According to one disclosed method, a magnet segment may be slid linearly along a first surface and onto a second surface of a back iron of a rotor, wherein the first surface is disposed at or above a rim that extends upwardly from the second surface at an outer edge of the back iron to enable the magnet segment to slide over the rim before the magnet segment is slid onto the second surface. According to another disclosed method, a first end of a magnet segment may be pressed against an elastic member located at an inner portion of a back iron for a rotor so that force exerted by the elastic member pushes a second end of the magnet segment against a rim located at an outer portion of the back iron.

An apparatus for manufacturing a laminated iron core includes a press device, circuitry, and a detecting unit. The press device includes a tab forming unit, a press-fit hole forming unit, and a punching unit. The punching unit is configured to use a die and a punch to punch out, from the workpiece, iron core pieces including press-fit holes and iron core pieces including tabs, stack the iron core pieces in the die to form a laminated body, and eject the laminated body through an ejection port. The detecting unit is configured to detect ejection of the laminated body through the ejection port. The circuitry is configured to determine that there is an anomaly in the press-fit hole forming unit when the detecting unit does not detect ejection of the laminated body within a predetermined detection time.

A method for manufacturing a laminated iron core includes forming a laminated body by punching out iron core pieces from a plate-shaped workpiece that is intermittently conveyed, measuring, at multiple measurement points arranged in a conveying direction of the workpiece, a thickness of a designated portion of the workpiece from which each iron core piece is to be punched out, calculating, as an average thickness of each iron core piece, an average value of measured values at the multiple measurement points, and calculating a lamination thickness of the laminated body by accumulating the average thicknesses of the iron core pieces.

A rotor core manufacturing method and system allow for molding permanent magnets in an unmolded rotor core to provide an electric motor molded rotor core. The unmolded rotor core includes a shaft and rotor core body having a central through-hole along a longitudinal axis, magnet cavities around the axis with magnets therein. The shaft lies in the central through-hole and projects therefrom, and the molded rotor core includes the rotor core body having the magnets fixed in the cavities. The method includes inserting an unmolded rotor core between the first and second molds of a rotor core molding system; moving the molds together to clamp the rotor core body of the unmolded rotor core with a predetermined pressure; providing a molding material into the magnet cavities; letting the molding material cure within the magnet cavities to a molded rotor core; opening the molds and removing the molded rotor core.

A system and method for manufacturing a stator-assembly for an electric machine, which comprises a stator and a busbar for electrically connecting coils of the stator to a controller of the electric machine. Simplified and cost-effective manufacture with reduced cycle times is achieved by encasing the busbar with an electrically insulating busbar material and then electrically connecting it to the coils, with joint sections in which the coils are electrically connected to the busbar also being separately electrically insulated after said electrical connecting.

A rotary machine according to the present disclosure includes a stator, a rotor, a rotary shaft, and a magnetic sensor. The rotor rotates relative to the stator. The rotary shaft is coupled to the rotor and rotates as the rotor rotates. The magnetic sensor detects a position of the rotor. The rotor includes a plurality of magnets. The magnetic sensor is arranged to face the rotor in an axial direction that is parallel to the rotary shaft. The magnetic sensor detects the position of the rotor based on a magnetic field generated by the plurality of magnets of the rotor.

In a method for manufacturing a stator, a stress removing step is performed that is a step of removing residual stress in a laminated core caused by a stamping process by generating heat in the laminated core by applying a current to an induction heating coil placed in each of a plurality of slots.

A rotor for an axial flux machine, the rotor comprising: a disc-shaped rotor body having an axis of rotation, the disc-shaped rotor body formed of a fibre reinforced composite material and having an opening at the axis of rotation; a plurality of permanent magnets mounted to a first face of the rotor body circumferentially around the axis of rotation, the plurality of permanent magnets arranged in a Halbach array configuration.

An example system includes: an electric motor; a mechanical device coupled to, and actuatable by, the electric motor; and an electronics module comprising: (i) a motor controller controlling the electric motor, and (ii) an actuator board that is electrically coupled to the motor controller, wherein the motor controller is removable and replaceable, wherein the actuator board remains attached to the system when the motor controller is removed and replaced, wherein the actuator board comprises (i) a memory storing one or more settings associated with the electric motor, or (ii) an identifier, wherein when a replacement motor controller is electrically connected to the actuator board, the replacement motor controller receives the one or more settings from the memory of the actuator board or receives the identifier, which allows the motor controller to retrieve the one or more settings.

The present disclosure provides a potting method of a coreless motor, a potting tooling thereof, and a coreless motor. Wherein the potting method includes the steps of providing a stator assembly and a housing, wherein the housing is sleeved on an outer wall of the stator assembly; providing a potting tooling, wherein the potting tooling includes a first potting fixture and a second potting fixture; inserting the first potting fixture into one end of the housing in an axial direction and inserting the second potting fixture into the other end of the housing in an axial direction to form a potting space; injecting glue into the potting space to form an encapsulation layer to encapsulate the stator assembly on the inner wall of the housing. With the potting method of the present disclosure, so as to improve the stability of the stator assembly in the potting process.