WO2024081440A1 - Systems and methods foran electric chore motor withan integrated motor controller - Google Patents

Abstract

An electric chore motor assembly includes a chore motor having a rotor, a stator, a base housing, an outer housing, and a drive shaft rotationally coupled to the rotor and extending through the base housing. The electric chore motor assembly includes a motor controller enclosed between the base housing and the outer housing. The motor controller is connected to the stator by phase wires that are enclosed between the base housing and the outer housing.

Description

SYSTEMS AND METHODS FORAN ELECTRIC CHORE MOTOR WITHAN INTEGRATED MOTOR CONTROLLER

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. Provisional Application No. 63/416,202, filed on October 14, 2022, the entire disclosure of which is hereby incorporated by reference herein.

BACKGROUND

[0002] Current trends for chore products and power equipment include adding electrification (e.g., batteries, battery packs, electric motors, blade motors, drive/tractive motors, etc.) to replace or supplement the power that has traditionally been provided by an internal combustion engine.

SUMMARY

[0003] At least one embodiment relates to an electric chore motor assembly that includes a chore motor having a rotor, a stator, a base housing, an outer housing, and a drive shaft rotationally coupled to the rotor and extending through the base housing. The electric chore motor assembly includes a motor controller enclosed between the base housing and the outer housing. The motor controller is connected to the stator by phase wires that are enclosed between the base housing and the outer housing.

[0004] At least one embodiment relates to an electric chore motor assembly that includes a chore motor, a motor controller, and a cable. The chore motor includes a rotor, a stator, a base housing having a mounting recess arranged between an inner hub and an outer wall, a drive shaft rotationally coupled to the rotor and extending through the base housing, a first mounting flange extending outwardly from the outer wall, and a second mounting flange extending outwardly from the outer wall. The motor controller is arranged within the mounting recess. The cable is electrically coupled to the motor controller and includes a first connector in communication with the motor controller and coupled to the base housing. The first connector is arranged between the first mounting flange and the second mounting flange. [0005] At least one embodiment relates to an electric chore motor assembly that includes a chore motor, a motor controller, and a cable. The chore motor includes a rotor, a stator, a drive shaft rotationally coupled to the rotor, and a base housing through which the drive shaft axially extends. The motor controller is arranged within the base housing. The cable is electrically coupled to the motor controller and includes a connector in communication with the motor controller. The connector only includes a positive power port, a negative power port, and a communication port.

[0006] This summary is illustrative only and is not intended to be in any way limiting. Other aspects, inventive features, and advantages of the devices or processes described herein will become apparent in the detailed description set forth herein, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements.

BRIEF DESCRIPTION OF THE FIGURES

[0007] The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements, in which:

[0008] FIG. 1 is a perspective view of a chore product, according to an exemplary embodiment;

[0009] FIG. 2 is a perspective view of a chore product, according to an exemplary embodiment;

[0010] FIG. 3 is a schematic diagram of the chore product of FIGS. 1 and 2;

[0011] FIG. 4 is a perspective view of a conventional electric motor and a conventional motor controller;

[0012] FIG. 5 is a cross section of an electric chore motor with an integrated motor controller;

[0013] FIG. 6 is a top perspective view of a base housing and the motor controller of the electric chore motor of FIG. 5;

[0014] FIG. 7 is a schematic illustration of the electric chore motor of FIG. 5; and

[0015] FIG. 8 is a front view of a connector of the electric chore motor of FIG. 5. DETAILED DESCRIPTION

[0016] Before turning to the figures, which illustrate certain exemplary embodiments in detail, it should be understood that the present disclosure is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology used herein is for the purpose of description only and should not be regarded as limiting.

[0017] The use herein of the term “axial” and variations thereof refers to a direction that extends generally along an axis of symmetry, a central axis, or an elongate direction of a particular component or system. For example, an axially-extending structure of a component may extend generally along a direction that is parallel to an axis of symmetry or an elongate direction of that component. Similarly, the use herein of the term “radial” and variations thereof refers to directions that are generally perpendicular to a corresponding axial direction. For example, a radially extending structure of a component may generally extend at least partly along a direction that is perpendicular to a longitudinal or central axis of that component. The use herein of the term “circumferential” and variations thereof refers to a direction that extends generally around a circumference or periphery of an object, around an axis of symmetry, around a central axis, or around an elongate direction of a particular component or system.

