A rotor coil for a revolving armature includes a strand coil that includes a part arranged in a core slot of the rotor and is composed of a plurality of element wires; and a solid coil welded to an end of the strand coil wherein the end of the strand coil and an end of the solid coil are welded by friction stir welding. A manufacturing method of a rotor coil includes the step of performing friction stir welding wherein the friction stir welding is performed for the butt joint with the end of the strand coil arranged in an advancing side defined by a rotation direction of a tool and with the solid coil arranged in a retreating side.

A method of manufacturing an electric-motor rotor may include providing a magnet of sintered magnetic material, the magnet having a first diameter; providing a sheath of composite material, the sheath having an inner diameter smaller than the first diameter; reducing the first diameter to a second diameter; fitting the sheath onto the magnet when the magnet has the second diameter; and letting the magnet with the sheath fitted thereon to interfere, allowing the sheath to exert inward pressure on the magnet. An electric-motor rotor may include a magnet of sintered magnetic material, the magnet having a first diameter; and a sheath of composite material, the sheath having an inner diameter smaller than the first diameter. The sheath may be associated with the magnet in such a way that the magnet with the sheath fitted thereon interfere so that the sheath exerts inward pressure on the magnet.

A component includes magnet elements adjoined to each other to form an arced segmented magnet section that is configured to fit in an a curved rotor slot gap of an electric machine. An electric machine that employs the component and method of assembly of the component are also disclosed. The present invention has been described in terms of specific embodiment(s), and it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the appending claims.

A motor rotor assembly that includes multiple motor rotor sections and a rotor bar that extends through the motor rotor sections, such that the rotor bar and the motor rotor sections are configured such that the rotor sections are step-skewed, or continuously skewed, from each other. The assembly may be used in an IPM or Synchronous Reluctance motor; and, the motor rotor sections may be of solid core or laminations. Various assembly components, IPM and Synchronous Reluctance motors, and methods of construction/assembly are also disclosed. The present invention has been described in terms of specific embodiment(s), and it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the appending claims.

A rotor comprises a first rotor lamination and a second rotor lamination. The first rotor lamination and the second rotor lamination are configured for defining, when joined into rotor assembly, a central axis of rotation and a plurality of interior magnet pockets disposed symmetrically about the central axis of rotation, each pocket of the plurality of interior magnet pockets is configured for housing and retaining a permanent magnet. A method of forming a rotor comprises forming a first rotor lamination and a second rotor lamination, rotating the second rotor lamination about an axis of symmetry of the second rotor lamination; and mating the first rotor lamination to the second rotor lamination such that a first notch of the first rotor lamination is disposed adjacent to the first notch of the second rotor lamination.

A method of vertically assembling a generator of a wind turbine is provided. The method includes A rotor part is arranged on a horizontal assembly which supports components of the generator such that a rotational axis of a component is essentially vertical during assembly, and the assembly support is configured to allow access to an interior of a generator component during the assembly procedure; a stator part is arranged in the rotor part; and the stator part is joined to the rotor part. An assembly arrangement for a vertical assembly of a generator of a wind turbine is provided. The assembly arrangement includes a horizontal assembly support for supporting components of the generator such that a rotational axis of a component is essentially vertical during assembly, and the assembly support is configured to allow access to an interior of a generator component during the assembly procedure.

A method of manufacturing an electrical machine includes selecting a desired threshold control current, selecting dimensions to modify stator teeth of a magnetic bearing based on the desired threshold control current, and modifying the stator teeth using the selected dimensions. A method of producing a rotating machine includes selecting an operating point of a magnetic bearing of the rotating machine, and shaping at least some stator teeth of the magnetic bearing to generate increased force at control currents above the control current at the selected operating point.

A method for producing rotating electrical machines having a motor coil produced in a cantilevered manner for motors or generators, wherein the coil already surrounds the inner part during the manufacturing process, i.e. is pre-assembled, and this is also used as an aid for coil shaping during the production of the coil, includes a first step, in which the motor coil is wound in a stepwide process between two end faces over the magnetic inner part and completely surrounds the inner part, a second step, in which the shaping of the motor coil is carried out by pressing the winding wires by moving the shaft with the surface of the inner part against the inner side of the motor coil, in particular by eccentrically rolling off of the latter and pressing it against an abutment, and a third step, in which the pressed motor coil is baked by way of applying heat. Also provided is a rotating electrical machine.

A blanking die apparatus includes multiple machining stations having respective cutting tools operated simultaneously to perform predetermined blanking operations on a belt-shaped workpiece fed progressively in a longitudinal direction and finally to perform a contour blanking operation on the workpiece, thereby forming core pieces used for manufacturing a laminated iron core, and an auxiliary cutting tool that forms a disposal hole by partly blanking a scrap forming area of the workpiece simultaneously with the operations of the cutting tools of the machining stations.

In a rotary electric machine including a stator and a rotor, the stator includes: a connected core (1) composed of a plurality of cores in which a first core (1b) and a second core (1c) are paired to connect in a belt shape to be rounded into a substantially cylindrical shape by being folded at a core connecting portion (1d) so as to surround the rotor; a plurality of coils in which a first coil (3f) and a second coil (3g) are paired; and a crossover wire (3c) which connects the winding end (3b) of the first coil (3f) to the winding start (3d) of the second coil (3g). The crossover wire (3c) are arranged on the inner diameter side than the core connecting portion (1d).