Abstract: A stator assembly that may be rounded into an annular form is disclosed that includes a plurality of stator segments where each stator segment defines a yoke portion and a stator tooth and a containment structure configured to position the stator segments relative to one another such that the stator segments do not physically touch one another and such that no magnetic circuit between adjacent stator segments is formed. Also disclosed is a method for forming a segmented stator, involving the steps of positioning a plurality of stator segment in a containment structure such that no magnetic circuit between adjacent stator segments is formed, forming a winding coil about at least some of the stator segments; and deforming the containment structure to form an annular stator and to establish a magnetic circuit between adjacent stator segments.

Abstract: An electric machine includes a housing, an end shield, a stator, and a rotor assembly. The end shield can define at least one pin, and the stator can define at least one track. The stator can be positioned on the end shield such that the pin is received within the track. The stator can be captured between the end shield and a stop within the housing. The rotor assembly can include an adaptor sleeve and/or a bearing with a plurality of steel rolling elements. End caps can be coupled to the stator, and power and control electronics can be integrated within the housing.

Abstract: An electrical connector includes a terminal attached to a length of wiring that extends from the stator windings of an electrical device, and a tubular insulating sleeve that extends along the length of wiring. The sleeve is secured stationary relative to both the wiring and the terminal by being secured to the stator windings by the same mechanical connection that binds the stator windings.

Abstract: An electric terminal connector block is provided with oblong tool openings that communicate with interior channels of the connector block and with openings in the motor wiring electric terminals positioned in each channel of the connector block. The oblong shapes of the tool openings enable insertion of tool pins through the tool openings and openings of the electric terminals and movement of the tool pins along the lengths of the oblong tool openings whereby the tool pins engage with the electric terminals and move the terminals relative to the connector block to insure that the terminals are locked in place in the connector block. In addition, the tooling used with the connector block is operated according to a method that insures that the terminals of the motor winding are moved to a position relative to the connector block where the terminals are locked in place.

Abstract: An interconnecting ring and wire guide for an electric machine includes an annular radial ring having a radially inner edge and a radially outer edge. An axial ring projects axially from the radially inner edge of the annular radial ring. A guide positioner positions the annular radial ring and the axial ring relative to the electric machine. Wire dividers are located on a radially outer surface of the radial ring. The wire dividers include a plurality of circumferential projections that are formed on the radially outer surface of the radial ring. A plurality of wire guides are located adjacent to a radially outer edge of the annular radial ring. Indicia on an outer surface of the annular radial ring identifies at least one of a mounting position for the interconnecting ring and wire guide and a wiring schematic for phases wiring of the electric machine.

Abstract: A mounting clip that attaches a circuit component to an electrical device attenuates vibration of the circuit component as the electrical device is operated. The mounting clip is designed for a thermo-protector of an electric motor and removably attaches the thermo-protector to a switch housing of the electric motor. The thermo-protector is connected in the circuit of the electric motor and wiring of the electric motor that communicates with the thermo-protector is attached to the mounting clip. The mounting clip is provided with a spring mechanism that engages an abutment provided on the switch housing and biases the mounting clip and the attached thermo-protector and thermo-protector wiring away from the switch housing and thereby attenuates vibration of the thermo-protector and its wiring.

Abstract: A stator assembly that may be rounded into an annular form is disclosed that includes a plurality of stator segments where each stator segment defines a yoke portion and a stator tooth and a containment structure configured to position the stator segments relative to one another such that the stator segments do not physically touch one another and such that no magnetic circuit between adjacent stator segments is formed. Also disclosed is a method for forming a segmented stator, involving the steps of positioning a plurality of stator segment in a containment structure such that no magnetic circuit between adjacent stator segments is formed, forming a winding coil about at least some of the stator segments; and deforming the containment structure to form an annular stator and to establish a magnetic circuit between adjacent stator segments.

Abstract: An interconnecting ring and wire guide for an electric machine includes an annular radial ring having a radially inner edge and a radially outer edge. An axial ring projects axially from the radially inner edge of the annular radial ring. A guide positioner positions the annular radial ring and the axial ring relative to the electric machine. Wire dividers are located on a radially outer surface of the radial ring. The wire dividers include a plurality of circumferential projections that are formed on the radially outer surface of the radial ring. A plurality of wire guides are located adjacent to a radially outer edge of the annular radial ring. Indicia on an outer surface of the annular radial ring identifies at least one of a mounting position for the interconnecting ring and wire guide and a wiring schematic for phases wiring of the electric machine.

Abstract: An electric terminal connector block is provided with oblong tool openings that communicate with interior channels of the connector block and with openings in the motor wiring electric terminals positioned in each channel of the connector block. The oblong shapes of the tool openings enable insertion of tool pins through the tool openings and openings of the electric terminals and movement of the tool pins along the lengths of the oblong tool openings whereby the tool pins engage with the electric terminals and move the terminals relative to the connector block to insure that the terminals are locked in place in the connector block. In addition, the tooling used with the connector block is operated according to a method that insures that the terminals of the motor winding are moved to a position relative to the connector block where the terminals are locked in place.

Abstract: A mounting clip that attaches a circuit component to an electrical device attenuates vibration of the circuit component as the electrical device is operated. The mounting clip is designed for a thermo-protector of an electric motor and removably attaches the thermo-protector to a switch housing of the electric motor. The thermo-protector is connected in the circuit of the electric motor and wiring of the electric motor that communicates with the thermo-protector is attached to the mounting clip. The mounting clip is provided with a spring mechanism that engages an abutment provided on the switch housing and biases the mounting clip and the attached thermo-protector and thermo-protector wiring away from the switch housing and thereby attenuates vibration of the thermo-protector and its wiring.

Abstract: A terminal block constructed of an insulator material receives a ground connector constructed of a conductive material where the ground connector has a plug projecting from the terminal block at one end and a tab with a fastener hole at its opposite end. Attachment of the terminal block to a stator of a dynamoelectric device simultaneously positions the tab of the ground connector with the tab hole aligned with a fastener hole of the stator and a fastener hole of an end plate of the device. Assembling the stator and end plate together by a threaded fastener also secures the tab of the ground connector between the stator and end plate.

Abstract: An electric motor comprising a stator having first and second ends and a cross section and a connector block mounted on one end of the stator, substantially entirely within the cross-sectional profile of the stator. The connector block has a plurality of electrical contacts oriented generally transversely outwardly with respect to the stator. An end shield is mounted over the end of the stator, overlying the top of the connector block. The end shield is spaced sufficiently from the stator in the vicinity of the connector block to allow free access to the electrical contacts of the connector block from the transverse direction.

Abstract: A reluctance machine system is provided that comprises a reluctance machine having a stator defining a plurality of stator poles, a plurality of phase windings wound around the stator poles, and a rotor defining rotor poles and inter-pole gaps. Contoured topsticks, a dust cover and an endshields are used to reduce the amount of noise in the reluctance system. A winged terminal housing is also used to allow manipulation of the terminal housing and enhance alignment while protecting critical wires.