Embodiments involve rotors for axial flux induction rotating electric machines that use a soft magnetic composite for the rotor core. A first embodiment is directed to a rotor for a rotating electrical machine that transmits magnetic flux parallel to a shaft of the rotor. The rotor includes a rotor winding and a plurality of cores. The rotor winding consists of a solid piece of conductive material that comprises a plurality of cavities. Each core is placed in a respective cavity and comprises a highly resistive isotropic ferromagnetic powder.

A repaired rotor of a multi-phase electric motor includes a plurality of annular laminations stacked to form a cylindrical core about a central axis, each of the laminations having notches aligned to form axially extending slots about a periphery of the core; a plurality of electrical conductors extending through the slots; a pair of conductive end rings, each attached to a different end of the cylindrical core and electrically connected to the plurality of electrical conductors; and an outer end ring abutting and electrically connected to one of the pair of conductive end rings and electrically connected to adjacent ends of the plurality of electrical conductors, the outer end ring providing an uninterrupted electrically conductive path connecting the plurality of electrical conductors.

A rotor for an electric machine. A laminated core with a plurality of short-circuit bars that pass through it and are joined at both ends by way of a respective short-circuit ring. A support disc, which is made of a material that has a higher strength than the material of the short-circuit ring, is axially arranged at each short-circuit ring.

A rotor stack assembly includes multiple plates each including multiple elongated slots each oriented radially outward from a longitudinal central axis of each plate toward an outer perimeter wall of the plate. Multiple openings are each positioned proximate to one of the slots and directed outwardly through the outer perimeter wall. Multiple runners individually extend through the plate and individually open into one of opposed ends of each of the slots. Multiple bars of a conductive material are each extended through aligned ones of the slots of each of the multiple plates.

A method of manufacturing a rotor of an electric motor or an electric generator includes positioning a plurality of amortisseur bars and using additive manufacturing to place electrically conductive material. More specifically, positioning the amortisseur bars may include circumferentially positioning the bars around a rotor stack and using additive manufacturing to place electrically conductive material may include forming a non-solid pattern of electrically conductive material, such as a pattern of electrically conductive traces, across opposite axial ends of the rotor stack to electrically interconnect an amortisseur circuit.

Provided herein are systems, apparatuses, and methods of providing a centrifugally cast rotor assembly for an induction motor of an electric vehicle. The rotor assembly includes a rotor lamination stack with a cylindrical shape that terminates in a first end surface and a second end surface. The rotor lamination stack has multiple lamination discs, and each lamination disc has multiple rotor slots. The rotor assembly further includes copper bars disposed within the rotor slots, a first intermediary end ring disposed at the first end surface, and a second intermediary end ring disposed at the second end surface. A centrifugally cast first copper end ring that electrically and mechanically couples each of the copper bars is located proximate the first end surface, and a centrifugally cast second copper end ring that electrically and mechanically couples each of the copper bars is located proximate the second end surface.

Apparatus and methods are provided for manufacturing a rotor. The rotor has a core with an open center, conductive bars extending across the core and conductive end rings at ends of the core. A mandrel has a body that extends through the open center and a head that extends over and engage the first end of the core around the open center. A central cap couples with the body, extends over and engages the second end of the core around the open center. An end cap covers the central cap and engages the core around the open center. The end cap defines at least part of a cavity around the conductive bars for receiving molten metal.

In a method for producing a squirrel-cage rotor for an asynchronous machine, conductor rods made from a first conductive material are inserted in substantially axial grooves of a laminated rotor core in such a manner that the conductor rods protrude from an end face of the laminated rotor core. A short circuit ring disc made from a second conductive material and heated above the recrystallization temperature is axially pressed onto the protruding conductor rods on the end face of the laminated rotor core, taking into account a temperature range, a deformation, and the rate of deformation of the short circuit ring, with a permissible shear stress of the first and second conductive materials being locally exceeded and material transitions being caused by diffusion at an interface between the conductor rods and the short circuit ring, thereby resulting in microwelding. Subsequently or simultaneously the short circuit ring disc is hot shaped.

A squirrel cage rotor having a shaft, a rotor plate stack with rotor bars arranged in the interior thereof, and cage rings, wherein at least one part of a cage ring includes a disk stack, which is constituted as a layered structure of disks with cut-outs, through which the ends of the rotor bars project out of the rotor plate stack. Adjoining disks in the disk stack are mutually spaced, and form a gap. The clearance between two adjoining disks, resulting from the gap, is constituted by moldings which are arranged on the disks wherein, in the gap, at least in the region of the moldings, a joint connection is provided.

A rotor of an induction machine includes a rotor core structure and a cage winding. The cage winding includes rotor bars in slots of the rotor core structure and end-rings connected to ends of the rotor bars. The ends of the rotor bars are attached to openings of the end-rings by expansion of the ends of the rotor bars in transverse directions of the rotor bars caused by axial press having been directed to the ends of the rotor bars. The material of the rotor bars is softer than the material of the end-rings. Thus, unwanted shape deformation of the end-rings can be avoided when the ends of the rotor bars are axially pressed. The material of the end-rings can be for example copper alloy with additions of chrome and zirconium, whereas the material of the rotor bars can be for example copper.