Abstract: A molded internal permanent magnet rotor having a plurality of laminate sections disposed circumferentially around the rotor and a permanent magnetic plastic material injection molded between the laminate sections. The permanent magnetic plastic material forms radially extending portions disposed between the laminate sections and an internal ring portion located radially inward from the laminate sections. The permanent magnetic plastic material, once cured, engages retaining features in the laminate sections to restrict radial displacement.

Abstract: Driver circuits for a low-cost two-phase motor are disclosed. Cost reductions may be further achieved by utilizing a printed circuit board (PCB)-based stator and methods of manufacturing, as disclosed herein. The disclosed technology can be particularly well matched for use in two-phase motors, such as axial-flux motors the utilize one or more ferrite-based rotors and a printed circuit board (PCB)-based stator. In certain implementations, part or all of the motor driver circuitry may be integrated onto the same PCB as is utilized to define the stator windings. In other implementations, the motor driver circuitry may be independently utilized with other traditional electrical motors.

Abstract: A printed circuit board (PCB)-based axial flux motor and methods of manufacturing are disclosed herein. The axial flux motor includes a printed circuit board (PCB) stator assembly having a plurality of PCB stator cores distributed about a central rotational axis, each of the PCB stator cores include at least one stator coil layer surrounding a corresponding PCB void and a stator core insert disposed in the corresponding PCB void. The axial flux motor includes one or more rotors attached to a common shaft, each rotor having at least two magnetic poles. The axial flux motor includes a frame having at least one bearing. The frame is configured to align and support the one or more rotors for rotation about the central rotational axis.

Abstract: An EC motor with an encapsulated electronic controller. The electronic controller is encapsulated by creating a silicone mold to include sufficiently detailed voids so that certain parts of the electronic controller adjacent the voids are encapsulated and other parts adjacent where the mold has no voids are left unencapsulated.

Abstract: An EC motor with a rotor. The rotor has a hub with outwardly extending silicon steel laminates with gaps between. Rectangular neodymium permanent magnets are positioned in the gaps. Wedge-shaped ferrite permanent magnets are positioned radially between the silicon steel laminates and the hub of the rotor.

Abstract: An EC motor with a rotor. The rotor has a hub with outwardly extending silicon steel laminates with gaps between. Rectangular neodymium permanent magnets are positioned in the gaps. Wedge-shaped ferrite permanent magnets are positioned radially between the silicon steel laminates and the hub of the rotor.

Abstract: An EC motor with an encapsulated electronic controller. The electronic controller is encapsulated by creating a silicone mold to include sufficiently detailed voids so that certain parts of the electronic controller adjacent the voids are encapsulated and other parts adjacent where the mold has no voids are left unencapsulated.

Abstract: An EC motor with a stator and a rotor mounted to a shaft. The motor has a cooling system, an over molded stator housing, and an optimized rotor. The stator has teeth with wound electromagnetic coils. The teeth and coils are distributed circumferentially with gaps between adjacent coils. The stator is over molded with plastic that forms axially oriented cooling passages between adjacent coil sections. An impeller fan then draws air into the motor through air inlets connected to air passages. The impeller fan directs the air through the axially oriented cooling passages in the stator and out air outlets. An optimized internal rotor has permanent magnets and silicon steel laminates spaced circumferentially and extending outwardly from a central hub. Rectangular shaped magnets are interposed in the gaps between the laminates. Wedge-shaped magnets are aligned radially with the laminates and between the laminates and the hub.

Abstract: An EC motor with a stator and a rotor mounted to a shaft. The motor has a cooling system, an over molded stator housing, and an optimized rotor. The stator has teeth with wound electromagnetic coils. The teeth and coils are distributed circumferentially with gaps between adjacent coils. The stator is over molded with plastic that forms axially oriented cooling passages between adjacent coil sections. An impeller fan then draws air into the motor through air inlets connected to air passages. The impeller fan directs the air through the axially oriented cooling passages in the stator and out air outlets. An optimized internal rotor has permanent magnets and silicon steel laminates spaced circumferentially and extending outwardly from a central hub. Rectangular shaped magnets are interposed in the gaps between the laminates. Wedge-shaped magnets are aligned radially with the laminates and between the laminates and the hub.

Abstract: A relatively inexpensive and accurate method for micro scale tool touch-off and remaining tool life estimation using advanced methods of tool-workpiece conductivity monitoring. Part registration is based on a conductive circuit detection technique that utilizes an analog DC voltage. A tool life estimation system is provided, and accomplished through the combined application of hardware signal filtering and advanced signal processing techniques implemented on a digital signal processing unit.