A rotor manufacturing method comprises an arranging step for arranging a rotor core, which is formed by stacking electromagnetic steel plates, to direct the stacked electromagnetic steel plates toward a vertical direction, a guide inserting step for inserting a rod-like guide into a magnet insertion hole formed to extend in the stacked direction of the rotor core after the arranging step, a sheet inserting step for inserting a plurality of sheets from above the rotor core into the magnet insertion hole along different side surfaces of the guide after the guide inserting step, a guide pull-out step for pulling out the guide from the magnet insertion hole after the sheet inserting step, and a magnet inserting step for inserting a permanent magnet between the plurality of sheets within the magnet insertion hole after the guide pull-out step.

In accordance with at least one aspect of this disclosure, a method of making a carbon rotor includes, providing a quantity of material, densifying the quantity of material, and forming the densified material into a disk shape.

A rotor core assembly that includes a magnet, a first end cap located at an end of the magnet, a second end cap located at an opposite end of the magnet, and a sleeve that surrounds the magnet and the end caps. The sleeve forms an interference fit with each of the end caps, and an adhesive is located between the magnet and the sleeve. Additionally, a method of manufacturing the rotor core assembly.

In a rotary electric machine that has excellent efficiency and light weight, a rotor (21) of a motor (23) includes a rotary shaft (24), a rotor core (61) that is fixed coaxially to the rotary shaft (24) and formed of electromagnetic steel, a first end plate (71) that is disposed to face a first end face (61a) of the rotor core (61), and a second end plate (72) that is disposed to face a second end face (61b) of the rotor core (61). The first end plate (71) and the second end plate (72) are formed of a bond magnet.

A rotary electric machine member manufacturing method includes: a step of providing a motor core by stacking a plurality of electromagnetic steel sheets; and a step of welding the motor core by keyhole welding while pressurizing the motor core in a stacking direction with a welding pressure lower than that at which the thickness of the motor core in the stacking direction levels off. The thickness is a length of the motor core between a first end of the motor core and a second end of the motor core.

A method of constructing an electrical machine by assembling a first structure (one of a rotor and stator structure) and a second structure (the other of the rotor and stator structure), along with a plurality of first elements (one of a plurality of permanent magnet elements and a plurality of winding elements) and a plurality of second elements (the other plurality of the permanent magnet elements and winding elements). The first elements are attached to a rim of the first structure, and the second elements are attached to the first elements, this attachment being caused by a magnetic attraction. The first structure is assembled with the second structure such that the second elements are positioned for a posterior attachment to a rim of the second structure, and the second elements are attached to the rim of the second structure.

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 method for manufacturing an electrical machine includes printing a stator core; printing a first part of a stator winding; coupling the first part of the stator winding to the stator core; printing a second part of the stator winding onto the first part of the stator winding to form a stator assembly; printing a first part of a rotor shaft; printing a rotor core onto the first part of the rotor shaft; printing a second part of the rotor shaft onto the rotor core; printing a first part of a rotor winding; coupling the first part of the rotor winding to the rotor core; and printing a second part of the rotor winding onto the first part of the rotor winding to form a rotor assembly.

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

In a pump, a resin magnet included in a rotor portion has a plurality of groove portions in an outer peripheral portion thereof, the groove portions extending in an axial direction.