A manufacturing method of a motor core includes laminating in an axial direction steel plates extending in a radial direction with respect to a central axis, each of the laminate steel plates including a base portion on a radially outer side of the central axis, annular portions separately disposed on a radially outer side of the base portion with penetrating portions therebetween, and connecting portions at predetermined intervals in a circumferential direction to extend in the radial direction and connect the base portion and the annular portions, the annular portions including coupling portions adjacent to both circumferential sides of the connecting portions, and cutting at least one of the two coupling portions adjacent to one connecting portion in the circumferential direction from an outer side to an inner side of the laminate steel plates in the radial direction with respect to the laminate steel plates that are laminated.

Various embodiments are described herein for a double-rotor switched reluctance machine. In one example embodiment, the double-rotor switched reluctance machine comprises an interior rotor, an exterior rotor spaced from the interior rotor and coaxially and concentrically disposed outside the interior rotor, and at least one stator disposed concentrically with the interior rotor and the exterior rotor. The interior rotor, the exterior rotor and the at least one stator are disposed within one machine set to provide an interior switched reluctance machine and an exterior switched reluctance machine. The interior switched reluctance machine and the exterior switched reluctance machine can operate as two motors, two generators, or a motor and a generator simultaneously.

A method of balancing a rotor and/or fixing rotor components includes arranging a plurality of generally like laminations side by side in a stack to form at least a part of a rotor. The rotor has a rotational center axis and each of the laminations having a plurality of apertures that cooperate to form passages that extend axially along a length of the stack. In accordance with an aspect of the method, a polymer based fixation material is filled in the passages in a manner to fix the laminations together in the stack. With the fixation material, a sprue is formed, projecting from an axial face of the stack. In accordance with another aspect of the method, a weight of the sprue is adjusted to rotationally balance the rotor about the rotor center axis.

Advantageous machines, such as flux-switching machines (FSMs) are provided. An FSM can be yokeless and can have two rotors, which can be displaced from one another (e.g., by half a pole pitch). An FSM can be a flux-switching permanent magnet machine (FSPMM), and all magnets can be magnetized in the same circumferential direction. FSMs of the subject invention are cost-effective, have high torque density, and can operate well even under fault conditions.

A manufacturing method for manufacturing a rotor such that a permanent magnet is inserted into a slot hole of a rotor core with a spacer includes: a step of placing, on the rotor core, a guide whose upper end has a curved guide surface such that the guide space continues with the slot hole in the up-down direction; a step of placing the spacer on the guide so that the spacer lies across the guide space; a step of inserting the permanent magnet into the guide space with the spacer being wound around the permanent magnet; and a step of inserting, into the slot hole, the permanent magnet around which the spacer is wound.

There are provided core part manufacturing method and apparatus for manufacturing a core part of a rotary electric machine. The core part manufacturing method includes: injecting a molten resin from a side on one end surface of an iron core body into a plurality of space portions provided in the iron core body in a state where the iron core body is sandwiched and pressed. In injecting of the resin, a contact surface on an opposite side to a side where the resin is injected includes: a relief portion that is recessed without contacting to the one end surface; and a remaining portion that is adjacent to a non-contact region. The remaining portion is disposed in the contact surface on an outer peripheral side from the non-contact region, and the relief portion is disposed further in the contact surface on an outer peripheral side from the remaining portion.

A rotor includes a plurality of permanent magnets inclined relative to the axial direction of a rotor core. A method for manufacturing the rotor includes producing each of the permanent magnets, and providing the permanent magnets on the outer periphery of the rotor core. The producing of each of the permanent magnets includes working a magnet block into a shape such that a first surface and a second surface have a parallelogram shape, a third surface and a fourth surface are parallel to each other, and a fifth surface and a sixth surface extend planarly from the third surface to the fourth surface. The providing of the permanent magnets includes arranging the permanent magnets so that, between the permanent magnets adjacent to each other, the fifth surface and the sixth surface face each other.

An EC motor is provided having a stator, in which an armature is rotatably supported, the armature including an armature shaft, on which an armature core having a plurality of permanent magnets is held, the armature core being electrically insulated against the armature shaft with the aid of a casting compound, and a balance ring being provided on at least one axial end of the armature core, which is accommodated on the armature shaft by a central recess, a gap between the armature shaft and the central recess of the balance ring being filled with casting compound, and the permanent magnets being held in pockets of the armature core by casting compound.

A motor includes a stator, a rotor, and a case. The stator includes a stator core and windings. The rotor is provided inside the stator. The rotor includes first and second rotor cores and a field magnet. The first and second rotor cores each includes a core base and claw-shaped magnetic poles. The core bases are opposed to each other and the claw-shaped magnetic poles of the first and second rotor cores are alternately disposed in a circumferential direction. The field magnet is disposed between the core bases in the axial direction. The field magnet is magnetized in the axial direction so as to cause the claw-shaped magnetic poles of the first rotor core and the second rotor core to function respectively as first magnetic poles and second magnetic poles. At least part of an end part of the case in the axial direction is made of a non-magnetic body.

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.