A method of manufacturing a rotor of an electric motor is disclosed. The method includes securing a plurality of permanent magnets to a sheet to form a magnet chain, bending the sheet to engage an inner surface of each permanent magnet with a curved outer surface of an insert mold, wrapping a metallic strip around an outer surface of the sheet to form a yoke of the rotor, and molding a polymeric material over the magnet chain and the yoke to form a cylindrical shell.

A rotor hub comprises an inside cylindrical portion extending in an axial direction on an inner surface side of a rotor yoke and an outside cylindrical portion extending in the axial direction on an outer surface side of the rotor yoke, a motor gear wheel is integrally moulded on a portion of said outside cylindrical portion, and a rotor unit is assembled with a stator unit in such a way that a fixed shaft is inserted into a cylindrical hole in the rotor hub and a rotor magnet and pole teeth are facing.

A rotor hub comprises an inside cylindrical portion extending in an axial direction on an inner surface side of a rotor yoke and an outside cylindrical portion extending in the axial direction on an outer surface side of the rotor yoke, a motor gear wheel is integrally moulded on a portion of said outside cylindrical portion, and a rotor unit is assembled with a stator unit in such a way that a fixed shaft is inserted into a cylindrical hole in the rotor hub and a rotor magnet and pole teeth are facing.

A rotor for an electric machine of a vehicle. The rotor includes permanent magnets, receptions for the permanent magnets and deformation components. The permanent magnets are adapted to be deformed elastically and are arranged within the receptions, which are designed such that the permanent magnets may deform within the receptions. The deformation components are adapted to deform the permanent magnets such that at least one of a magnetic induction, a conductor length and a rotor radius is adjusted.

An in-wheel motor, comprising: a rotor (14) of a surface permanent magnet type, wherein a plurality of permanent magnets (15) are fixed along an inner circumferential surface of the rotor; wedge-shaped protrusions (42) for fixing the permanent magnets (15) on the rotor (14); and a stator (30) disposed inside the rotor (14), wherein teeth (35) and slots (36) are alternately formed on an outer circumferential portion of the stator; wherein the number of the permanent magnets (15) is 32, and the number of the slots 36 is 24; wherein each of the permanent magnets (15) has chamfers (43) on each of the ends so that a magnetic flux cannot concentrate, and is convex toward the stator (30), in a cross-section perpendicular to a rotary axis of the rotor (14).

A radial flux electric machine includes a rotor configured to rotate about an axis of rotation, a plurality of electromagnetic coils, and a stator. The stator may have an annular stator ring and a plurality of core tooth-portions extending in a radial direction. The annular stator ring and the plurality of core tooth-portions may be integrally formed of a Soft Magnetic Composite (SMC). The SMC may include one or more isotropic ferromagnetic materials, a magnetic saturation induction of greater than or equal to about 1.6 Tesla, and an electrical resistivity greater than 10 micro-ohm/m.

A radial flux electric machine includes a rotor configured to rotate about an axis of rotation, a plurality of electromagnetic coils, and a stator. The stator may have an annular stator ring and a plurality of core tooth-portions extending in a radial direction. The annular stator ring and the plurality of core tooth-portions may be integrally formed of a Soft Magnetic Composite (SMC). The SMC may include one or more isotropic ferromagnetic materials, a magnetic saturation induction of greater than or equal to about 1.6 Tesla, and an electrical resistivity greater than 10 micro-ohm/m.

Disclosed are various embodiments for a motor/generator where the stator is a coil assembly and the rotor is a magnetic toroidal cylindrical tunnel or where the rotor is a coil assembly and the stator is a magnetic toroidal cylindrical tunnel, and where the magnetic toroidal cylindrical tunnel comprises magnets having a NNSS or SSNN pole configuration.

A motor includes a stator and a rotor rotatably coupled to a rotation shaft. The rotor includes: rotor core segments arranged along a circumferential direction of the rotor on the inner side or the outer side of the stator and spaced apart from one another to define permanent magnet arrangement slots between the rotor core segments; permanent magnets inserted into the permanent magnet arrangement slots, respectively; and a rotor frame including rotor frame pins that fix each of the permanent magnets between the rotor core segments. Each of the rotor core segments defines a rotor core hole that extends parallel to an axial direction of the rotation shaft. The rotor frame comprises: a base formed to surround the plurality of rotor core segments and the plurality of permanent magnets in a direction parallel to an axial direction of the rotation shaft; and a plurality of permanent magnet fixing jig holes formed only at an inner end between the inner and outer ends of the base to expose the plurality of permanent magnets.

A brushless direct-current motor is provided includes an inner stator and an outer rotor. A rotor shaft extends through a stator core of the inner stator. A first end cap includes a radial back plate disposed on a first side of the stator and a front center opening through which the rotor shaft is supported via a front bearing. A second end cap includes an inner annular body extending axially inwardly and forming a rear center opening, an outer annular body, and a main body extending on a second side of the stator. The inner annular body includes a first portion that extends at least partially into an opening of the stator core and supports the rotor shaft via a rear bearing, and a second portion rearward of the first portion that received a rear end of the rotor shaft therein and houses a sensor board therein.