Abstract: A method provides, on a printed circuit board 16, at least a first and a second printed circuit board fuse trace A, B placed in parallel with each other in a main current carrying path 18. In a normal operating condition, it is ensured that 1) all of the traces carry a portion of a load current and 2) the traces are configured to prevent opening of the traces in the normal operating condition. When a fault condition occurs, it is ensured that the first trace A opens before a resistance thereof increases so as to divert more of a load current to the second trace B, thereby causing the second trace B to open after opening of the first trace A.

Abstract: A method of connecting stranded wire to a lead-frame body 10 includes the provision of a stranded wire 12. It is ensured that insulation is stripped from an end 14 of the stranded wire. An electrically conductive lead-frame connection structure 16 is associated with the lead-frame body. The end 14 of the stranded wire is inserted into the lead-frame connection structure 16 so that the lead-frame connection structure substantially surrounds the wire end. Solder flux is injected so as to be substantially about a portion of the end of the stranded wire. The lead-frame connection structure is placed in contact with a bottom resistance welding electrode 18 or a top resistance welding electrode 20.

Abstract: A dual motor arrangement includes a first motor M1, a first MOSFET Q1 constructed and arranged to control operation of the first motor, a second motor M2, a second MOSFET Q2 constructed and arranged to control operation of the second motor, an RFI filter structure L1, C_RFI, a freewheeling circuit L2, C2, and a controller S. The controller is constructed and arranged to provide a first PWM signal to the first MOSFET and a second PWM signal to the second MOSFET. The second PWM signal is in staggered time relation with respect to the first PWM signal. When one motor is in a freewheeling mode of operation for at least a portion of a time that the MOSFET, associated with the other motor, is on, freewheeling of the one motor decreases an amount of current drawn by the other motor during turn on of the other motor. The inductors L1, L2 can be coupled to define a transformer.

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 dual motor configuration 10 is provided for driving two fans for moving air to cool an engine. The dual motor configuration includes a primary brushless motor 18 constructed and arranged to be electronically controlled to drive a first fan 16 over a range of speeds. A secondary brush motor 24 is constructed and arranged to be electronically controlled to drive a second fan 22 over a range of speeds. The secondary brush motor includes an electronic switching device 26 associated therewith for receiving a pulse width modulated signal for controlling speed of the secondary brush motor. Thus, different combinations of speeds of the first and second motors can be selectively chosen to meet cooling requirements.

Abstract: A closed-loop system 10 is provided for controlling a DC motor. The system includes a DC motor 12, a controller 18 associated with the motor and constructed and arranged to control operation of the motor, a voltage sensor 14 constructed and arranged to measure a voltage supplied to the motor, a speed sensor 16 associated with the motor and constructed and arranged to obtain a measured speed of the motor, and a conditioning circuit 21 constructed and arranged to receive a speed signal and condition the speed signal to provide to the controller, a nominal speed based on the voltage supplied to the motor, or nominal rate of acceleration or deceleration upon a change in the desired speed. The controller 18 is constructed and arranged to compare the measured speed with a certain speed, that is less than the nominal speed, at a voltage corresponding to a measured voltage, and if the measured speed is less than the certain speed, a fault condition is defined by the controller.

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 circuit 100 for a five phase DC brushless motor includes a first coil A and a first primary switch S1 for controlling current through the first coil; a second coil B and a second primary switch S3 for controlling current through the second coil; a third coil C and a third primary switch S5 for controlling current through the third coil; a fourth coil D and a fourth primary switch S7 for controlling current through the fourth coil; a fifth coil E and a fifth primary switch S9 for controlling current through the fifth coil.

Abstract: A dual motor configuration 10 includes a primary brushless motor 18 electronically controlled to be driven at various speeds throughout a range of motor speeds. A secondary brush motor 24 electronically controlled be driven at various speeds throughout a range of motor speeds. The secondary brush motor includes an electronic switching device 26 associated therewith for receiving a pulse width modulated signal for controlling speed of the secondary brush motor. Thus, different combinations of speeds, throughout the ranges of motor speeds, of the first and second motors can be selectively chosen.

Abstract: A method and system for determining the commutation position in a DC machine using a single-bit rotor sensor and the back EMF signal from a stator winding by calculating a delay value, which is equal to the time elapsed between detection of the position signal and the back EMF signal, and establishing commutation after a period of time equal to the delay value has elapsed from when the position signal is detected.

