A primary adhesive agent is applied to a core laminate in which separation layers are interposed between multiple blocks each consisting of a predetermined number of core constituting plates, the separation layers are removed after the primary adhesive agent is cured, a secondary adhesive agent is applied to lamination surfaces between the blocks, and the secondary adhesive agent is cured.

A method is used for producing metal sheets for packets of metal sheets of a rotor and of a stator for three-phase drives, in particular for reluctance machines (reluctance motors) made of magnetic, in particular magnetically soft materials by means of additive production processes, in which the magnetizable material is melted and fed to at least one print head which applies the melted material to form a rotor/stator sheet. The melted material is influenced by an applied magnetic field so that the finished rotor/stator sheet has an area with high magnetic conductivity determining the desired direction of flow.

A varnish impregnation method of a stator coil winding. The varnish impregnation method includes: a first step of maintaining an inside of a vacuum chamber to be in a vacuum state; a second step of injecting varnish into a slot of a stator core through a varnish supply hole formed in a lower housing of the varnish impregnation device; a third step of causing an air pressure within the vacuum chamber to come to equilibrium with an external air pressure, discharging the varnish from the vacuum chamber, and transferring the varnish again to the varnish storage tank; a fourth step of stopping the operation of the air pump when the discharge of the varnish from the vacuum chamber is completed; and a fifth step of separating the stator from the varnish impregnation device, withdrawing the stator from the vacuum chamber, and curing the varnish in a curing device.

An aligning apparatus for a hairpin type stator coil includes a frame, at least one storage including storage guides, which are arranged in a storage stacking portion installed in the frame and are inclined downward, and on which I-shaped stator coils are loaded, at least one cartridge including cartridge guides arranged in a downward direction and loading the I-shaped stator coils which are taken out from the at least one storage, and the at least one cartridge arranged in front of at least one storage to extract the I-shaped stator coils, and a robot gripper configured to move along a predetermined path by a handling robot to grip and un-grip the I-shaped stator coils, which are output one by one from the at least one cartridge, and insert the I-shaped stator coils into a predetermined position in the alignment jig.

A coil stripping apparatus is configured for manufacture of a hairpin for a motor of an electric vehicle. The coil stripping apparatus includes a base frame provided with a guide rail having a straight path, at least two stripping units configured to press both sides of the material coil while moving along the guide rail to remove an insulating film, and a controller configured to control movement and operation of the stripping units. The stripping units include a first stripping unit disposed upstream based on a material coil feeding path and a second stripping unit disposed downstream of the first stripping unit.

A rotor includes a rotor core and a plurality of magnets accommodated in each accommodation hole of the rotor core. The rotor core has a radial core thickness that is different on one side and the other side in a radial direction with the accommodation hole in between. The accommodation hole is formed surrounded by first side surfaces facing each other in a radial direction and second side surfaces facing each other in a circumferential direction. The magnet consists of two divided magnets arranged in the circumferential direction within the accommodation hole. The two divided magnets are biased in the radial direction so as to be close to the first side surface on a side having a thicker radial core thickness among both radial sides of the accommodation hole, and are biased so as to be close to the second side surface in the circumferential direction.

A rotor manufacturing apparatus is configured to manufacture a rotor that includes a tubular rotor core having multiple slots, multiple magnets respectively accommodated in the slots, and multiple pieces of plastic fixing the magnets to the rotor core. The rotor manufacturing apparatus includes plungers configured to extrude the plastic toward the slots, and a drive unit configured to be movable toward and away from the rotor core. The drive unit includes accommodating portions and an urging section. The accommodating portions respectively receive the plungers such that the plungers are movable relative to the accommodating portions in a movement direction of the drive unit. The urging section urges the plungers in an extrusion direction of the plastic from inside the accommodating portions.

Presented are electric machines with rotor shaft-mounted heat pipes/vapor chambers thermally coupled to endcap-integrated heat sinks, methods for making/using such machines, and vehicles equipped with such machines. An electric machine includes an outer housing, a stator assembly mounted to the housing, and a rotor assembly rotatably mounted adjacent the stator assembly. The stator assembly includes one or more stator windings mounted to an annular stator core. The rotor assembly includes one or more electromagnetic rotor windings mounted to a cylindrical rotor core. A rotor power transfer circuit (PTC) is electrically connected to the rotor assembly to electrify the rotor winding(s). A rotor shaft is attached to the rotor core to rotate in unison therewith. One or more heat pipes are mounted on the rotor shaft's outer surface and project axially between the rotor PTC and rotor core. Each heat pipe passively extracts and transfers thermal energy from the rotor PTC.

A rotor core molding system, for molding magnets in an unmolded rotor core to provide a molded rotor core for an electrical motor, comprises first and second molds arranged to allow clamping at least one unmolded rotor core between the molds, a pre-adjustment arrangement for allowing to pre-adjust a distance between the molds in a preset open configuration of the molds to a pre-adjusted distance, and a mold closure arrangement for allowing to close the molds from the preset open configuration to a closed configuration by moving the molds towards one another to clamp unmolded rotor core(s) provided between the molds with a predetermined pressure in between the molds in the closed configuration. The pre-adjustment arrangement is configured to provide a relatively long-range distance movement, especially corresponding to one or more rotor core heights. The mold closure arrangement is configured to provide a relatively short-range distance movement.

A method of manufacturing a rotor for an electric motor comprises: positioning a permanent magnet within a magnet hole formed in a rotor body, the rotor body and the permanent magnet to form a rotor for an electric motor; providing an electrically insulating layer between the permanent magnet and a surface of the rotor body, the surface at least partially defines the magnet hole; performing an electrical continuity test on the permanent magnet and the rotor body while the permanent magnet is within the magnet hole and the electrically insulating layer is between the permanent magnet and the surface of the rotor body; determining whether the electrically insulating layer provides at least a threshold electric insulation to prevent of eddy currents circulating; and based on the electrically insulating layer providing at least the threshold electric insulation, approving the rotor for the electric motor.