Process and adjustable rotor position sensor mount for correlated motor and sensor alignment

An electric motor assembly comprising:

• a motor including—
• a stator assembly,
• a rotor assembly comprising a rotor shaft rotatable about a rotor axis,
• a housing defining a motor chamber receiving at least a portion of the rotor assembly and the stator assembly, the housing including an endshield rotatably supporting the shaft, and
• a sensor target fixed relative to the rotor shaft and thereby oriented in a known position relative to a back electromotive force (BEMF) waveform of the motor;
• a rotary position sensor configured to sense the sensor target;
• and
• an alignment plate;
• said rotary position sensor being fixed relative to the alignment plate,
• said alignment plate being adjustably coupled to the endshield for rotational adjustment that is substantially concentric with the rotor axis, such that the rotary position sensor is adjustable to align a signal waveform produced by the rotary position sensor with the BEMF waveform within a predetermined measurement range,
• said endshield including a counterbore defined therein, the counterbore being substantially concentric with the rotor axis,
• said counterbore defining an annular wall and an adjacent planar base wall, the planar base wall being substantially perpendicular to the annular wall and the rotor axis,
• said alignment plate presenting an outer diameter,
• said annular wall presenting an inner diameter sized to define a slip fit between the annular wall and the alignment plate,
• said outer diameter of the alignment plate being in a range between and including about one hundred and fifteen (115) millimeters and about one hundred and twenty-five (125) millimeters.

An electric motor assembly comprising:

• a motor including—
• a stator assembly,
• a rotor assembly comprising a rotor shaft rotatable about a rotor axis,
• a housing defining a motor chamber receiving at least a portion of the rotor assembly and the stator assembly, the housing including an endshield rotatably supporting the shaft, and
• a sensor target fixed relative to the rotor shaft and thereby oriented in a known position relative to a back electromotive force (BEMF) waveform of the motor;
• a rotary position sensor configured to sense the sensor target;
• and
• an alignment plate;
• said rotary position sensor being fixed relative to the alignment plate,
• said alignment plate being adjustably coupled to the endshield for rotational adjustment that is substantially concentric with the rotor axis, such that the rotary position sensor is adjustable to align a signal waveform produced by the rotary position sensor with the BEMF waveform within a predetermined measurement range,
• said electric motor assembly further comprising two or more spaced apart alignment pins,
• said rotary position sensor including a sensor housing defining two or more pin holes,
• said alignment plate defining two or more pin openings, each of which is aligned with a respective one of the pin holes,
• each of said alignment pins being received in aligned ones of the pin holes and pin openings, such that the pins secure the rotary position sensor in a rotatably fixed position relatively to the alignment plate.

An electric motor assembly comprising:

• a motor including—
• a stator assembly,
• a rotor assembly comprising a rotor shaft rotatable about a rotor axis,
• a housing defining a motor chamber receiving at least a portion of the rotor assembly and the stator assembly, the housing including an endshield rotatably supporting the shaft, and
• a sensor target fixed relative to the rotor shaft and thereby oriented in a known position relative to a back electromotive force (BEMF) waveform of the motor;
• a rotary position sensor configured to sense the sensor target;
• and
• an alignment plate;
• said rotary position sensor being fixed relative to the alignment plate,
• said alignment plate being adjustably coupled to the endshield for rotational adjustment that is substantially concentric with the rotor axis, such that the rotary position sensor is adjustable to align a signal waveform produced by the rotary position sensor with the BEMF waveform within a predetermined measurement range,
• said alignment plate defining a central opening therethrough,
• said central opening having an inner diameter in the range between and including about forty-five (45) millimeters and about fifty-five (55) millimeters.