Abstract: A motor includes a stator comprising windings configured to be energized, and a rotor electromagnetically coupled to the stator and configured to turn relative thereto when the stator is energized. The motor also includes a motor controller configured to measure a speed at which the rotor turns, and energize said stator to generate a first torque output at the rotor when the measured speed is below a first threshold. The motor controller is also configured to energize the stator to generate a second torque output at the rotor when the measured speed is at least the first threshold, wherein the second torque output is greater than the first torque output.

Abstract: An alternating current (AC) motor system and control methods are provided herein. The AC motor system includes a motor having a first rated horsepower and configured to be coupled to a power source, and a drive circuit configured to be electrically coupled between the power source and the motor. The drive circuit has a second rated horsepower that is lower than the first rated horsepower.

Abstract: A motor controller for controlling an electric motor includes at least one integrated sensor disposed on the electric motor. The least one integrated sensor is configured to collect sensor data associated with a status of the electric motor for a period of time, the period of time beginning at an activation time and extending at least until an installation time. The motor controller may include an energy management system configured to power the at least one integrated sensor for at least a portion of the period of time, and a memory device configured to store the sensor data. The motor controller may include a data management system configured to communicate the sensor data from the at least one integrated sensor to at least one of the memory device and a remote device.

Abstract: A motor controller for controlling an electric motor includes at least one integrated sensor disposed on the electric motor. The least one integrated sensor is configured to collect sensor data associated with a status of the electric motor for a period of time, the period of time beginning at an activation time and extending at least until an installation time. The motor controller may include an energy management system configured to power the at least one integrated sensor for at least a portion of the period of time, and a memory device configured to store the sensor data. The motor controller may include a data management system configured to communicate the sensor data from the at least one integrated sensor to at least one of the memory device and a remote device.

Abstract: An electric motor for use with a power supply includes a housing and a stator fixedly secured to the housing. The stator has a plurality of coils secured to the stator. The motor also includes a first rotor secured to the stator and having a first number of poles and a second rotor secured to the stator and having a second number of poles. The second number being different than the first number. The plurality of coils cooperates with the first rotor to rotate the first rotor at a first rotor rotational speed and the plurality of coils cooperates with the second rotor to rotate the second rotor at a second rotor rotational speed. The second rotor rotational speed is substantially different than the first rotor rotational speed.

Abstract: Controllers for controlling hybrid motor drive circuits configured to drive a motor are provided herein. A controller is configured to drive the motor using an inverter when a motor commanded frequency is not within a predetermined range of line input power frequencies, and couple line input power to an output of the inverter using a first switch device when the motor commanded frequency is within the predetermined range of line input power frequencies.

Abstract: A pump includes a housing including a first portion thereof defining opposed parallel spaced apart internal and exterior generally planar surfaces. The pump also includes a first impeller rotatably secured to the housing and positioned within the housing. The pump also includes a first axial flux motor connected to the first impeller and at least partially positioned within the housing. The first axial flux motor includes a first motor rotor fixedly secured to the first impeller. The first motor rotor has a generally planar surface thereof positioned adjacent to and parallel to the internal generally planar surface of the first portion of the housing. The first axial flux motor includes a first motor stator fixedly secured to the housing. The first motor stator has a generally planar surface thereof positioned adjacent to and parallel to the external generally planar surface of the first portion of the housing.

Abstract: A motor includes a stator comprising windings configured to be energized, and a rotor electromagnetically coupled to the stator and configured to turn relative thereto when the stator is energized. The motor also includes a motor controller configured to measure a speed at which the rotor turns, and energize said stator to generate a first torque output at the rotor when the measured speed is below a first threshold. The motor controller is also configured to energize the stator to generate a second torque output at the rotor when the measured speed is at least the first threshold, wherein the second torque output is greater than the first torque output.

Abstract: A stator assembly includes an annular body extending about a central axis and a first stator tooth extending radially from the annular body. The first stator tooth includes a first tip spaced radially from the annular body. The stator assembly also includes a second stator tooth extending radially from the annular body and spaced circumferentially from the first stator tooth. The second stator tooth includes a second tip spaced radially from the annular body. The stator assembly further includes a stiffener positioned between the first stator tooth and the second stator tooth. The stiffener is configured to resist deformation of the stator assembly.

Abstract: A pumping device for pumping a fluid is provided. The pumping device includes a pump and a power housing. At least a portion of the pump is positioned within the power housing. The pumping device also includes a first motor and a second motor. The first motor is operably connected to the pump and adapted to provide energy to the pump. At least a portion of the first motor is positioned within the power housing. The second motor is operably connected to the pump and adapted to provide energy to the pump. At least a portion of the second motor is positioned within the power housing.

