Abstract: An electric motor is described in which a first magnet wire forms a first pole of the coil, is disposed across two terminals of a fuse, and terminates at a first end on a power switch. The portion of the first magnet wire between the terminals of the fuse is severed such that all current of the motor must travel through the conductor of the fuse. The second end of the first magnet wire terminates at dual tang terminal disposed on the brush housing.

Abstract: A vacuum cleaner includes a tank having a bottom and an inlet for receiving debris, a motor assembly disposed adjacent to the tank, the motor assembly adapted to draw debris into the tank through the inlet, a battery pack disposed adjacent the bottom of the tank, and a connection from the battery pack to the motor assembly that is adapted to carry current between the battery pack and the motor assembly. The battery pack includes at least one battery and supplies power to the motor assembly.

Abstract: Disclosed herein is a battery charger control circuit having a voltage detector to generate a signal indicative of a source voltage level to select one of a first charging mode and a second charging mode, and a charge controller coupled to the voltage detector to enable charging in accordance with one of the first charging mode and the second charging mode based on the signal from the voltage detector. The first and second charging modes establish charging at differing, non-zero rates. The source voltage level may be sampled at a sampling rate to minimize power consumed by monitoring the source voltage level.

Abstract: The disclosed mulcher has a base unit and a shredding blade in a removable assembly. Two different embodiments are disclosed. In both embodiments, shredded material is removed from air exiting the shredding blade before it reaches an exhaust port. In one embodiment, the material is removed by a filter. In the other embodiment, walls are arranged so that debris must double back against high-speed airflow leaving the shredding blade before exiting the unit. The shredding blade can be mounted in front of and on the same shaft as an air impeller, with the back surface of the shredding blade being supported by the impeller. In another embodiment, the air impeller and the shredding blade are carried in assemblies that are separable from each other and are each separately attachable to a base unit. A detachable power module and a detachable blower are also shown. The power module has a safety switch that disables the power module when it is removed.

Abstract: A motor is disclosed that operates on either AC outlet power or DC battery power with decreased power drop when switching between AC and DC power. The AC power to the motor may be stepped down by using a clipper circuit, while the DC power supplied to the motor may be increased by switching motor field windings from a series wound circuit to a parallel wound circuit. The motor may be used in a vacuum motor embodiment, or in other consumer devices that utilize electric motors.

Abstract: A reluctance machine includes a stator having a stator core. The stator core includes a central bore and a plurality of stator poles extending inwardly from the stator core. Each of the stator poles includes a stator pole face. The reluctance machine further includes a rotor having a plurality of rotor poles. Each of the rotor poles includes a rotor pole face. Each of the rotor pole faces includes a first portion, a second portion that is radially inwardly stepped with respect to the first portion to create a non-uniform air gap between the rotor pole face and a corresponding stator pole face, and a protrusion located at an edge of the second portion of the rotor pole face.

Abstract: A method for assembling a motor shaft with a bearing, a motor housing, and an impeller is disclosed. A motor shaft extension is used to retain the impeller axially on the motor shaft and allows the motor shaft to drive an additional component, such as an impeller, located a distance from the motor. The motor shaft extension may be fabricated from aluminum or hardened steel. Additionally, the motor shaft extension may be embodied in a tube extending past the end of the motor shaft and a shaft extension pressed into the end of the tube.

Abstract: A system and method of restarting a switched reluctance motor after a cycling of power provided to the motor is provided that includes receiving at the motor a power-off signal followed by a power-on signal, determining a rotational speed of a rotor, and energizing a stator only when the rotational speed of the rotor is determined to be less than a threshold speed.

Abstract: A switched reluctance machine includes a stator body having a stator pole. A bobbin is located on the stator pole. A stator winding is disposed on the bobbin. The switched reluctance machine further includes a first housing unit for receiving the stator body and an insulating member coupled to the first housing unit. The insulating member includes a first mounting element for engaging a first end of the bobbin to secure the bobbin against displacement during machine operation.

Abstract: A vacuum cleaner is provided having a tank with an inlet for receiving liquid material and defining an interior. An air impeller housing has an opening in air flow communication with the tank interior, and an air impeller is disposed inside the air impeller housing. A motor is disposed inside a motor housing and operatively coupled to the air impeller, and a switch is provided having a first position in which power is provided to the motor and a second position in which power to the motor is interrupted. A float is disposed in the tank and a float rod extends between the tank and the switch, the float rod being capable of moving the switch from the first position to the second position. A seal is positioned intermediately along the float rod to create a water-tight barrier between opposite ends of the float rod.

Abstract: A method for assembling a motor shaft with a bearing, a motor housing, and an impeller is disclosed. A motor shaft extension is used to retain the impeller axially on the motor shaft and allows the motor shaft to drive an additional component, such as an impeller, located a distance from the motor. The motor shaft extension may be fabricated from aluminum or hardened steel. Additionally, the motor shaft extension may be embodied in a tube extending past the end of the motor shaft and a shaft extension pressed into the end of the tube.

