Abstract: An electric machine is provided. The electric machine includes a stator having an electromagnetic coil and a rotor. The rotor is configured to rotate relative to the stator. The electric machine further includes a controller. The controller is adapted to control the electromagnetic coil. The controller includes a plurality of electrical components and an isolation member. The isolation member includes a first portion positioned in a first direction between two adjacent electrical components of the plurality of electrical components and a second portion positioned in a second direction normal to the first direction.

Abstract: An electric motor comprises a shaft, an interior magnet rotor core comprising a central bore and a pair of opposing ends faces, and at least one resilient structure inserted within the central bore between the pair of opposing end faces. The at least one resilient component is inserted within the central bore between the pair of opposing end faces such that the at least one resilient component does not extend beyond one of the opposing end faces. The resilient component comprises an outer rigid structure inserted within the central bore, a resilient component inserted within the outer rigid structure, and an inner rigid structure inserted within the resilient component, wherein the shaft is inserted through the inner rigid structure.

Abstract: A housing for enclosing electronics of a motor having an axis of rotation is provided. The housing includes an end cap having an outer surface and an inner surface. A control board is coupled to the inner surface, wherein the printed circuit board includes a first side, a second side and an edge located between the first side and the second side. The housing further includes a first circuit coupled to the first side which includes a plurality of first electrical components. Each first electrical component includes a tab extending beyond the edge. A second circuit is coupled to the second side and a fastener assembly is coupled to the tab and the inner surface.

Abstract: An electric machine is provided. The electric machine includes stator having an electromagnetic coil and a rotor. The rotor is configured to rotate relative to the stator. The electric machine thriller includes a controller. The controller is adapted to control the electromagnetic oil. The controller includes a plurality of electrical components and an isolation member. The isolation member includes a first portion positioned in a first direction between two adjacent electrical components of the plurality of electrical components and a second portion positioned in a second direction normal to the first direction.

Abstract: A method for manufacturing an interior magnet rotor core motor is described herein. The method includes attaching a resilient material to an inner rigid structure configured to engage a shaft associated with the motor, engaging the structure with the motor shaft, positioning the shaft and structure assembly with respect to the rotor core, and affixing the resilient material to the rotor core.

Abstract: A housing for enclosing electronics of a motor having an axis of rotation is provided. The housing includes an end cap having an outer surface and an inner surface. A control board is coupled to the inner surface, wherein the printed circuit board includes a first side, a second side and an edge located between the first side and the second side. The housing further includes a first circuit coupled to the first side which includes a plurality of first electrical components. Each first electrical component includes a tab extending beyond the edge. A second circuit is coupled to the second side and a fastener assembly is coupled to the tab and the inner surface.

Abstract: An electric motor comprises a shaft, an interior magnet rotor core comprising a central bore and a pair of opposing ends faces, and at least one resilient structure inserted within the central bore between the pair of opposing end faces. The at least one resilient component is inserted within the central bore between the pair of opposing end faces such that the at least one resilient component does not extend beyond one of the opposing end faces. The resilient component comprises an outer rigid structure inserted within the central bore, a resilient component inserted within the outer rigid structure, and an inner rigid structure inserted within the resilient component, wherein the shaft is inserted through the inner rigid structure.

Abstract: A method for manufacturing an interior magnet rotor core motor is described herein. The method includes attaching a resilient material to an inner rigid structure configured to engage a shaft associated with the motor, engaging the structure with the motor shaft, positioning the shaft and structure assembly with respect to the rotor core, and affixing the resilient material to the rotor core.

Abstract: A magnet motor with rotor assembly is provided that has a plurality of magnet members that circumscribe a wall of the rotor core or stator in an orientation that minimizes or eliminates gaps therebetween. The magnet members can have non-parallel opposing sides to allow for elimination of the gaps. The magnet members may have trapezoidal-like shapes.

Abstract: An endshield assembly for an electronically commutated motor includes an endshield, a control assembly, and a power assembly. The endshield includes a plurality of recessed fins on an outer surface, and a substantially flat raised portion on an internal surface. The raised portion is in contact with a thermal pad. The control assembly includes the thermal pad and a control board on which is located a plurality of power transistors. The thermal pad provides thermal contact between the transistors and the endshield to enable the endshield to dissipate heat from the transistors. The transistors include a plurality of leads that extend substantially parallel to the control board which enable the leads to be coated for protection against harsh external environments. The power assembly includes a power board having an insulator positioned between the power board and the control board.

Abstract: A rotor assembly comprising: a rotor having an outer circumference and a longitudinal axis; and a plurality of magnet members secured to said outer circumference, each of said plurality of magnet members having a degree of curvature about said longitudinal axis, wherein a sum of said degrees of curvature is greater than 355.5 degrees.

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 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: 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: 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 control board enclosure includes an opening extending through a side wall to permit moisture to drain from the enclosure and a potting compound to protect the control board. A plug is sized to fit in sealable contact with the opening. The potting material is placed within the enclosure to cover the control board and a portion of the plug. A drainage channel is formed and extends to the opening through the potting compound when the plug is removed from the enclosure.

Abstract: A motor assembly includes a stationary assembly having a plurality of winding stages adapted to be electrically energized to generate an electromagnetic field and a rotatable assembly including a plurality of permanent magnet elements in magnetic coupling relation with the stationary assembly. The motor assembly also includes first and second substantially flat end members parallel to each other and having inner facing sides between which the stationary assembly and the rotatable assembly are located. Each of the members has an outer side opposite its inner side. Control circuitry is connected to the winding stages and positioned adjacent the outer side of the first member, for applying a voltage to one or more of the winding stages at a time and for commutating the winding stages in a preselected sequence to rotate the rotatable assembly about an axis of rotation. A cap on the outer side of the first member forms a closure with the first member within which the control circuitry is located.

Abstract: An electronically commutated motor has a printed circuit board with opposite sides and a heat dissipating means arranged in spaced apart relation at least in part in the path of at least some of the cooling circulated in the electronically commutated motor by the rotatable assembly thereof. A plurality of insulated gate transistors are located on the heat dissipating means in heat transfer relation therewith adjacent one opposite side of the printed circuit board and are operable to commutate power supplied to the winding stages of the electronically commutated motor. Other solid state components for controlling the conductivity of the insulated gate transistors are located on the other opposite side of the printed circuit board, and the insulated gate transistors and the other solid state components are connected in circuit relation with the printed circuit board.