A resin injection apparatus configured to manufacture a rotor of a rotary electric machine includes a resin injector having an ejection port for ejecting a resin, and a runner having a charging port connectable to the ejection port, and a plurality of ejection ports communicating with the charging port and disposed at positions associated with hole portions of a rotor core where magnets are disposed.

A method for molding a magnetic material into a rotor stack, including providing a polymer melt including magnetic compound particles and a polymer binder, providing a rotor including a plurality of cavities, the rotor being arranged in a mold having a mold cavity surface, and providing a gap between the outer periphery of the rotor and the mold cavity surface. The method also includes filling a first volume of the polymer melt into the cavities of the rotor at a first pressure and filling a second volume of the polymer melt into the rotor at one or more second pressures, the one or more second pressures being less than the first pressure and above an ambient pressure.

An electric propulsion system for a vertical takeoff-and-landing aircraft having an inverter assembly, a gearbox assembly, an electric motor assembly. The inverter assembly, the gearbox assembly, and the electric motor assembly may be substantially aligned along an axis. The inverter assembly, a gearbox assembly, and electric motor assembly may each abut at least one of the others. The electric engine may use a liquid, such as oil, for cooling and lubricating components of the inverter assembly, gearbox assembly, and electric motor assembly. Further, the electric engine may use volumes of oil for cooling and lubricating components below a threshold volume so that the electric engines do not require a fire protective barrier.

Heating parts (212a to 212l, 222a to 222l) are brought into contact with planned heating regions (11a to 11l) of outermost electrical steel sheets (10a, 10b) of an electrical steel sheet group (100), to simultaneously pressurize and heat the planned heating regions (11a to 11l).

An electrical machine including: a stator core extending along an axial direction and supported by a stator frame. An intermediate plate is provided between the stator core and the stator frame and configured to support the stator core. One of the stator frame and the intermediate plate includes a stopping formation configured to abut the other of the stator frame and the intermediate plate to constrain movement of the stator core relative to the stator frame in at least one direction in the axial direction. The stopping formation is movable relative to the one of the stator frame and the intermediate plate.

A coil for an electric machine including a conductive strand having a first end, a second end, and a plurality of windings between the first and second ends and an electric insulating body within which the conductive strand is at least partially encased, wherein at least a portion of the insulating body includes perforations that allow a coolant to penetrate into the insulating body to cool the coil during use of the electric machine. A method of making the coil includes molding or printing the insulating body about the conductive strand so as to have perforations therein.

An electric propulsion system for a vertical take-off and landing (VTOL) aircraft having a heat exchanger to cool fluids used in an electrical engine, the electric propulsion system comprising at least one electrical engine mechanically connected directly or indirectly to a fuselage of the VTOL aircraft and electrically connected to an electrical power source. The electrical engine may comprise an electrical motor having a stator and a rotor; a gearbox assembly comprising a sun gear; at least one planetary gear; a ring gear; and a planetary carrier. The electric engine may include an inverter assembly comprising a thermal plate and an inverter assembly housing; an end bell assembly that is connected to the thermal plate of the inverter assembly; and a heat exchanger comprising an array of cooling fins and tubes.

In order to enable positioning of wire ends of the wound wires with a simple configuration, the workpiece holding apparatus includes a plurality of chucks configured to hold a workpiece provided with salient poles (cores), in a state where wires fed from nozzles are wound around the salient poles, by moving in radial direction of the workpiece and coming into contact with the workpiece. Among the plurality of chucks, each first chuck includes a holding part configured to hold a first portion of the corresponding wire located between the corresponding salient pole and the corresponding nozzle, and the wires are cut in a state where their first portions are held.

Equipment for welding a motor stator to a substrate includes a protective hood and a hot pressing head. The protective hood covers the motor stator and the substrate to protect the motor stator from undesired displacing and possible damage, and is provided with a plurality of wire slots, via which lead-out wires of coil windings of the motor stator can be pulled out to expose from the protective hood. The hot pressing head has a hot pressing end corresponding to welding points on the substrate and is movable to cover an outer side of the protective hood while the hot pressing end heats and welds the lead-out wires and the welding points together. With the equipment, all the coil windings of the motor stator can be welded to the substrate in one single movement while the motor stator is protected against splattered solders during the welding operation.

A method for welding a motor stator to a substrate includes steps of: providing a motor stator and a substrate; preliminarily fixing the motor stator to the substrate; pulling out lead-out wires of coil windings wound on the motor stator to align with solders of welding points on the substrate; covering a protective hood on the motor stator; covering the hot pressing head around the protective hood while the hot pressing end is located corresponding to the welding points; heating and compressing the welding points to melt the solders; and waiting the molten solders on the welding points to cool and cure to weld the coil windings of the motor stator to the welding points. With the present invention, all the coil windings of the motor stator can be welded to the substrate in one single movement while the motor stator is protected against splattered solders during the welding operation.