Various embodiments may include a rotor for an electric machine, the rotor comprising: a first shaft journal; a second shaft journal; a laminated rotor core; a filler body cast onto the laminated rotor core wherein the filler body and the laminated rotor core rotate conjointly; and a cooling duct extending through the shaft journals and the filler body along an axis of the filler body and the rotor core. The filler body rotates with the shaft journals and a torque applied to the shaft journals is transmitted to the laminated rotor core.

A method for casting aluminum on a rotor, comprising: installing casting equipment on a casting workbench and storing enough molten aluminum in the casting equipment, wherein the casting equipment comprises an heat preserving furnace and an electromagnetic pump arranged at a side of the heat preserving furnace; assembling a plurality of rotor iron cores with a plurality of dies respectively and preheating outside the casting workbench; installing the plurality of preheated dies on a plurality of liquid outlet gates at a top end of the electromagnetic pump, wherein each liquid outlet gate is matched with a liquid inlet gate of the dies; heating and keeping the installed die in a multi-stage heating mode; controlling the pressurizing pressure of the electromagnetic pump in time-period when the electromagnetic pump is used for casting; and after completing casting, moving the plurality of dies out of the casting workbench to be cooled. According to the method for casting aluminum through the rotor, the casting efficiency is improved by reasonably distributing the heating time and the one-time multi-casting mode; the top-down temperature gradient is matched with accurate pressure control, so that the compensation capacity is improved.

Provided herein are systems, apparatuses, and methods of providing a centrifugally cast rotor assembly for an induction motor of an electric vehicle. The rotor assembly includes a rotor lamination stack with a cylindrical shape that terminates in a first end surface and a second end surface. The rotor lamination stack has multiple lamination discs, and each lamination disc has multiple rotor slots. The rotor assembly further includes copper bars disposed within the rotor slots, a first intermediary end ring disposed at the first end surface, and a second intermediary end ring disposed at the second end surface. A centrifugally cast first copper end ring that electrically and mechanically couples each of the copper bars is located proximate the first end surface, and a centrifugally cast second copper end ring that electrically and mechanically couples each of the copper bars is located proximate the second end surface.

A heat-sink base provided with heat-sink fin portions, a manufacturing method and a motor provided with the heat-sink base. The base is produced by pouring cast metal into a mold cavity to replace a pattern having a predetermined sublimation temperature. The base includes a preformed heat-sink member comprising a plurality of heat-sink fin portions and at least one anchor portion embedded at least partially in the pattern, and a base body comprising an enclosed base portion and a holder portion for receiving and holding the at least one anchor portion. By virtue of the invented method, the heat-sink member having an extremely thin thickness can be mounted on the base body and the overall surface area of the heat-sink base is increased considerably.

A mold assembly for use in forming a component having an outer wall of a predetermined thickness includes a mold and a jacketed core. The jacketed core includes a jacket that includes a first jacket outer wall coupled against an interior wall of the mold, a second jacket outer wall positioned interiorly from the first jacket outer wall, and at least one jacketed cavity defined therebetween. The at least one jacketed cavity is configured to receive a molten component material therein. The jacketed core also includes a core positioned interiorly from the second jacket outer wall. The core includes a perimeter coupled against the second jacket outer wall. The jacket separates the perimeter from the interior wall by the predetermined thickness, such that the outer wall is formable between the perimeter and the interior wall.

The present invention relates to a heat-sink base provided with heat-sink fin portions, it manufacturing method and a motor provided with the heat-sink base. The base is produced by pouring cast metal into a mold cavity to replace a pattern having a predetermined sublimation temperature. The base includes a preformed heat-sink member comprising a plurality of heat-sink fin portions and at least one anchor portion embedded at least partially in the pattern, and a base body comprising an enclosed base portion and a holder portion for receiving and holding the at least one anchor portion. By virtue of the invented method, the heat-sink member having an extremely thin thickness can be mounted on the base body and the overall surface area of the heat-sink base is increased considerably.

Apparatus and methods are provided for manufacturing a rotor. The rotor has a core with an open center, conductive bars extending across the core and conductive end rings at ends of the core. A mandrel has a body that extends through the open center and a head that extends over and engage the first end of the core around the open center. A central cap couples with the body, extends over and engages the second end of the core around the open center. An end cap covers the central cap and engages the core around the open center. The end cap defines at least part of a cavity around the conductive bars for receiving molten metal.

Provided herein are systems, apparatuses, and methods of providing a centrifugally cast rotor assembly for an induction motor of an electric vehicle. The rotor assembly includes a rotor lamination stack with a cylindrical shape that terminates in a first end surface and a second end surface. The rotor lamination stack has multiple lamination discs, and each lamination disc has multiple rotor slots. The rotor assembly further includes copper bars disposed within the rotor slots, a first intermediary end ring disposed at the first end surface, and a second intermediary end ring disposed at the second end surface. A centrifugally cast first copper end ring that electrically and mechanically couples each of the copper bars is located proximate the first end surface, and a centrifugally cast second copper end ring that electrically and mechanically couples each of the copper bars is located proximate the second end surface.

Apparatus and methods are provided for manufacturing a rotor. The rotor has a core with an open center, conductive bars extending across the core and conductive end rings at ends of the core. A mandrel has a body that extends through the open center and a head that extends over and engage the first end of the core around the open center. A central cap couples with the body, extends over and engages the second end of the core around the open center. An end cap covers the central cap and engages the core around the open center. The end cap defines at least part of a cavity around the conductive bars for receiving molten metal.

Provided herein are systems, apparatuses, and methods of providing a centrifugally cast rotor assembly for an induction motor of an electric vehicle. The rotor assembly includes a rotor lamination stack with a cylindrical shape that terminates in a first end surface and a second end surface. The rotor lamination stack has multiple lamination discs, and each lamination disc has multiple rotor slots. The rotor assembly further includes copper bars disposed within the rotor slots, a first intermediary end ring disposed at the first end surface, and a second intermediary end ring disposed at the second end surface. A centrifugally cast first copper end ring that electrically and mechanically couples each of the copper bars is located proximate the first end surface, and a centrifugally cast second copper end ring that electrically and mechanically couples each of the copper bars is located proximate the second end surface.