[0018] The present disclosure is directed to battery-powered outdoor power equipment or chore products. A “chore product” as used herein refers to any type of equipment, machine, or vehicle that may be used to perform a chore (e.g., an outdoor chore, an indoor chore, lawn care, etc.). For example, a chore product may include a motor, a pump, an actuator, a compressor, and/or another device that is electrically-powered to operate some function of the chore product to facilitate performing a chore. In some embodiments, a chore is a task performed, either by a user or autonomously, at or near a household, a farm, an agricultural facility, a building, a sidewalk, a park, a parking lot, a forest, a field, and/or a lawn. In some embodiments, a chore product transports an operator and performs a chore. In some embodiments, a chore product autonomously operates to perform a chore without an operator being present on the chore product or physically/manually manipulating the chore product.

[0019] Referring to the figures generally, the various exemplary embodiments disclosed herein relate to systems, apparatuses, and methods for an electric chore motor with an integrated motor controller. In some embodiments, the motor controller is at least partially enclosed within a housing of the motor controller. Arranging the motor controller within the housing of the electric chore motor, substantially reduces the number of wires that are required to install the electric chore motor on a chore product, and to connect the motor controller to a global or vehicle controller. For example, motor controllers typically require power wires, phase wires, and communication wires to facilitate operation of an electric motor. Mounting the motor controller within the housing of the electric chore motor enables the phase wires to remain enclosed within the housing, and only requires power wires and communication wires to be connected between the motor controller and the vehicle controller (e.g., with a single connector). With the motor controller and the phase wires enclosed within the housing of the electric chore motor, the house may act like a Faraday cage and significantly reduce or block the interference (e.g., electrical interference, noise) generated by the phase wires. And integrating the motor controller into the housing frees up space on a chore product that would have otherwise been used to mount a motor controller.

[0020] According to the exemplary embodiment shown in FIG. 1, the chore product 10 is configured as a zero turn radius (“ZTR”) mower. According to the exemplary embodiment shown in FIG. 2, the chore product 10 is configured as a stand-on mower. In some embodiments, the chore product 10 is configured as a ride-on or riding mower (i.e., a non- ZTR ride-on or riding mower). In some embodiments, the chore product 10 is configured as a walk-behind mower.

[0021] While the chore product 10 is shown to be configured as a mower, it is contemplated that the chore product 10 may be configured as or the features thereof (e.g., the electric chore motor with an integrated motor controller described herein) may be implemented on other electrified chore products or “light” electrified vehicles, machines, or equipment, including outdoor power equipment, indoor power equipment, light vehicles, floor care devices, golf carts, lift trucks and other industrial vehicles, pavement surface preparation devices, recreational utility vehicles, industrial utility vehicles, lawn and garden equipment, and/or still other suitable vehicles, machines, or equipment. Outdoor power equipment may include lawn mowers, riding tractors, snow throwers, pressure washers, tillers, log splitters, walk-behind mowers, riding mowers, and turf equipment such as sod cutters, aerators, spreaders, sprayers, seeders, power rakes, and blowers. Outdoor power equipment may, for example, use one or more electric motors to drive an implement, such as a rotary blade of a lawn mower, a pump of a pressure washer, the auger of a snow thrower, the alternator of a generator, and/or a drivetrain of the outdoor power equipment. Indoor power equipment may include floor sanders, floor buffers and polishers, vacuums, etc. Recreational utility vehicles may include all-terrain vehicles (“AT Vs”), utility task vehicles (“UTVs”), etc. Industrial utility vehicles may include forklifts, aircraft tugs, aerial lifts such as scissor lifts and boom lifts, etc.

