Abstract: An electric machine includes a housing having an air intake, an air outlet, and defining an air passage therein. The air passage includes a first channel extending from the air intake in a radial direction and a second channel extending in the radial direction to the outlet. The electric machine further includes a motor assembly positioned within the housing that includes a shaft that rotates about a rotational axis that is generally perpendicular to the radial direction. The electric machine further includes an electronics assembly within the housing interior and a heat sink positioned at least partially within the air passage and thermally connected to the electronics assembly. Operation of the motor assembly draws an ambient airflow into the air passage in the radial direction through the air intake, directs the airflow along the heat sink, and exhausts the airflow through the air outlet in the radial direction.

Abstract: An electric machine includes a housing having an air intake, an air outlet, and defining an air passage therein. The air passage includes a first channel extending from the air intake in a radial direction and a second channel extending in the radial direction to the outlet. The electric machine further includes a motor assembly positioned within the housing that includes a shaft that rotates about a rotational axis that is generally perpendicular to the radial direction. The electric machine further includes an electronics assembly within the housing interior and a heat sink positioned at least partially within the air passage and thermally connected to the electronics assembly. Operation of the motor assembly draws an ambient airflow into the air passage in the radial direction through the air intake, directs the airflow along the heat sink, and exhausts the airflow through the air outlet in the radial direction.

Abstract: A fluid circulating assembly having a rotation axis is provided. The fluid circulating assembly includes a fan impeller including an inlet ring and a rear plate that together define a central fan chamber. The fluid circulating assembly also includes an electrical machine having a rotor assembly, a stator assembly, and at least one bearing assembly. The rotor assembly is coupled to the rear plate such that the electrical machine is located entirely outside the central fan chamber. The rotor assembly includes a hub portion having a radially inner wall that at least partially defines a central opening extending entirely through the electrical machine and oriented about the rotation axis such that the central opening does not include a shaft extending therethrough.

Abstract: A blower includes an impeller housing, an impeller rotatably secured to the housing and an electric motor. The motor has a motor housing with a central portion and a radially extending portion extending from the central portion, a venturi chamber adjacent the motor housing and opposed to the impeller housing, a stator secured to the central portion of the motor housing, a rotor rotatably secured to the central portion of the housing, and at least one heat generating electrical component secured to the radially extending portion of the motor housing. The impeller housing has a first air pressure therein and the motor housing has a second air pressure therein different that the first air pressure. The venturi housing and the motor housing define a passageway therebetween whereby the difference in air pressure generates air flow within the motor housing to cool the at least one heat generating electrical component.

Abstract: An electric machine comprising a permanent magnet rotor assembly is provided. The electric machine comprises a permanent magnet rotor assembly comprising a plurality of permanent magnets coupled to a rotor disk and a plurality of magnet shims coupled to the plurality of permanent magnets opposite the rotor disk. Each magnet shim of the plurality of magnet shims has a substantially complementary shape as a respective permanent magnet of the plurality of permanent magnets. The electric machine further comprises a stator core comprising a plurality of stator teeth that define a plurality of slots therebetween. At least one of the plurality of magnet shims is configured to direct magnetic flux from at least one of the plurality of permanent magnets to at least one stator tooth of the plurality of stator teeth.

Abstract: A fluid circulating assembly having a rotation axis is provided. The fluid circulating assembly includes a fan impeller including an inlet ring and a rear plate that together define a central fan chamber. The fluid circulating assembly also includes an electrical machine having a rotor assembly, a stator assembly, and at least one bearing assembly. The rotor assembly is coupled to the rear plate such that the electrical machine is located entirely outside the central fan chamber. The rotor assembly includes a hub portion having a radially inner wall that at least partially defines a central opening extending entirely through the electrical machine and oriented about the rotation axis such that the central opening does not include a shaft extending therethrough.

Abstract: A fluid circulating assembly includes a fan impeller having an inlet ring and a rear plate that together define a central fan chamber. The fluid circulating assembly also includes an electrical machine having a rotor assembly, a stator assembly, and a housing. The rotor assembly is attached to the fan impeller rear plate such that the electrical machine is located entirely outside the central fan chamber. The housing includes an annular center section and at least two extension portions extending radially outward from the annular center section.

Abstract: A centrifugal blower assembly includes a housing defining an interior space and an impeller configured to channel an airflow within the interior space. The blower assembly also includes a motor coupled to the impeller and configured to rotate the impeller about an axis. The motor includes a motor shell and a motor mounting assembly coupled to the motor. The motor mounting assembly includes an end shield coupled to the motor and a plurality of mounting arms coupled to the end shield. At least a portion of at least one mounting arm extends axially along the motor such that a continuous radial gap is defined between the at least one mounting arm and the motor shell.

Abstract: A centrifugal fan assembly having an axis of rotation includes an inlet ring, a back plate, and a plurality of blades coupled between the inlet ring and the back plate. At least one blade of the plurality of blades includes a radially inner edge, a radially outer edge, and at least one flow channel extending obliquely therebetween. The at least one flow channel includes an inlet defined on the radially inner edge and an outlet defined on the radially outer edge, wherein the inlet and the outlet are positioned at different axial locations along a length of the blade.

Abstract: A fluid circulating assembly includes an electrical machine having a rotor assembly, a stator assembly, and a housing. The housing includes an annular center section and at least two extension portions extending radially outward from the annular center section of the housing. The fluid circulating assembly also includes a controller assembly coupled to the housing. The said controller assembly is positioned radially outward from the stator assembly and located in at least one of the at least two extension portions.