Abstract: A permanent split capacitor (PSC) motor includes a stator defining an axis of rotation and a rotor disposed adjacent the stator. The stator includes a start winding, a capacitor electrically coupled in series with the start winding, a first plurality of windings, and a second plurality of windings. At least one winding of the first plurality of windings is energized in parallel with at least one winding of the second plurality of windings at a first voltage and in series with the at least one winding of the second plurality of windings at a second voltage. The first and second pluralities of windings are energized to produce a plurality of motor speeds. The rotor rotates relative to the stator about the axis of rotation at a selected one of the plurality of motor speeds induced at least partially by a magnetic output of the windings of the stator.

Abstract: An alternating current (AC) motor system and control methods are provided herein. The AC motor system includes a motor having a first rated horsepower and configured to be coupled to a power source, and a drive circuit configured to be electrically coupled between the power source and the motor. The drive circuit has a second rated horsepower that is lower than the first rated horsepower.

Abstract: An electric motor assembly includes a rotor assembly configured to rotate about a central axis and a stator assembly configured to extend about the rotor assembly. The rotor assembly includes at least one of the following: a plurality of spokes and at least one neodymium iron boron magnet. The stator assembly includes an annular body including an inner surface and an outer surface. A first thickness is defined between the inner surface and the outer surface. The stator assembly also includes a plurality of stator teeth extending radially from the annular body and spaced circumferentially about the annular body. Each stator tooth has a second thickness. A ratio of the second thickness to the first thickness is in a range of about 0.5 to about 1. The stator assembly includes no more than 24 slots defined by the plurality of stator teeth.

Abstract: Controllers for controlling hybrid motor drive circuits configured to drive a motor are provided herein. A controller is configured to drive the motor using an inverter when a motor commanded frequency is not within a predetermined range of line input power frequencies, and couple line input power to an output of the inverter using a first switch device when the motor commanded frequency is within the predetermined range of line input power frequencies.

Abstract: A method for making a component for use in an electric machine is provided. The method includes applying first and second portions of a first material to a first surface, applying a second material to the first portion of first material; bonding the second material to the first portion of the first material, removing the second portion of the first material to form a void defined by the first portion of the first material, applying a conductive material in the void, and applying an insulating layer to the second material, wherein the process for preparing the component further comprising the steps of: applying first and second portions of a third material to the insulating layer; applying a fourth material to the first portion of third material, and bonding the fourth material to the first portion of the third material.

Abstract: In one embodiment, a permanent magnet rotor is provided. The permanent magnet rotor includes at least one permanent magnet and a substantially cylindrical rotor core including an outer edge and an inner edge defining a central opening. The rotor core includes a radius R, at least one pole, and at least one radial aperture extending radially though the rotor core from the outer edge to a predetermined depth less than the radius. The at least one radial aperture is configured to receive the at least one permanent magnet. The rotor further includes at least one protrusion extending into the at least one radial aperture, the at least one protrusion positioned substantially along a bottom of the at least one radial aperture and configured to facilitate retention of the at least one permanent magnet within the at least one radial aperture.

Abstract: In one embodiment, a permanent magnet rotor is provided. The permanent magnet rotor includes at least one permanent magnet and a substantially cylindrical rotor core including an outer edge and an inner edge defining a central opening. The rotor core includes a radius R, at least one pole, and at least one radial aperture extending radially though the rotor core from the outer edge to a predetermined depth less than the radius. The at least one radial aperture is configured to receive the at least one permanent magnet. The rotor further includes at least one protrusion extending into the at least one radial aperture, the at least one protrusion positioned substantially along a bottom of the at least one radial aperture and configured to facilitate retention of the at least one permanent magnet within the at least one radial aperture.

Abstract: A method for making a component for use in an electric machine is provided. The method includes applying first and second portions of a first material to a first surface, applying a second material to the first portion of first material; bonding the second material to the first portion of the first material, removing the second portion of the first material to form a void defined by the first portion of the first material, applying a conductive material in the void, and applying an insulating layer to the second material, wherein the process for preparing the component further comprising the steps of: applying first and second portions of a third material to the insulating layer; applying a fourth material to the first portion of third material, and bonding the fourth material to the first portion of the third material.

Abstract: An electric motor controller and methods of determining which input power line of a plurality of input power lines of a motor drive controller has been energized are provided. An electric motor controller configured to be coupled to an electric motor includes a plurality of power input lines configured to receive an alternating current (AC) input voltage from an AC power source, an energized line detection device configured to sense that a power input line has been energized by the AC power source, and configured to output an isolated signal, and a rectifier configured to convert the AC input voltage having a frequency to a direct current (DC) voltage. The controller also includes a computing device coupled downstream from the energized line detection device and configured to determine which input power line has been energized.

Abstract: Controllers for controlling hybrid motor drive circuits configured to drive a motor are provided herein. A controller is configured to drive the motor using an inverter when a motor commanded frequency is not within a predetermined range of line input power frequencies, and couple line input power to an output of the inverter using a first switch device when the motor commanded frequency is within the predetermined range of line input power frequencies.