[0022] As shown in FIGS. 1-3, a chore product 10 includes a chassis, shown as frame assembly 12; a chassis cover, shown as chore product body 14, positioned over and extending along a least a portion of the frame assembly 12 (e.g., a rear half thereof, a rear and/or center portion thereof, etc.); an operator area, shown as operator area 16, including various operator interfaces, shown as operator controls 18; an implement assembly, shown as mower deck 20, coupled to the frame assembly 12 and positioned in front of the chore product body 14 and the operator area 16; an energy storage device (e.g., a battery bank, a battery array, etc.), shown as battery module 30, coupled to or otherwise supported by the frame assembly 12; various tractive elements including first tractive elements, shown as rear wheels 40, and second tractive elements, shown as front wheels 42; an electrical distribution system, shown as electrical bus 50; and a powertrain or drivetrain, shown as driveline 100, coupled to and supported by the frame assembly 12. In some embodiments, the rear wheels 40 and/or the front wheels 42 are replaced with track elements. As shown in FIGS. 1 and 2, (a) the frame assembly 12 defines a first axis, shown as longitudinal axis 2, that is centrally aligned and extends longitudinally from the front end to the rear end of the chore product 10 and (b) the driveline 100 defines a second axis, shown as lateral axis 4, that extends laterally across the chore product 10 through the centers of the rear wheels 40.

[0023] According to the exemplary embodiment shown in FIG. 1, the operator area 16 is a seating area that includes a seat for the operator to sit while driving or otherwise controlling operations of the chore product 10. According to the exemplary embodiment shown in FIG. 2, the operator area 16 is a stand-on area that includes a platform for the operator to stand on while driving or otherwise controlling operations of the chore product 10. In some embodiments, the operator area 16 is or includes handles or a handlebar that the operator walks behind. The operator controls 18 may include various input and/or output devices to facilitate operator control of the chore product 10 (e.g., joysticks, a steering wheel, a gear selector, a throttle or accelerator pedal, a brake lever or brake pedal, switches, knobs, displays, gauges, etc.). [0024] As shown in FIGS. 1-3, the mower deck 20 includes a housing, shown as shroud 22; one or more implement motors, shown as implement or chore motors 24, coupled to the shroud 22; and a plurality of implements, show as cutting blades 26, coupled to and driven by the implement motors 24. While the mower deck 20 is shown as being positioned proximate the front of the chore product 10, in other embodiments, the mower deck 20 is positioned beneath the operator area 16 (e.g., on a ride-on or riding mower) or is trailed behind and pulled by the chore product 10. In other embodiments, the mower deck 20 is replaced or supplemented with a variety of other types of implements based on the intended end use of the chore product 10 (e.g., an auger assembly for a snow blower, an aerator mechanism for an aerator, etc.). In such non-mower implementations, the implement motors 24 may drive other types of implements than the cutting blades 26 (e.g., blowers, spreaders, power rakes, polishers, augers, aerators, compressors, pumps, etc.).

[0025] As shown in FIG. 1, the battery module 30 is positioned rearward of the operator area 16 and the chore product body 14. As shown in FIG. 2, the battery module 30 is positioned underneath the chore product body 14. In other embodiments, the battery module 30 is otherwise positioned (e.g., above the mower deck 20, trailed, etc.). As shown in FIG. 3, the battery module 30 is electrically coupled to and configured to power various electrical components or systems of the chore product 10 (e.g., the driveline 100, the implement motors 24, the operator controls 18, lights, displays, etc.) via the electrical bus 50. The battery module 30 may include a plurality of battery packs and/or cells. In some embodiments, the battery module 30 is removable. In some embodiments, the battery module 30 is a fixed battery pack. In some embodiments, the battery module 30 is rechargeable. The battery module 30 may include battery cells having one or more battery chemistries including, but not limited to, lithium ion, lithium iron phosphate, lithium polymer, nickel cadmium, lead- acid, nickel-metal hydride, and/or the like. The battery module 30 may be interchangeable between different chore products (e.g., between the chore product 10, a mower, a snow blower, a UTV, an ATV, a golf cart, an aerator, etc.). In some embodiments, the battery module 30 is removable without the use of tools. For example, the battery module 30 may be removably coupled to the chore product 10 by one or more latches, straps, detents, magnets, electrical coupler, slots, compartments, etc., or any combination thereof.