Abstract: A fluid circulating assembly includes a fan impeller having an inlet ring and a rear plate that define a central chamber. The fluid circulating assembly includes an electrical machine having a rotor assembly, a stator assembly, and a housing. The electrical machine is coupled to the rear plate of the impeller such that the electrical machine is positioned entirely outside the central chamber. The housing includes a plurality of fins on a side of the housing opposite the rear plate. The fins extend axially away from the stator assembly. The assembly includes a duct attached to the housing. The duct covers a portion of the fins and extends radially outward from the housing towards an outer edge of the rear plate. The duct is configured to channel air over the portion of the fins to facilitate cooling the electrical machine.

Abstract: A stator 20 for an axial flux machine such as a motor or generator. The stator includes a stator core 32 having a back plane 24 which in use is disposed perpendicularly about a rotational axis of the machine. A plurality of teeth 26 extend axially from the back plane so as to form winding receiving slots 28 between adjacent teeth. The stator also includes an electrical winding 30 including a plurality of coils 32, each coil being located about a tooth of the stator core and being electrically isolated from the stator tooth by means of an insulating former 34 having a shape which closely conforms to the shape of the stator tooth. The coils 32 are interconnected to form the winding 30. A method of constructing a stator is also disclosed.

Abstract: A centrifugal fan impeller includes a front endring, a rear endring, and a plurality of blades coupled between the front and the rear endrings. At least one blade of the plurality of blades includes a blade span extending between the front endring and the rear endring, a leading edge, and a trailing edge. The at least one blade further includes a first elliptical cross-sectional profile extending between the leading and the trailing edges.

Abstract: A motor controller configured to be coupled to a motor that is coupled to a fan is described. The motor controller includes a processor coupled to a memory, and is configured to operate the motor in a first operating mode in which the motor rotates the fan in a first direction at a first speed. The motor controller is further configured to operate the motor in a restriction detection mode in which the motor rotates the fan in a second direction that is opposite the first direction, determine a torque associated with the motor while the motor is rotating the fan in the second direction, determine that the torque is not within a predefined threshold range in the memory, and determine that a restriction exists in a fluid flow path associated with the motor in response to determining that the torque is not within the predefined threshold range.

Abstract: A blower includes an impeller housing, an impeller rotatably secured to the housing and an electric motor. The motor has a motor housing with a central portion and a radially extending portion extending from the central portion, a venturi chamber adjacent the motor housing and opposed to the impeller housing, a stator secured to the central portion of the motor housing, a rotor rotatably secured to the central portion of the housing, and at least one heat generating electrical component secured to the radially extending portion of the motor housing. The impeller housing has a first air pressure therein and the motor housing has a second air pressure therein different that the first air pressure. The venturi housing and the motor housing define a passageway therebetween whereby the difference in air pressure generates air flow within the motor housing to cool the at least one heat generating electrical component.

Abstract: A centrifugal blower assembly includes a housing defining an interior space and an impeller configured to channel an airflow within the interior space. The blower assembly also includes a motor coupled to the impeller and configured to rotate the impeller about an axis. The motor includes a motor shell and a motor mounting assembly coupled to the motor. The motor mounting assembly includes an end shield coupled to the motor and a plurality of mounting arms coupled to the end shield. At least a portion of at least one mounting arm extends axially along the motor such that a continuous radial gap is defined between the at least one mounting arm and the motor shell.

Abstract: In one aspect, an electric machine is provided. The electric machine includes a housing including at least one air intake, an air outlet, and an air passage extending between the at least one air intake and the air outlet. The electric machine also includes a first heat sink positioned at least partially within the air passage, and a second heat sink positioned at least partially within the air passage downstream of the first heat sink. A cooling airflow through the at least one air intake flows through the air passage to cool the first heat sink and the second heat sink before the cooling airflow is exhausted through the air outlet.

Abstract: A fluid circulating assembly includes an electrical machine having a rotor assembly, a stator assembly, and a housing. The housing includes an annular center section and at least two extension portions extending radially outward from the annular center section of the housing. The fluid circulating assembly also includes a controller assembly coupled to the housing. The said controller assembly is positioned radially outward from the stator assembly and located in at least one of the at least two extension portions.

Abstract: A fluid circulating assembly includes a fan impeller having an inlet ring and a rear plate that define a central chamber. The fluid circulating assembly includes an electrical machine having a rotor assembly, a stator assembly, and a housing. The electrical machine is coupled to the rear plate of the impeller such that the electrical machine is positioned entirely outside the central chamber. The housing includes a plurality of fins on a side of the housing opposite the rear plate. The fins extend axially away from the stator assembly. The assembly includes a duct attached to the housing. The duct covers a portion of the fins and extends radially outward from the housing towards an outer edge of the rear plate. The duct is configured to channel air over the portion of the fins to facilitate cooling the electrical machine.

Abstract: A fluid circulating assembly includes a fan impeller having an inlet ring and a rear plate that together define a central fan chamber. The fluid circulating assembly also includes an electrical machine having a rotor assembly, a stator assembly, and a housing. The rotor assembly is attached to the fan impeller rear plate such that the electrical machine is located entirely outside the central fan chamber. The housing includes an annular center section and at least two extension portions extending radially outward from the annular center section.