A rotor assembly includes a rotor core having winding slots, and one or more coils, which have slot-inserted segments included in the winding slots, and first and second end-turn segments external to the winding slots and located around opposite axial ends of the rotor core, respectively. The rotor assembly further includes a first containment band located around at least a portion of the first end-turn segments and configured to prevent the first end-turn segments from moving away from the rotor core radially, a second containment band located around at least a portion of the second end-turn segments and configured to prevent the second end-turn segments from moving away from the rotor core radially, and one or more sticks mounted in one or more of the winding slots, respectively. The first and second containment bands are retained via the sticks against moving away axially.

A rotor assembly includes a rotor core having winding slots, and one or more coils, which have slot-inserted segments included in the winding slots, and first and second end-turn segments external to the winding slots and located around opposite axial ends of the rotor core, respectively. The rotor assembly further includes a first containment band located around at least a portion of the first end-turn segments and configured to prevent the first end-turn segments from moving away from the rotor core radially, a second containment band located around at least a portion of the second end-turn segments and configured to prevent the second end-turn segments from moving away from the rotor core radially, and one or more sticks mounted in one or more of the winding slots, respectively. The first and second containment bands are retained via the sticks against moving away axially.

Methods and apparatus are disclosed for assembling a motor rotor. The apparatus includes a rotor fixing module, a conductive bar driving module, a plurality of conductive bars and a pump module. The rotor fixing module supports and holds the rotor. The conductive bar driving module has a plurality of assembling slots. When the pumping module is attached to the conductive bar driving module and each of the conductive bars seals the assembling slots, the pumping module and the assembling slots cooperatively form a sealed chamber, and the pumping module vacuums the sealed chamber to generate a suction force on each of the conductive bars, and the suction force further drives the conductive bars into the assembling slots. The method is for assembling the rotor by utilizing the same procedure mentioned above.

Methods and apparatus are disclosed for assembling a motor rotor. The apparatus includes a rotor fixing module, a conductive bar driving module, a plurality of conductive bars and a pump module. The rotor fixing module supports and holds the rotor. The conductive bar driving module has a plurality of assembling slots. When the pumping module is attached to the conductive bar driving module and each of the conductive bars seals the assembling slots, the pumping module and the assembling slots cooperatively form a sealed chamber, and the pumping module vacuums the sealed chamber to generate a suction force on each of the conductive bars, and the suction force further drives the conductive bars into the assembling slots. The method is for assembling the rotor by utilizing the same procedure mentioned above.

A method of manufacturing an induction motor rotor assembly, the method includes the steps of: providing a rotor; machining a plurality of re-entrant slots axially along an outer surface of the rotor; positioning a sleeve concentrically over the outer surface of the rotor; applying a friction stir welding process to the sleeve along each re-entrant slot axially along the outer surface of the rotor to cause the sleeve material to plasticise and flow into the axial re-entrant slot to form an axial re-entrant slot bar; and providing an electrical connection at each of the opposing axial ends of the rotor between respective ones of opposing ends of each of the axial re-entrant slot bars to thereby form the induction motor rotor.

A method of manufacturing an induction motor rotor assembly, the method includes the steps of: providing a rotor; machining a plurality of re-entrant slots axially along an outer surface of the rotor; positioning a sleeve concentrically over the outer surface of the rotor; applying a friction stir welding process to the sleeve along each re-entrant slot axially along the outer surface of the rotor to cause the sleeve material to plasticise and flow into the axial re-entrant slot to form an axial re-entrant slot bar; and providing an electrical connection at each of the opposing axial ends of the rotor between respective ones of opposing ends of each of the axial re-entrant slot bars to thereby form the induction motor rotor.

The present invention relates to a rotor (1) of a rotary electric machine, comprising: a body (3) comprising a cylindrical central core (5) and a circumferential plurality of arms (B1 . . . B18) extending radially out from the cylindrical central core (5), the body (3) being intended to be mounted with the ability to move about an axis of rotation X, a coilset produced by windings of turns and forming at least one series of coils (C1 . . . C9, C1 . . . C9, C1 . . . C9, C1 . . . C9), a coil (C1 . . . C9, C1 . . . C9, C1 . . . C9, C1 . . . C9) comprising a predetermined number of turns around at least two arms (B1 . . . B18) of the body, two adjacent coils (C1 . . . C9, C1 . . . C9, C1 . . . C9, C1 . . . C9) of a series being angularly offset from one another with a partial overlap,
in which the rotor (1) comprises at least one additional retaining loop (S1, S1, S2, S2) wound around at least two arms (B1 . . . B18) of which at least one is common to the arms (B1 . . . B18) around which is wound the last coil (C9, C9, C9, C9), situated radially outermost, of at least one series and of which at least one is distinct from the arms around which the said last coil (C9, C9, C9, C9) is wound, so that the at least one additional retaining loop (S1, S1, S2, S2) partially overlaps the turns of the said last coil (C9, C9, C9, C9).

The present invention relates to a rotor (1) of a rotary electric machine, comprising: a body (3) comprising a cylindrical central core (5) and a circumferential plurality of arms (B1 . . . B18) extending radially out from the cylindrical central core (5), the body (3) being intended to be mounted with the ability to move about an axis of rotation X, a coilset produced by windings of turns and forming at least one series of coils (C1 . . . C9, C1 . . . C9, C1 . . . C9, C1 . . . C9), a coil (C1 . . . C9, C1 . . . C9, C1 . . . C9, C1 . . . C9) comprising a predetermined number of turns around at least two arms (B1 . . . B18) of the body, two adjacent coils (C1 . . . C9, C1 . . . C9, C1 . . . C9, C1 . . . C9) of a series being angularly offset from one another with a partial overlap,
in which the rotor (1) comprises at least one additional retaining loop (S1, S1, S2, S2) wound around at least two arms (B1 . . . B18) of which at least one is common to the arms (B1 . . . B18) around which is wound the last coil (C9, C9, C9, C9), situated radially outermost, of at least one series and of which at least one is distinct from the arms around which the said last coil (C9, C9, C9, C9) is wound, so that the at least one additional retaining loop (S1, S1, S2, S2) partially overlaps the turns of the said last coil (C9, C9, C9, C9).

A method for manufacturing an induction rotor includes placing a lamination stack into a fixture in which the first end of the lamination stack is rotated in an opposite rotational direction from the second end of the lamination stack to skew the conduction bars to an angle . Vertical members are fixed to an outer perimeter of each of the plurality of laminates of the lamination stack. Hoop members are fixed to each of the plurality of vertical members and an outer edge of each of the plurality of conduction bars. A conduction ring is fixed on each of the ends of the lamination stack. An outer perimeter of the lamination stack is machined to remove the plurality of vertical members and the plurality of hoop members from the lamination stack.

A method for manufacturing an induction rotor includes placing a lamination stack into a fixture in which the first end of the lamination stack is rotated in an opposite rotational direction from the second end of the lamination stack to skew the conduction bars to an angle . Vertical members are fixed to an outer perimeter of each of the plurality of laminates of the lamination stack. Hoop members are fixed to each of the plurality of vertical members and an outer edge of each of the plurality of conduction bars. A conduction ring is fixed on each of the ends of the lamination stack. An outer perimeter of the lamination stack is machined to remove the plurality of vertical members and the plurality of hoop members from the lamination stack.