[0026] Turning to FIG. 4, a conventional electric motor assembly 150 includes an electric motor 152 and a motor controller 154 that is arranged remotely from the electric motor 152 (e.g., not enclosed within any portion thereof). As illustrated, the conventional electric motor assembly 150 includes a first cable 156 extending from the electric motor 152 to the motor controller 154. The first cable 156 includes motor-side communication wires 158 and phase wires 160 that are split out and connected to different locations on the motor controller 154. From the motor controller 154, vehicle-side communication wires 162 extend to a vehicle controller, which is configured to communicate with the motor controller 154 and control operation of the electric motor 152, and power wires 164 extend to a power source (e.g., a battery). The conventional electric motor assembly 150 includes at least four sets of wires and connectors (e.g., a connector for each of the motor-side communication wires 158, the phase wires 160, the vehicle-side communication wires 162 and the power wires 164) and requires mounting space for both the electric motor 152 and the motor controller 154. Accordingly, the conventional electric motor assembly 150 requires a significant amount of mounting space (e.g., on a chore product) for the electric motor 152, the motor controller 154, and all of the wiring/connectors.

[0027] FIGS. 5-7 illustrate an electric chore motor assembly 200 that includes a motor controller that is integrated into an electric motor. The integration of the motor controller within the electric motor reduces the number of wires/connectors required to connect the electric motor to a vehicle controller, reduces interference or noise within the electrical architecture of a chore product, and increases an amount of free space within a chore product due to the removed need to mount the motor controller separately from the electric chore motor and account for the space required by the number of wires external to the electric motor required by a conventional arrangement. In general, the electric chore motor assembly 200 includes a chore motor 202 that is configured to operate an implement or function of a chore product (e.g., the chore product 10) to facilitate performing a chore. In some embodiments, the electric chore motor assembly 200 may be installed on the chore product 10 as the implement or chore motors 24. In some embodiments, the electric chore motor assembly 200 may be installed on another chore product described herein.

[0028] The electric chore motor assembly 200 includes a motor controller 204 that is enclosed within the chore motor 202. The chore motor 202 includes a rotor 206, a stator 208 (e.g., having a plurality of electric coils), a plurality of magnets 210 arranged radially between the rotor 206 and the stator 208, a drive shaft 212 rotationally coupled to the rotor 206 (e.g., rotation of the rotor 206 results in the same rotation of the drive shaft 212), a base housing 214, and an outer housing 216. A central axis 218 extends axially along the drive shaft 212 and defines an axis of rotation for the drive shaft 212. [0029] The motor controller 204 is arranged within the base housing 214 and at least partially enclosed within the base housing 214. In general, the motor controller 204 is configured to receive input power (e.g., from the battery module 30 or a battery pack) and control a rotary speed of the drive shaft 212. For example, the base housing 214 includes an inner hub 220 that the drive shaft 212 extends through and an outer wall 222. The outer wall 222 is arranged radially outwardly relative to the inner hub 220. In some embodiments, the motor controller 204 is arranged radially between the inner hub 220 and the outer wall 222. The motor controller 204 is arranged within a mounting recess 224 formed between the inner hub 220 and the outer wall 222. In some embodiments, the mounting recess 224 extends axially downwardly (e.g., from the perspective of FIG. 5) relative to an upper surface of the inner hub 220. The motor controller 204 may extend circumferentially around mounting recess 224 (e.g., the motor controller 204 may extend within the mounting recess 224 about 180 degrees circumferentially around the inner hub 220).

