A molding apparatus and method for fixing permanent magnets in a rotor core during production of drive motors for environmental vehicles, in which the permanent magnets, which are inserted into magnet insertion apertures of the rotor core, are aligned at identical positions with respect to the axial direction of the rotor core, thus contributing to an improvement in the performance of the drive motors.

An electric motor includes a stator, a rotor, and weights removably attached to the rotor shell for use in balancing the rotor. The removable weights may be integrally formed with a rotor shell such that the weights and the rotor shell form a unitary, one-piece construction. The removable weights may be substantially uniformly spaced apart around an entirety of the outer perimeter of the rotor shell. In a method of making an electric motor, the stator is coupled to the rotor such that the weights are accessible for selective removal during balancing of the rotor.

A flywheel energy storage system incorporates various embodiments in design and processing to achieve a very high ratio of energy stored per unit cost. The system uses a high-strength steel rotor rotating in a vacuum envelope. The rotor has a geometry that ensures high yield strength throughout its cross-section using various low-cost quenched and tempered alloy steels. Low-cost is also achieved by forging the rotor in a single piece with integral shafts. A high energy density is achieved with adequate safety margins through a pre-conditioning treatment. The bearing and suspension system utilizes an electromagnet that off-loads the rotor allowing for the use of low-cost, conventional rolling contact bearings over an operating lifetime of several years.

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 component that includes a longitudinal axle, having a multiple keybars that extend outward from a surface of the axle, such that each of the keybars are disposed axially along and circumferentially around the axle. Also the axis of the keybars is parallel to the axle, such that a profile of all midpoints of the keybars is helicoidal around the axle, also the helicoidal profile is such that they make up one or more helicoidal paths. The profile may be herringbone skewed. The component may be part of a rotor assembly that is part of an electric machine such as an interior permanent magnet (IPM) or Synchronous Reluctance motor.

A method is provided for fabricating a rotor assembly for an electric motor which utilizes pre-fabricated conductive rotor bars and die cast end rings. Containment rings, which may be installed on the end rings either before or after casting, may be used to inhibit end ring creep at high rotational speeds.

A lifting apparatus for assembly of exhaust turbocharger allows the removal of the rotor block from the housing in a horizontal direction. The lifting apparatus includes a cantilever, which is fastened on a vertical stop, i.e. on an axial end, of the housing, and on which there is arranged a structure which can be moved along the cantilever and which is likewise fastened on a vertical stop, i.e. an axial end of the rotor block.

A flywheel energy storage system incorporates various embodiments in design and processing to achieve a very high ratio of energy stored per unit cost. The system uses a high-strength steel rotor rotating in a vacuum envelope. The rotor has a geometry that ensures high yield strength throughout its cross-section using various low-cost quenched and tempered alloy steels. Low-cost is also achieved by forging the rotor in a single piece with integral shafts. A high energy density is achieved with adequate safety margins through a pre-conditioning treatment. The bearing and suspension system utilizes an electromagnet that off-loads the rotor allowing for the use of low-cost, conventional rolling contact bearings over an operating lifetime of several years.

A permanent magnet for a permanent magnet electric motor is bonded to a rotor. A hole having a chamfered outer edge is formed in the permanent magnet. A corresponding mounting hole is formed in the body of the rotor. A bolt is threaded through the hole in the permanent magnet and threaded into the mounting hole of the rotor. An O-ring is positioned between the head of the bolt and the permanent magnet. The O-ring may be made of an elastomeric material which may prevent cracking of the permanent magnet as components of the electric motor expand and contract with fluctuations in temperature. A magnet may be held to a rotor by a dovetail or may include a flange to be held to the rotor by a retaining ring.

Provided is an armature for a rotating electrical machine, which is capable of improving heat dissipation performance of an edgewise coil to enhance efficiency of the rotating electrical machine. The armature for a rotating electrical machine includes: a core including a yoke section and a tooth section that protrudes from the yoke section; an edgewise coil to be inserted onto the tooth section through intermediation of an insulating member, the edgewise coil being formed by winding a rectangular wire having a rectangular conductor cross-section through edgewise bending; and a heat transfer member filled into a gap between the tooth section and the edgewise coil. The armature has different gaps formed at two regions between the tooth section and a long side of the edgewise coil.