Disclosed within are a structure and method for forming a component for a rotor to be used in an electric machine. The formed rotor components can include a rotor assembly or rotor shaft. The rotor assembly can include a plurality of poles spaced about a rotor core. The plurality of poles can include a pole shoe or pole body. Quasi-laminations that can result in a unitary structure that includes support structures can be used to form all or a portion of the pole shoe or pole body.

A rotor for an electric machine includes a heat pipe cooling system. A rotor core has a number of cavities internal to the rotor core. The cavities are surrounded by a wall defined by the rotor core. A magnetic element disposed in the at least one cavity leaving a void in the at least one cavity between the magnetic element and the wall. A heat pipe evaporator is disposed in the void and conforms to the available space, contacting the magnetic element and the wall to remove heat from the rotor core.

Electrical generators having one or more conformal support and cooling devices for use in supporting and cooling rotating elements of the generator are disclosed herein. An electrical generator includes a housing, a shaft disposed axially through the housing, a rotor assembly including a plurality of poles that are disposed within the housing and mounted on the shaft, a support wedge disposed between two of the plurality of poles. The conformal support and cooling device includes an internal cooling channel in a helical configuration or a V-shape configuration that extends from a first length-wise end of the support and cooling device to a second length-wise end of the support and cooling device. Additive manufacturing processes are employed to fabricate the conformal support and cooling device.

Electrical generators having one or more conformal support and cooling devices for use in supporting and cooling rotating elements of the generator are disclosed herein. An electrical generator includes a housing, a shaft disposed axially through the housing, a rotor assembly including a plurality of poles that are disposed within the housing and mounted on the shaft, a support wedge disposed between two of the plurality of poles. The conformal support and cooling device includes an internal cooling channel in a helical configuration or a V-shape configuration that extends from a first length-wise end of the support and cooling device to a second length-wise end of the support and cooling device. Additive manufacturing processes are employed to fabricate the conformal support and cooling device.

A machine includes a liquid lubrication system and a shaft, the shaft being rotatable about a rotation axis, the shaft including a first part, a second part engaged coaxially with the first part, and a journal bearing between the first part and the second part, the first part being rotatable relative to the second part about the rotation axis, a helical feature disposed between the first part and the second part and configured to define a helical pump between the first part and the second part, the pump being hydraulically connected to the liquid lubrication system, the journal bearing being disposed adjacent to the helical feature.

A machine includes a liquid lubrication system and a shaft, the shaft being rotatable about a rotation axis, the shaft including a first part, a second part engaged coaxially with the first part, and a journal bearing between the first part and the second part, the first part being rotatable relative to the second part about the rotation axis, a helical feature disposed between the first part and the second part and configured to define a helical pump between the first part and the second part, the pump being hydraulically connected to the liquid lubrication system, the journal bearing being disposed adjacent to the helical feature.

Disclosed are a rotor plate and a rotor assembly including the same. The rotor plate includes a plate body including a first part having a first hole at a center, and a second part having a second hole at a center, the second part having a diameter corresponding to the first part, and connected to the first part in a first direction that is an axial direction perpendicular to the first part, and a diameter of the second hole is larger than a diameter of the first hole, a first slot recessed on an outer peripheral surface of the plate body, a second slot recessed on the outer peripheral surface of the plate body, and a first plate passage formed on a wall of the first part in the second direction that is opposite to the first direction, and connecting the first slot and the first hole.

A shaft of a motor includes a first shaft and a second shaft extending from the first shaft to one axial side. A housing includes a neutralizing device holder that holds a first neutralizing device. The neutralizing device holder includes a seal holder that is arranged radially outward of the second shaft and holds a seal member. The first neutralizing device electrically connects the second shaft and the neutralizing device holder. The seal member seals a gap between the second shaft and the seal holder, and is arranged on the other axial side of the first neutralizing device.

A drive device includes a first bearing lubricated by a fluid and a second bearing lubricated by a lubricant having a higher electrical conductivity than the fluid. The first bearing rotatably supports a shaft extending in the axial direction along the rotation axis. A housing of the drive device has a first bearing holder that holds the first bearing. The second bearing is arranged between the shaft and the housing and rotatably supports the shaft. The second bearing is arranged in a space isolated from the first bearing holder.

An axial flux machine, in particular a single-sided axial flux motor, for an electrical machining device, includes a machine shaft, in particular a motor shaft, a disc-shaped stator, and a disc-shaped rotor which is arranged adjacent to the stator in the axial direction of the machine shaft. The stator is formed as a winding carrier with a plurality of stator teeth for at least one stator winding and the rotor, which is connected to the machine shaft in a rotationally fixed manner, can be set in a rotational movement relative to the stator. The rotor of the axial flux machine has a rotor yoke configured as a bidirectional fan or which is permanently connected to a bidirectional fan by a joining process, the bidirectional fan having at least one radial and one axial air flow direction for cooling the axial flux machine, in particular the stator and the rotor.