A method of forming a rotor lamination includes, with a laser, fabricating a first region of a lamination layer with a first powdered metal having a first composition. The first region at least partially defines a magnet pocket. The method further includes, with a laser, fabricating a second region of the lamination layer with a second powdered metal having a second composition different than the first composition. The second region is disposed immediately adjacent the first region.

The invention relates to a method of manufacturing a rotor for an electric machine, wherein the rotor is composed of at least one electric sheet wherein at least one electric sheet is thermally treated regionally to directly modify its magnetic permeability in the treated region.

A manufacturing method of a laminated iron core by laminating a plurality of blanked members to form a laminate, the laminate including a pair of first and second end surfaces and the plurality of blanked members being interlocked by a caulk in a lamination direction of the laminate, includes: forming the laminate such that a protrusion of the caulk protrudes downward from the first end surface being in a downward state; placing the laminate on support such that the protrusion is not in contact with a support surface of the support; and processing the laminate in a state where the laminate is placed on the support.

A method of manufacturing a rotational electric machine rotor includes: forming a rotor shaft having a non-circular sectional outer shape; forming a rotor core by stacking a predetermined number of magnetic body thin plates each including a center hole having a non-circular shape corresponding to the non-circular sectional outer shape of the rotor shaft; and forming a protruding part for fixing the rotor core and the rotor shaft to each other by inserting the rotor shaft into the non-circular center hole of the rotor core and squashing the rotor shaft extending out of an axial-direction end face of the rotor core by using a predetermined swaging jig to expand the rotor shaft outward beyond an outer periphery of the non-circular section along the axial-direction end face of the rotor core.

A method of manufacturing a rotational electric machine rotor includes: forming a rotor shaft having a non-circular sectional outer shape; forming a rotor core by stacking a predetermined number of magnetic body thin plates each including a center hole having a non-circular shape corresponding to the non-circular sectional outer shape of the rotor shaft; and forming a protruding part for fixing the rotor core and the rotor shaft to each other by inserting the rotor shaft into the non-circular center hole of the rotor core and squashing the rotor shaft extending out of an axial-direction end face of the rotor core by using a predetermined swaging jig to expand the rotor shaft outward beyond an outer periphery of the non-circular section along the axial-direction end face of the rotor core.

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.

Generator rotor comprising a rotor rim and a plurality of permanent magnet modules and a plurality of anchors arranged at an outer or inner circumference of the rotor rim such that the anchors substantially fix the permanent magnet modules to the rotor, wherein the permanent magnet modules comprise a base having a bottom surface, two axially extending side surfaces and a top surface, and one or more rows of magnets mounted on said top surface, wherein the two side surfaces of the permanent magnet modules each comprise an axially extending groove, and wherein the anchors have a shape that substantially fits exactly in axially extending grooves of neighboring permanent magnet modules.

Exchangeable stator components are selected and exchangeable rotor components are selected to transform a motor from one motor class to another motor class. [0006] A motor comprises at least two stator rings, at least two outer rotor rings, a first input, and a second input. The first input comprises an exchangeable stator component selected from a stator component group consisting of a stator spacer ring and an axially magnetized stator magnet ring, the axially magnetized stator magnet ring comprising a solid axially magnetized ring magnet. The second input comprises an exchangeable rotor component selected from a rotor component group consisting of a rotor spacer ring and an axially magnetized rotor magnet ring. The first input and the second input determine a motor class for the motor, the exchangeable stator component being exchangeable for a different exchangeable stator component from the stator component group to manufacture another motor having a different motor class, the exchangeable rotor component being exchangeable for a different exchangeable rotor component from the rotor component group to manufacture another motor having another different motor class.

A motor has an axis of rotation and includes a housing, a first shaft coupled to the housing, and a second shaft coupled to the first shaft. The motor further includes a stator, a rotor coupled to the first shaft, a gearbox, and a bearing assembly coupled to the rotor. The stator includes an outer circumferential surface and an inner circumferential surface. The inner circumferential surface defines a stator bore around the axis of rotation. The rotor includes a first arm and a second arm. The first arm is configured to extend axially along the axis of rotation and within the stator bore, and the second arm is configured to extend radially from the axis of rotation. The first arm and the bearing assembly are positioned within the stator bore, and the second arm is positioned entirely outside of the stator bore.

A moisture resistant rotor sleeve includes a plurality of stacked laminations forming a sleeve having an outer periphery, an inner periphery, and spaces between adjacent laminations. The rotor sleeve also includes a sealant coupled to the inner periphery such that the outer periphery is free of sealant. The sealant seals the spaces to prevent fluid from traveling through the spaces of the sleeve between the inner periphery and the outer periphery.