[0030] In some embodiments, the motor controller 204 is enclosed between the base housing 214 and the outer housing 216. As described herein with respect to the conventional motor assembly 150, motor controllers typically include power wires that are connected to phase wires. The phase wires facilitate control of the motor by providing three-phase power to the wire coils of the stator at a predetermined magnitude and direction to generate a rotary force on the rotor. For example, the chore motor 202 may be a three-phase motor that is powered by three-phase AC power (e.g., the stator 208 is energized with three-phase power), and the input power provided to the chore motor 202 may be DC power (e.g., from the battery module 30). As shown in FIG. 7, the motor controller 204 may include a DC- AC inverter 294 that converts the DC power from the battery module 30 to three-phase AC power that is supplied to the stator 208 by phase wires 296. The incorporation of the motor controller 204 within the base housing 214 enables the phase wires 296 (and the power electronics associated with the phase wires 296 (e.g., the DC-AC inverter 294)) to also be arranged within the base housing 214 and enclosed between the base housing 214 and the outer housing 216. The enclosure formed by the base housing 214 and the outer housing 216 acts like a Faraday cage and significantly blocks or eliminates electrical interference or noise generated by the phase wires 296 and the motor controller 204 in general. In addition, the phase wires 296 are not required to extend out of the base housing 214 so the remaining electrical architecture on the chore product (e.g., the chore product 10) is not exposed to the noise generated by the phase wires 296. [0031] A single cable 260 extends from the chore motor 202 and includes a connector 250 at the end of the cable 260 located distally from the chore motor 202 and a second connector 262 (substantially similar to connector 250) located at the other end of the cable 260 and within the base housing 214 of the chore motor 202. The second connector 262 within the base housing 214 is electrically connected to the motor controller 204 by the appropriate power, phase, and/or data wires. The second connector 262 is secured within an opening 264 in the outer wall 222. In some embodiments, an o-ring, gasket, or other seal is provided to prevent water ingress into the base housing 214 through the opening 264.

[0032] The base housing 214 includes four mounting flanges 266, 268, 270, and 272 that extend outwardly from the circular outer wall 222. Each mounting flange 266, 268, 270, and 272 includes a through hole 274, 276, 278, and 280, respectively, that allows a bolt or other appropriate fastener to be used to secure the electric chore motor assembly 200 to an appropriate mounting location (e.g., to the top of the mower deck 20). The cable 260 extends outwardly from the outer wall 222 along a longitudinal axis 282 defined at least in part by a strain relief 284 or other stiffening feature. The longitudinal axis 282 is arranged to intersect the central axis 218 that extends axially along the drive shaft 212. A plane including the central axis 218 and the longitudinal axis 282 is equally spaced from a plane 286 that includes the longitudinal axes of the through holes 276 and 278 and from a plane 288 that includes the longitudinal axes of the through holes 274 and 280 so that the distance 290 is equal to the distance 292. This arrangement centers the opening 264 in the outer wall 222 and the second connector 262 between the through holes 274 and 276 of the mounting flanges 266 and 268 such that the longitudinal axis 282 of the cable 260 is arranged at 45 degree angle from an axis extending from the central axis 218 to the longitudinal axis of the through hole 274 and at a 45 degree angle from an axis extending from the central axis 218 to the longitudinal axis of through hole 276. This arrangement simplifies mounting of the electric chore motor assembly 200 and routing of the cable 260 by providing the cable 260 with a fixed direction/orientation relative to the mounting flanges 266, 268, 270, and 272.

[0033] The incorporation of the motor controller 204 within the chore motor 202 also simplifies the electrical connection to the chore motor 202. For example, a single connector may be used to provide power and communication (e.g., CAN communication) to the chore motor 202 and the motor controller 204 arranged therein. FIG. 8 illustrates on embodiment of a connector 250 that may be used to connect to the chore motor 202 and the motor controller 204 arranged therein. The connector 250 includes a positive power port 252, a negative power port 254, and a communication port 256 (e.g., CAN communication). The positive power port 252 and the negative power port 254 may be provided with electrical power from a battery module or a battery pack and the communication port 256 may provide communication between the motor controller 204 and a vehicle controller. Accordingly, the connector 250 is required to both provided power and facilitate communication to the motor controller 204 and the chore motor 202 from a vehicle controller, and only the single cable 260 extends from the electric chore motor assembly 200, which reduces the amount of wires and cables when compared to convention motor controller connections. The single cable 260 and connector 250 function as an electrical lead that is integral to the rest of the electric chore motor assembly 200. In some embodiments of a chore product 10, multiple electric chore motor assemblies 200 are provided, each with a cable 260 having the same length as the cables of the other electric chore motor assemblies. The electric chore motor assemblies 200 are each mounted to the top of the mower deck 20 with a vehicle controller located within reach of the cables 260 of the electric chore motor assemblies 200 such that each cable 260 is directly connected to the vehicle controller by the connector 250 at the end of each cable 260. By using identical electric chore motor assemblies 200 in this manner, manufacturing is simplified because fewer components are needed to be stocked to produce the chore product 10.

