An electrical motor includes a stator; a rotor attached to an output shaft and supported within the stator; a cylindrical case housing the stator and the rotor inside; ball bearings rotatably supporting the output shaft; and a second cover member closing an opening of the case, the ball bearing being attached to the second cover member. An outer ring of the ball bearing and the second cover member are integrally formed of resin material.

An electrical motor includes a stator; a rotor attached to an output shaft and supported within the stator; a cylindrical case housing the stator and the rotor inside; ball bearings rotatably supporting the output shaft; and a second cover member closing an opening of the case, the ball bearing being attached to the second cover member. An outer ring of the ball bearing and the second cover member are integrally formed of resin material.

A rotor includes a yoke, an end cap, and a rotary shaft. The yoke is fixed relative to the end cap. The rotary shaft extends into the yoke. One end of the rotary shaft is connected to the end cap. The end cap is formed on the yoke and the rotary shaft by injection molding. The present invention further provides a motor and an electric tool including the rotor. In the rotor of this invention, the end cap is formed by injection molding, and the yoke and the rotary shaft are connected into a whole at the same time of forming the end cap. The traditional aluminium end cap is replaced with the molded end cap, which makes the rotor easier to fabricate and have a lighter weight and lower cost.

A rotor includes a yoke, an end cap, and a rotary shaft. The yoke is fixed relative to the end cap. The rotary shaft extends into the yoke. One end of the rotary shaft is connected to the end cap. The end cap is formed on the yoke and the rotary shaft by injection molding. The present invention further provides a motor and an electric tool including the rotor. In the rotor of this invention, the end cap is formed by injection molding, and the yoke and the rotary shaft are connected into a whole at the same time of forming the end cap. The traditional aluminium end cap is replaced with the molded end cap, which makes the rotor easier to fabricate and have a lighter weight and lower cost.

Apparatuses and methods relating to hub motors having enhanced thermal characteristics may include a hub motor having a stator comprising steel and a central axle (e.g., a mandrel and shaft) comprising a material with a substantially higher thermal conductivity than the stator (e.g., aluminum). Heat may be transferred from the stator through the axle of the motor to an outside heat sink. Manufacturing of thermally enhanced hub motors may include extrusion and/or cryogenic fitting methods relating to the central mandrel and shaft.

A linear motor includes an excitation unit including a shaft and a plurality of permanent magnets located in the shaft, and an armature including a plurality of coils surrounding the excitation unit and a magnetic cover covering the coils. The plurality of coils of the same phase group are continuously wound over a plurality of insulative bobbins. A tap conductor, a jumper wire between the coils, and a terminal wire of the coils in different phase groups that are continuously wound are separately disposed in different corner portions in the magnetic cover, and the terminal wire of each phase is connected to a circuit board.

A linear motor includes an excitation unit including a shaft and a plurality of permanent magnets located in the shaft, and an armature including a plurality of coils surrounding the excitation unit and a magnetic cover covering the coils. The plurality of coils of the same phase group are continuously wound over a plurality of insulative bobbins. A tap conductor, a jumper wire between the coils, and a terminal wire of the coils in different phase groups that are continuously wound are separately disposed in different corner portions in the magnetic cover, and the terminal wire of each phase is connected to a circuit board.

A method of manufacturing a motor, which begins with robotically positioning a flexible insulating sleeve over a first motor sub-assembly to produce a second motor sub-assembly. The first motor sub-assembly includes a motor assembly and an end-cap. The motor assembly includes a stator, a rotor, and wiring connected to the stator. The end-cap includes an electrical fitting for feeding the wiring externally of the motor. The method continues with robotically positioning a flexible enclosure, that includes a formed housing section and a connecting section, loosely over the second motor sub-assembly. The method continues with tightening the connecting section until the formed housing section tightly fits over the second sub-assembly compressing the flexible insulating sleeve to produce an insulating seal.

A method of manufacturing a motor, which begins with robotically positioning a flexible insulating sleeve over a first motor sub-assembly to produce a second motor sub-assembly. The first motor sub-assembly includes a motor assembly and an end-cap. The motor assembly includes a stator, a rotor, and wiring connected to the stator. The end-cap includes an electrical fitting for feeding the wiring externally of the motor. The method continues with robotically positioning a flexible enclosure, that includes a formed housing section and a connecting section, loosely over the second motor sub-assembly. The method continues with tightening the connecting section until the formed housing section tightly fits over the second sub-assembly compressing the flexible insulating sleeve to produce an insulating seal.

Various embodiments of the teachings herein include a canned electrical rotating machine or liquid pump. The machine or pump may include a can made of a first material. The first material comprises, at least in a proportion of more than 50% by weight, a composite material with high-modulus or ultrahigh-modulus (HM/UHM) carbon fiber reinforcement.