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.

The present disclosure provides a rotor mechanism includes a rotor core and a plurality of rotor bars. The rotor core has a plurality of insertion slots arranged along an edge of the rotor core. Each of the plurality of rotor bars has an insertion portion and two protruding portions. The insertion portions are respectively located in the plurality of insertion slots, wherein in each of the plurality of rotor bars, the two protruding portions are respectively connected to two opposite ends of the insertion portion and respectively protrude from two opposite sides of the rotor core, and the two protruding portions each has an extension direction, that has an angle with respect to an extension direction of the insertion portion, in order to clamp and fix the rotor core therebetween. In addition, the present disclosure also provides a method for manufacturing the rotor mechanism.

An electric fan includes a plurality of blades and an electric motor for rotating the blades. The electric motor includes a stator and a rotor rotatable relative to the stator about an axis. The rotor includes a backing ring and a diecast rotor can. The can includes a non-machined sidewall that is diecast integrally as part of the rotor can. The sidewall extends about the axis. The rotor can is diecast in an overlying relationship with at least part of the backing ring, with the sidewall and backing ring being securely interengaged so as to restrict relative shifting therebetween.

A rotor for an induction motor includes a first shorting end ring, a second shorting end ring, and a plurality of conductor bars. Each conductor bar has a first end and a second end and is coated with an electrically conductive material. The first end of each conductor bar is in electrical and mechanical contact with the first shorting end ring, and the second end of each conductor bar is in electrical and mechanical contact with the second shorting end ring. The conductive material is disposed between each conductor bar and the respective shorting end rings.

A rotor for an electric machine, wherein the rotor comprises a plurality of stack elements and each of the stack elements includes material of first magnetic conductance. Each of the stack elements includes a plurality of sectorial sections distributed round a rotational axis of the rotor. Each of the sectorial sections includes one or more flux barriers. At least one of the one or more flux barriers has a difference associated with filing of an electrically conductive material of third magnetic conductance in different sectorial halves of a common sectorial section, the first magnetic conductance being larger than the third magnetic conductance.

Methods are provided for manufacturing a component. In one method, first metal material is cast into a first body. At least a portion of the first body is machined. Second metal material is cast onto at least the machined portion of the first body to form a monolithic second body. A first portion of the second body is formed by the first metal material, A second portion of the second body is formed by the second metal material. The second metal material is different from the first metal material.

A rotor designed as a reluctance rotor includes a laminated core which defines an axis and has end faces. The laminated core includes sheets which are at least partly axially layered, with the sheets having flux-conducting portions and flux-blocking portions to form a specified number of poles. A cage made of electric conductors runs in a substantially axial direction and is connected at the end faces of the laminated core by short-circuit rings. The conductors are located in a radially outer region of at least some of the flux-blocking portions arranged one behind another substantially in the axial direction, with the conductors defining conductor bars formed by conductive material at a quantity determinative to define an internal diameter of the conductor bars.

A method for casting comprising: providing a seed, the seed characterized by: an arcuate form and a crystalline orientation progressively varying along an arc of the form; providing molten material; and cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material.

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.

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.