[0034] As utilized herein with respect to numerical ranges, the terms “approximately,” “about,” “substantially,” and similar terms generally mean +/- 10% of the disclosed values. When the terms “approximately,” “about,” “substantially,” and similar terms are applied to a structural feature (e.g., to describe its shape, size, orientation, direction, etc.), these terms are meant to cover minor variations in structure that may result from, for example, the manufacturing or assembly process and are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the disclosure as recited in the appended claims.

[0035] It should be noted that the term “exemplary” and variations thereof, as used herein to describe various embodiments, are intended to indicate that such embodiments are possible examples, representations, or illustrations of possible embodiments (and such terms are not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

[0036] The term “coupled” and variations thereof, as used herein, means the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent or fixed) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members coupled directly to each other, with the two members coupled to each other using a separate intervening member and any additional intermediate members coupled with one another, or with the two members coupled to each other using an intervening member that is integrally formed as a single unitary body with one of the two members. If “coupled” or variations thereof are modified by an additional term (e.g., directly coupled), the generic definition of “coupled” provided above is modified by the plain language meaning of the additional term (e.g., “directly coupled” means the joining of two members without any separate intervening member), resulting in a narrower definition than the generic definition of “coupled” provided above. Such coupling may be mechanical, electrical, or fluidic.

[0037] References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below”) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.

[0038] The hardware and data processing components used to implement the various processes, operations, illustrative logics, logical blocks, modules and circuits described in connection with the embodiments disclosed herein may be implemented or performed with a general purpose single- or multi-chip processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general purpose processor may be a microprocessor, or, any conventional processor, controller, microcontroller, or state machine. A processor also may be implemented as a combination of computing devices, such as a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration. In some embodiments, particular processes and methods may be performed by circuitry that is specific to a given function. The memory (e.g., memory, memory unit, storage device) may include one or more devices (e.g., RAM, ROM, Flash memory, hard disk storage) for storing data and/or computer code for completing or facilitating the various processes, layers and modules described in the present disclosure. The memory may be or include volatile memory or non-volatile memory, and may include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described in the present disclosure. According to an exemplary embodiment, the memory is communicably connected to the processor via a processing circuit and includes computer code for executing (e.g., by the processing circuit or the processor) the one or more processes described herein.

[0039] The present disclosure contemplates methods, systems and program products on any machine-readable media for accomplishing various operations. The embodiments of the present disclosure may be implemented using existing computer processors, or by a special purpose computer processor for an appropriate system, incorporated for this or another purpose, or by a hardwired system. Embodiments within the scope of the present disclosure include program products comprising machine-readable media for carrying or having machine-executable instructions or data structures stored thereon. Such machine-readable media can be any available media that can be accessed by a general purpose or special purpose computer or other machine with a processor. By way of example, such machine-readable media can comprise RAM, ROM, EPROM, EEPROM, or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to carry or store desired program code in the form of machine-executable instructions or data structures and which can be accessed by a general purpose or special purpose computer or other machine with a processor. Combinations of the above are also included within the scope of machine-readable media. Machine-executable instructions include, for example, instructions and data which cause a general purpose computer, special purpose computer, or special purpose processing machines to perform a certain function or group of functions.

[0040] Although the figures and description may illustrate a specific order of method steps, the order of such steps may differ from what is depicted and described, unless specified differently above. Also, two or more steps may be performed concurrently or with partial concurrence, unless specified differently above. Such variation may depend, for example, on the software and hardware systems chosen and on designer choice. All such variations are within the scope of the disclosure. Likewise, software implementations of the described methods could be accomplished with standard programming techniques with rule-based logic and other logic to accomplish the various connection steps, processing steps, comparison steps, and decision steps.

