverter is configured to receive an input voltage and to provide a conditioned output voltage to the electric motor. The control unit is configured to control the electric motor to produce positive torque when direct current (DC) link voltage has a 100% voltage ripple. Methods for controlling an electric motor using the electric motor controller are also provided.

Abstract: A control system for a motor includes an inverter coupled to the motor. The control system further includes a microcontroller coupled to the inverter. The microcontroller includes a processor programmed to measure an input voltage and acquire a back EMF voltage of the motor. The processor is also programmed to control the inverter to regulate the motor voltage based on the input voltage and the back EMF voltage to facilitate controlling the motor.

Abstract: A motor assembly includes a control sub-assembly configured to be mounted either remotely or integrally to a motor. The control sub-assembly includes a control housing, a control housing cover, electronic control components, and at least one sensing wire connected to the motor. The control housing cover includes a first attachment portion and a second attachment portion. The first attachment portion attaches the control housing cover to the control housing and the second attachment portion attaches the control housing cover to the motor. If the control sub-assembly is to be mounted remotely from the motor, the second attachment portion is not connected to the motor.

Abstract: A rotor position sensor mounting system includes a sensor assembly fixedly engaged with a stator assembly. The stator assembly includes a plurality of stator laminations including a plurality of sections separated by a plurality of first gaps. Each first gap is defined by a first pair of edges. The stator assembly also includes first and second stator end caps attached to the stator laminations and including a plurality of sections separated by a plurality of second gaps. Each second gap is defined by a pair of stator end cap section edges. At least one pair of stator end cap section edges includes a first notch and a second notch separated by a bridge. The sensor assembly engages the second notch and is maintained in position with the bridge and the stator laminations.

Abstract: A motor assembly includes a control sub-assembly configured to be mounted either remotely or integrally to a motor. The control sub-assembly includes a control housing, a control housing cover, electronic control components, and at least one sensing wire connected to the motor. The control housing cover includes a first attachment portion and a second attachment portion. The first attachment portion attaches the control housing cover to the control housing and the second attachment portion attaches the control housing cover to the motor. If the control sub-assembly is to be mounted remotely from the motor, the second attachment portion is not connected to the motor.

Abstract: An electric motor includes a rotor cup housing having an annular flange extending circumferentially from a sidewall. The motor further includes a stator including a stator core having a winding thereon and a rotor positioned at least partially around the stator. A rotor shaft is positioned at least partially within the stator.

Abstract: An electronically commutated motor assembly permits a user to select discrete operating speed options to operate an electronically commutated motor. The assembly includes a motor, an input/output unit electrically connected to the motor, a connector and board and a microprocessor. The connector and board includes an electrically erasable programmable read-only memory (EEPROM), a plurality of low voltage signal connections for programming the EEPROM, and a plurality of speed signal connections for selecting an operating speed for the electronically commutated motor. The low voltage signal connections permit the EEPROM to be programmed with speed tables containing schedules of operating speeds.

Abstract: A rotor position sensor mounting assembly includes a housing, a hall effect device, a printed circuit board, a plurality of leads, and a cable tie. The housing includes two pairs of guides that fixedly attach the housing to a stator end cap and a plurality of stator laminations. The second pair of housing guides extend substantially flush with the top wall. A gap extends between the first pair of housing guides and the second pair of housing guides and the first pair of housing guides has a wedge shape. In addition, a pair of internal guides extend from the second side walls into the cavity such that the internal guides form the cavity into a substantially inverted T at a first end of the housing to precisely locate the hall effect device.

Abstract: A motor system including a gate drive for driving a motor. An inverter bridge circuit selectively connects power supply link rails to a winding of the motor for energizing the winding with a motoring current. The bridge circuit has upper and lower power switches connected between the winding and the upper and lower power supply link rails, respectively. Each lower switch corresponds to one of the upper switches on the same side of the winding as the lower switch to define an arm of the bridge circuit. A control circuit generates a motor control signal to control the switches. A drive circuit drives the upper switches in response to the state of the corresponding lower switches, which are responsive to the motor control signal. The drive circuit includes a voltage gain element connected to each arm of the bridge circuit that is responsive to current in the respective lower switch for maintaining the corresponding upper switch in its nonconducting state.

Abstract: An electronically commutated motor assembly permits a user to select discrete operating speed options to operate an electronically commutated motor. The assembly includes a motor, an input/output unit electrically connected to the motor, a connector and board and a microprocessor. The connector and board includes an electrically erasable programmable read-only memory (EEPROM), a plurality of low voltage signal connections for programming the EEPROM, and a plurality of speed signal connections for selecting an operating speed for the electronically commutated motor. The low voltage signal connections permit the EEPROM to be programmed with speed tables containing schedules of operating speeds.

Abstract: A method for assembling an inside out motor includes the step of stacking a plurality of laminations together to form a pole member. A stator is molded around the pole member so that an end of the pole member is located adjacent an exterior surface of the molded stator. An electrically conductive magnet wire is wound around the molded stator adjacent the pole member to form a winding of the motor.

Abstract: An inside out electric motor includes a rotor having an interior surface defining an interior space and a magnetic element mounted on the rotor. The motor also includes a stator having a bobbin. The bobbin has a bearing positioned at a central axis of the bobbin. The bearing rotatably engages the rotor to permit the rotor to freely rotate with respect to the stator. The bobbin also has a pole member molded into the bobbin so that an end of the pole member is spaced radially inward from and at least partially aligned with the magnetic element, and a winding wound around the bobbin so that the winding passes adjacent the pole member.

Abstract: A motor system having a stationary assembly including a winding and a rotatable assembly in magnetic coupling relation to the stationary assembly. A power supply link having upper and lower rails supplied by a power supply provides power to the motor winding. The power supply link has power switches responsive to a motor control signal for selectively connecting the rails to the winding to energize the winding with a motor current whereby an electromagnetic field is produced for rotating the rotatable assembly. The power switches include a set of upper power switches and a set of lower power switches. Each of the power switches has a conducting state and a nonconducting state. The system includes a disable circuit for selectively generating a disable signal and a control circuit for generating the motor control signal to control the power switches.

Abstract: A system for controlling circulating currents in a motor. A power supply link having upper and lower rails supplied by a power supply provides power to the motor windings. The power supply link also has power switches responsive to a motor control signal for selectively connecting the rails to the windings in alternating on and off intervals. The system includes a first resistive shunt in the upper rail of the power supply link between the power supply and the power switches and a second resistive shunt in the lower rail of the power supply link between the power supply and the power switches. The power supply link routes current circulating in the power supply link and windings through either the first or second resistive shunt for continuously sensing current in the rails. The system also includes a current regulation circuit which generates an overcurrent signal as a function of the current sensed in either the first or second resistive shunt exceeding a maximum current level.

Abstract: A current regulation circuit for a motor. The motor includes a stationary assembly having windings adapted for energization in at least one preselected sequence and a rotatable assembly in magnetic coupling relation to the stationary assembly. A power supply link connects the windings to a power supply and includes power switching devices for selectively energizing the windings in the preselected sequence by selectively connecting the power supply link to the windings to produce an electromagnetic field for rotating the rotatable assembly. The power switching devices each have a conducting state and a nonconducting state. The current regulation circuit includes a timing circuit, a current sensing circuit and a control circuit. The timing circuit defines preset periods during which each of the power switching devices may be nonconducting. The current sensing circuit senses current in the power supply link.