In an aspect of the present disclosure is an electric aircraft motor with a fully welded rotor. The motor includes a stator and a rotor. The stator includes an inner cylindrical surface and an outer cylindrical surface. The rotor includes a cylindrical portion and spokes welded to the cylindrical portion. In another aspect of the present disclosure is a method for manufacturing a fully welded rotor.

A method for manufacturing a coil with an insulating film 130 is provided that includes: a preparation step of preparing a formed workpiece W to which the insulating film has not yet been applied; and an electrodeposition coating step of generating, with the workpiece W immersed in an electrodeposition bath, a potential difference between a first electrode connected to the workpiece W and a second electrode in the electrodeposition bath. In the electrodeposition coating step, the insulating film is simultaneously applied to a portion of the workpiece W and another portion of the workpiece W in such a manner that a film thickness on the portion is thicker than a film thickness on the other portion.

Various embodiments of the teachings herein include an electrical machine. The electrical machine may include a rotor and/or a stator with a stack of soft magnetic laminations. Each soft magnetic lamination has a first respective flat side and a second respective flat side facing away from the first one. Each soft magnetic lamination tapers from the first flat side to the second flat side. Each of the soft magnetic laminations in the stack are oriented with the respective second flat side in the same direction.

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 of manufacturing a stator sleeve starts with wrapping a cylindrical mandrel with a heated prepreg tape using automated fiber placement. The prepreg tape has a continuous fiber reinforcement within a polymer matrix. Next, cool and remove the cylindrical mandrel from the wrapped prepreg tape resulting in an unfinished cylindrically shaped stator sleeve. Each end of the unfinished stator sleeve is trimmed. Next, abut a first and a second end ring respectively against a first and a second ends of the trimmed stator sleeve using a cylindrical fixture tool. The first and second end rings are the same material as the polymer matrix of the prepreg tape. Finally, laser welding or melt bonding the first and second rings to the first and second ends of the trimmed stator sleeve.

A method and a device for joining a reinforcement sleeve onto a rotor of an electric motor. The method includes providing the reinforcement sleeve and the rotor, the reinforcement sleeve has a cylindrical inner periphery which is undersized with respect to a cylindrical outer periphery of the rotor; attaching at least two vacuum cups onto an outer lateral surface of the reinforcement sleeve, such that the vacuum cups adhere to the outer lateral surface of the reinforcement sleeve in a reversibly detachable manner on account of a vacuum generated between the vacuum cup and the outer lateral surface; and joining the reinforcement sleeve onto the rotor, in that the rotor is pressed into the reinforcement sleeve in a pressing direction.

A rotor manufacturing method is a method that allows magnetized magnets inserted in second magnet holes of a second rotor core to be inserted, while retaining magnetism, into first magnet holes of a first rotor core. This method includes a placing step of placing the second rotor core on a first end surface, in a stack thickness direction, of the first rotor core such that the second magnet holes overlap the first magnet holes, and an extruding step of extruding the magnetized magnets from the second magnet holes toward the first magnet holes using a non-magnetic jig.

Methods of estimating tribological damage described herein include examples where varying power is applied between surfaces engaged in frictional contact. Calculations evaluate power consumed at the relevant frictional contact and temperature values may be gathered to supplement the calculated power. Instantaneous and cumulative assessments of damage are calculated based on that information. Measurements or calculations of electrical power may be used as part of the damage assessment.

A stator for an electric actuator or motor, including: a solid body; a ferromagnetic core region between the layers of semiconductor material, electrically insulated from the layers of semiconductor material; a plurality of conductive through vias through the solid body; a first plurality of conductive strips, which extend parallel to one another above the core; and a second plurality of conductive strips, which extend parallel to one another above the core and opposite to the first plurality of conductive strips; wherein the first plurality of conductive strips, the plurality of conductive through vias, and the second plurality of conductive strips form a winding or coil of the stator.

A magnetizing apparatus is to magnetize a permanent magnet of a motor. The motor includes an annular stator mounted to an inner side of a compressor shell and having a winding, and a rotor provided on an inner side of the stator and having the permanent magnets. The magnetizing apparatus includes an outer circumferential yoke detachably mounted to an outer side of the compressor shell and being made of a magnetic material, and a power supply device applying a magnetization current to the winding of the stator.