[0041] It is important to note that the construction and arrangement of the electric chore motor assembly 200 as shown in the various exemplary embodiments is illustrative only. Additionally, any element disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed herein. Although only one example of an element from one embodiment that can be incorporated or utilized in another embodiment has been described above, it should be appreciated that other elements of the various embodiments may be incorporated or utilized with any of the other embodiments disclosed herein.

Claims

WHAT IS CLAIMED IS:

1. An electric chore motor assembly, comprising: a chore motor including: a rotor; a stator; a base housing; an outer housing; and a drive shaft rotationally coupled to the rotor and extending through the base housing; and a motor controller enclosed between the base housing and the outer housing, wherein the motor controller is connected to the stator by phase wires that are enclosed between the base housing and the outer housing.

2. The electric chore motor assembly of claim 1, wherein the base housing includes an inner hub and an outer wall.

3. The electric chore motor assembly of claim 2, wherein the motor controller is arranged between the inner hub and the outer wall.

4. The electric chore motor assembly of claim 2, wherein the base housing includes a first mounting flange extending outwardly from the outer wall and a second mounting flange extending outward from the outer wall.

5. The electric chore motor assembly of claim 4, further comprising a cable coupled to the base housing, wherein the cable is coupled to the outer wall at a location that is centered between the first mounting flange and the second mounting flange.

6. The electric chore motor assembly of claim 5, wherein the cable includes a connector arranged distally from the base housing, and wherein the connector only includes a positive power port, a negative power port, and a communication port.

7. The electric chore motor assembly of claim 1, wherein the enclosure formed between the base housing and the outer housing is configured to block at least a portion of an electrical interference generated by the motor controller and the phase wires.

8. An electric chore motor assembly, comprising: a chore motor including: a rotor; a stator; a base housing including a mounting recess arranged between an inner hub and an outer wall; a drive shaft rotationally coupled to the rotor and extending through the base housing; a first mounting flange extending outwardly from the outer wall; and a second mounting flange extending outwardly from the outer wall; a motor controller arranged within the mounting recess; and a cable electrically coupled to the motor controller and including a first connector in communication with the motor controller and coupled to the base housing, wherein the first connector is arranged between the first mounting flange and the second mounting flange.

9. The electric chore motor assembly of claim 8, wherein the first connector is centered between the first mounting flange and the second mounting flange.

10. The electric chore motor assembly of claim 8, wherein the cable includes a second connector arranged distally from the first connector, wherein the second connector only includes a positive power port, a negative power port, and a communication port.

11. The electric chore motor assembly of claim 8, wherein the motor controller is electrically coupled to the stator by phase wires.

12. The electric chore motor assembly of claim 11, wherein the phase wires are at least partially enclosed within the base housing.

13. The electric chore motor assembly of claim 8, further comprising an outer housing coupled to the base housing.

14. The electric chore motor assembly of claim 13, wherein the motor controller is enclosed between the base housing and the outer housing.

15. An electric chore motor assembly, comprising: a chore motor including: a rotor; a stator; a drive shaft rotationally coupled to the rotor; and a base housing through which the drive shaft axially extends; a motor controller arranged within the base housing; and a cable electrically coupled to the motor controller and including a connector in communication with the motor controller, wherein the connector only includes a positive power port, a negative power port, and a communication port.

16. The electric chore motor assembly of claim 15, wherein the base housing includes an inner hub and an outer wall.

17. The electric chore motor assembly of claim 16, wherein the motor controller is arranged radially between the inner hub and the outer wall.

18. The electric chore motor assembly of claim 16, further comprising a first mounting flange extending outward from the outer wall and a second mounting flange extending outward from the outer wall, wherein the cable is centered in the outer wall between the first mounting flange and the second mounting flange.

19. The electric chore motor assembly of claim 15, wherein the base housing is configured to block at least a portion of an electrical interference generated by the motor controller.

20. The electric chore motor assembly of claim 15, wherein the motor controller is electrically coupled to the stator by phase wires, and wherein the phase wires are at least partially enclosed within the base housing.