Abstract: A method of starting a brushless DC motor 12 at any initial speed (A) establishes a initial stator-field speed and setting a counter of synchronization, (B) measures a speed of a rotor of the motor, (C) compares the speed of the rotor with the stator-field speed to determine if the rotor is synchronized with the stator-field. If the rotor is not synchronized with the stator-field, the method includes (a) re-setting the counter of synchronization, (b) increasing an acceleration portion of motor current (Iacc) to enhance torque, (c) setting the stator-field speed higher than the rotor speed, (d) calculating a period of an open-loop timer, (e) calculating a value for a load portion of the motor current (Ild), where total motor current I=Iacc+Ild, (f) performing commutation based on the open-loop timer and returning to step (B) until the rotor is synchronized with the stator-field.

Abstract: A system 10 provides a variable output voltage to a DC brush motor. The system includes a DC brush motor 14, a DC voltage source 12, a step-up, step-down DC/DC converter 16 including a switch 18. The DC/DC converter is constructed and arranged to step-up and step-down voltage from the source to provide an output voltage to the motor between 0 and 42 volts. A control unit 22 is constructed and arranged to receive an input signal 20 and to control the switch based on the input signal to control the motor.

Abstract: A method and system for determining the commutation position in a brushless DC machine using a single-bit position sensor and the back EMF signal from a stator winding by measuring a delay value, which is equal to the time elapsed between detection of the position signal and the back EMF signal, and establishing commutation after a period of time equal to the delay value has elapsed from when the position signal is detected.

Abstract: A dual motor configuration 10 is provided for driving two fans for moving air to cool an engine. The dual motor configuration includes a primary brushless motor 18 constructed and arranged to be electronically controlled to drive a first fan 16 over a range of speeds. A secondary brush motor 24 is constructed and arranged to be electronically controlled to drive a second fan 22 over a range of speeds. The secondary brush motor includes an electronic switching device 26 associated therewith for receiving a pulse width modulated signal for controlling speed of the secondary brush motor. Thus, different combinations of speeds of the first and second motors can be selectively chosen to meet cooling requirements.

Abstract: A method of starting a brushless DC motor 12 at any initial speed (A) establishes a initial stator-field speed and setting a counter of synchronization, (B) measures a speed of a rotor of the motor, (C) compares the speed of the rotor with the stator-field speed to determine if the rotor is synchronized with the stator-field. If the rotor is not synchronized with the stator-field, the method includes (a) re-setting the counter of synchronization, (b) increasing an acceleration portion of motor current (Iacc) to enhance torque, (c) setting the stator-field speed higher than the rotor speed, (d) calculating a period of an open-loop timer, (e) calculating a value for a load portion of the motor current (Ild), where total motor current I=Iacc+Ild, (f) performing commutation based on the open-loop timer and returning to step (B) until the rotor is synchronized with the stator-field.

Abstract: A heat sink 28 is provided for removing heat from a component 30 on a circuit board 22. The heat sink 28 includes a base 12 having a top 14, a bottom 16, and opposing sides 18 and 20. The top is generally planar for being adhered to a circuit board. Each of the opposing sides has a cutout defining a stepped shoulder 26. The heat sink also includes a plurality of fins 24 extending from the bottom of the base. Locating structure 50 is provided on the top of the heat sink for locating the heat sink with respect to the circuit board 22. Since the heat sink can be glued to the circuit board, a common heat sink can be used for any power electronics component.

Abstract: A system 10 provides a variable output voltage to a DC brush motor. The system includes a DC bush motor 14, a DC voltage source 12, a step-up, step-down DC/DC converter 16 including a switch 18. The DC/DC converter is constructed and arranged to step-up and step-down voltage from the source to provide an output voltage to the motor between 0 and 42 volts. A control unit 22 is constructed and arranged to receive an input signal 20 and to control the switch based on the input signal to control the motor.

Abstract: A heat sink 28 is provided for removing heat from a component 30 on a circuit board 22. The heat sink 28 includes a base 12 having a top 14, a bottom 16, and opposing sides 18 and 20. The top is generally planar for being adhered to a circuit board. Each of the opposing sides has a cutout defining a stepped shoulder 26. The heat sink also includes a plurality of fins 24 extending from the bottom of the base. Locating structure 50 is provided on the top of the heat sink for locating the heat sink with respect to the circuit board 22. Since the heat sink can be glued to the circuit board, a common heat sink can be used for any power electronics component.

Abstract: A circuit 100 for a five phase DC brushless motor includes a first coil A and a first primary switch S1 for controlling current through the first coil; a second coil B and a second primary switch S3 for controlling current through the second coil; a third coil C and a third primary switch S5 for controlling current through the third coil; a fourth coil D and a fourth primary switch S7 for controlling current through the fourth coil; a fifth coil E and a fifth primary switch S9 for controlling current through the fifth coil.

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.