A rotor (10) of an electric machine has a shaft (11) a laminated core (12) arranged on the shaft (11) and balancing bodies (13) arranged on the shaft (11). The balancing bodies (13) have an aperture (15) situated outside the center of gravity. Each balancing body (13) is mounted by way of the aperture (15) on the shaft (11) of the rotor (10) in a defined angular position. Positioning sleeves (20) are arranged on the shaft (11) to define a distance between bearings (16, 17) of the shaft (11) and the laminated core (12) or the balancing bodies (13) and to provide an anti-rotational safeguard for the balancing bodies (13).

A drive unit is disclosed that includes case portions, a gasket interposed between the case portions, shafts, bearings having respective bearing races, and a bearing shim plate. One shaft includes an input oil tube which provides a fluid pathway between the bearing shim plate and a rotor of the drive unit. Interposed between bearings, and the bearing shim plate, are shims. An approach for sizing shims for use with a drive unit is also disclosed, the approach including determining the distance from a mating flange of a case portion, to different bearing races, selecting shims based on the determined distances, and attaching the bearing shim plate to the case portion with shims interposed therebetween.

An electric drive unit and method of assembling the same is disclosed. The electric drive unit includes a rotor having a rotor shaft, and gear shaft, where the rotor shaft is inserted into the gear shaft. The gear shaft is supported by two bearings, while the rotor shaft supported directly at one end by a bearing and at the other by the gear shaft. A wave spring is also disclosed that provides an axial loading to the rotor shaft. Also disclosed is a balancing ring secured to an end of the rotor via a locknut. The balancing ring can be machined in order to balance the rotor. The rotor shaft can be connected to the gear shaft via a spline connection. The rotor shaft can bear against the gear shaft via a pilot journal and pilot bore defined on the rotor shaft and gear shaft respectively.

A gear box and method of providing oil through the same is provided. The gear box includes a windage tray that includes a tray having a bleed hole therein, and another tray having another second bleed hole therein. Oil is provided through the bleed holes to respective gears situated in the trays. The windage tray may also include a magnet positioned within a magnet slot of the windage tray, for removing debris from the oil. A tube may also be attached to the windage tray, which tube can include a bleed hole therein, for spraying the oil out of the tube and towards a differential, for example. The windage tray and tube can be made from molded plastic, and can be made using the same mold. The gear box housing may further define a drain in an inner side wall to provide oil to a differential bearing, for example.

The present invention is an electrical machine comprising a stator and a rotor (10), with rotor being formed with a rotor body (20) from a stack of laminations (14) placed on a rotor shaft (12). According to the invention, the rotor comprises at least one cavity (38) for receiving at least one balance weight (48) for the dynamic balancing of the said rotor.

A method of making a motor having a shaft; a pair of end plates arranged to be spaced apart from each other on the shaft; a magnet disposed between the pair of end plates; and a rotor case which surrounds the outer peripheries of the pair of end plates and the outer periphery of the magnet and is made of a synthetic resin material, wherein each of the pair of end plates includes: a flange part, one surface of which faces the magnet; and a cylinder part protruding in a direction opposite to the magnet from the flange part, and the flange part includes a tapered part having an outer diameter which decreases toward the cylinder part.

A rotor for an electrical machine includes a rotor core having a plurality of circumferentially spaced apart rotor poles. Windings are seated in gaps between circumferentially adjacent pairs of the rotor poles. A wedge secures the windings in each gap. The wedge includes a first member made of a first material and at least one second member made of a second material. The second material has a higher electrical conductivity than the first material. The wedge is configured to supply Q-axis damping. A pair of end plates is connected electrically to the at least one second member at opposing longitudinal ends thereof thereby completing a Q-axis winding circuit for each wedge.

The invention is a flywheel rotor that includes a number of adjacent laminations, stacked one on top of another, where each of the laminations has the same shape and is rotationally symmetric around a center axis, and where the shape is substantially circular and includes a plurality of protrusions on the circumference, and each of the laminations includes at least one hole for at fastening bolts to pass through. The invention typically includes an endplate at each end of stack of laminations and one of the two endplates attaches to a stubshaft.

A switched reluctance machine has a stator core salient with stator poles disposed concentrically with a rotor that is salient with rotor poles. A plurality of coil windings are wound about the stator core so that a pair of windings are adjacent each of the stator poles. The pair of coil windings induces magnetic flux in the adjacent stator poles and the rotor rotates to align the rotor poles with the stator poles having the induced magnetic flux. The rotor is rotatable at high speeds of up to 50,000 RPM and the coil windings can be directly cooled.

A method for reducing stress concentration on a rotor sleeve during balance cutting comprising: providing an axial protrusion to an outer diameter of a first end cap and a second end cap of a rotor assembly; and radially cutting at least one of the sleeve or the axial protrusion to balance the rotor assembly.