Abstract: A support structure includes first and second support members which are interlocked with a body. The second support member is placed in a die such that a hole of the second support member is located at a predetermined position and the body is placed on the second support member. The first support member is placed on the body such that apertures of the support members and an opening of the body are aligned. A shaping pin is then advanced toward the first support member in alignment with the predetermined position so that a shoulder of the shaping pin extends into the first support member. The shaping pin continues to advance through the first support member until a portion of the body extends past a surface of the second support member, thereby joining the first and second support members and the body together.

Abstract: A vacuum cleaner is provided having a tank with an inlet for receiving liquid material and defining an interior. An air impeller housing has an opening in air flow communication with the tank interior, and an air impeller is disposed inside the air impeller housing. A motor is disposed inside a motor housing and operatively coupled to the air impeller, and a switch is provided having a first position in which power is provided to the motor and a second position in which power to the motor is interrupted. A float is disposed in the tank and a float rod extends between the tank and the switch, the float rod being capable of moving the switch from the first position to the second position. A seal is positioned intermediately along the float rod to create a water-tight barrier between opposite ends of the float rod.

Abstract: A vacuum cleaner capable of drawing different current levels in vacuum and blower modes is disclosed. The vacuum cleaner comprises at least one electric motor and an impeller disposed in an impeller housing, the impeller driven by the at least one electric motor. A receptacle has an inlet and an orifice in fluid communication with the impeller housing, wherein the impeller creates a low pressure area in the receptacle thereby drawing air into the inlet. An outlet is in air flow communication with the impeller housing, wherein air from the impeller is expelled through the outlet. A switch is associated with the outlet, wherein the switch has a first position in which a first current may be drawn by the at least one motor and a second position in which a second current, less than the first current, may be drawn by the at least one motor. A device is removably attached to the outlet for directing air.

Abstract: A thermal protection mechanism for electric motors includes a pair of spaced contacts secured to an electrically insulating carrier having a cavity and a surface adjacent to a motor winding. The surface of the carrier has an aperture that forms a thermal passage between the surface of the carrier and the cavity. The contacts are engaged with a fusible electrically conductive pin made of solder that is disposed within the cavity and that interposes along a current path to the windings of a motor. A high winding temperature causes the pin to fuse, thereby terminating operation of the motor.

Abstract: A support structure includes first and second support members which are interlocked with a body. The second support member is placed in a die such that a hole of the second support member is located at a predetermined position and the body is placed on the second support member. The first support member is placed on the body such that apertures of the support members and an opening of the body are aligned. A shaping pin is then advanced toward the first support member in alignment with the predetermined position so that a shoulder of the shaping pin extends into the first support member. The shaping pin continues to advance through the first support member until a portion of the body extends past a surface of the second support member, thereby joining the first and second support members and the body together.

Abstract: A support structure includes first and second support members which are interlocked with a body. The second support member is placed in a die such that a hole of the second support member is located at a predetermined position and the body is placed on the second support member. The first support member is placed on the body such that apertures of the support members and an opening of the body are aligned. A shaping pin is then advanced toward the first support member in alignment with the predetermined position so that a shoulder of the shaping pin extends into the first support member. The shaping pin continues to advance through the first support member until a portion of the body extends past a surface of the second support member, thereby joining the first and second support members and the body together.

Abstract: A sensing circuit is useful with a power outlet and a power tool having power supplied thereto via the power outlet. The sensing circuit includes a generator, a transmitter, and a detector. A first signal having a high frequency is developed by the generator and supplied to a first terminal of the power outlet by the transmitter. The detector is coupled to the second terminal of the power outlet and tuned in accordance with the high frequency to develop a second signal indicative of whether the power tool is coupled to the power outlet. The sensing circuit may be used in conjunction with a regulating circuit and a two-position switch useful for controlling the electrical energy supplied to the power tool and a vacuum cleaner having the power outlet disposed thereon.

Abstract: A thermal protection mechanism for electric motors includes a pair of spaced contacts secured to an electrically insulated carrier. The contacts are engaged with a fusible electrically conductive pin made of solder that interposes along a current path to the windings of a motor. A thermal overload conditions causes the pin to fuse, thereby terminating operation of the motor.

Abstract: A motor housing for a vacuum cleaner includes a main body, a peripheral rim, and an interconnecting base bounding portions of a working air chamber. A portion of the peripheral rim defines a sidewall having a plurality of vanes and a plurality of exhaust openings, with the vanes and the exhaust openings cooperating to exhaust air from the working air chamber in response to rotation of the impeller. Each of the vanes having an airfoil-shaped cross section, and each vane is oriented such that the airfoil of each vane is oriented oppositely relative to the airfoil of its adjacent vanes. Thus, a first set of the vanes are positioned to direct air through the exhaust openings, while a second set of vanes are positioned to direct excess air from adjacent the exhaust openings toward the chamber and back into the flow pattern.