A method of forming a component having an internal passage defined therein includes positioning a jacketed core with respect to a mold. The jacketed core includes a hollow structure formed from a first material, and an inner core formed from an inner core material disposed within the hollow structure. The method also includes introducing a component material in a molten state into a cavity of the mold, such that the component material in the molten state at least partially absorbs the first material from a portion of the jacketed core within the cavity. The method further includes cooling the component material in the cavity to form the component, and removing the inner core material from the component to form the internal passage.

The invention relates to a method for producing an electric motor housing, comprising the steps: (a) positioning at least stator part (30) in a support body interior chamber of support body (22), (b) arranging a casting core (42) on the support body (22), (c) then casting the liquid metal around the support body (22) and the casting core (42), resulting in a torque-proof connection between stator part (30) and a casting (26) as a result of the solidification of the liquid metal.

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.

A method of forming a component having an internal passage defined therein includes forming a precursor core having a shape corresponding to a shape of the internal passage, and forming a hollow structure around the precursor core. The method also includes removing the precursor core from within the hollow structure, and disposing an inner core within the hollow structure to form a jacketed core. The method further includes positioning the jacketed core with respect to a mold, and introducing a component material in a molten state into a cavity of the mold, such that the component material in the molten state at least partially absorbs the hollow structure from a portion of the jacketed core within the cavity. Additionally, the method includes cooling the component material in the cavity to form the component. The inner core defines the internal passage within the component.

A rotor casting includes a lamination stack and a cast structure including proximal and distal cast end rings respectively adjacent proximal and distal end faces of the lamination stack. Cast axial ribs are distributed radially on a peripheral surface of the lamination stack and extend between the proximal and distal cast end rings. Cast feed members extend axially from the proximal cast end ring and are respectively positioned radially between an adjacent pair of axial ribs. In one example, cast bar segments integral to the proximal and distal cast end rings are formed in axial slots of the lamination stack. In one example, a bar insert in each axial slot has insert ends that extend respectively from the proximal and distal end faces of the lamination stack and are fully encapsulated respectively in the proximal and distal cast end rings. A method of forming the rotor casting is provided.

A rotor casting includes a lamination stack and a cast structure including proximal and distal cast end rings respectively adjacent proximal and distal end faces of the lamination stack. Cast axial ribs are distributed radially on a peripheral surface of the lamination stack and extend between the proximal and distal cast end rings. Cast feed members extend axially from the proximal cast end ring and are respectively positioned radially between an adjacent pair of axial ribs. In one example, cast bar segments integral to the proximal and distal cast end rings are formed in axial slots of the lamination stack. In one example, a bar insert in each axial slot has insert ends that extend respectively from the proximal and distal end faces of the lamination stack and are fully encapsulated respectively in the proximal and distal cast end rings. A method of forming the rotor casting is provided.

A rotor casting includes a lamination stack and a cast structure including proximal and distal cast end rings respectively adjacent proximal and distal end faces of the lamination stack. Cast axial ribs are distributed radially on a peripheral surface of the lamination stack and extend between the proximal and distal cast end rings. Cast feed members extend axially from the proximal cast end ring and are respectively positioned radially between an adjacent pair of axial ribs. In one example, cast bar segments integral to the proximal and distal cast end rings are formed in axial slots of the lamination stack. In one example, a bar insert in each axial slot has insert ends that extend respectively from the proximal and distal end faces of the lamination stack and are fully encapsulated respectively in the proximal and distal cast end rings. A method of forming the rotor casting is provided.

A rotor of an asynchronous machine with a cage rotor includes a laminated core formed from a plurality of partial laminated cores. The laminated core has substantially axially extending conductors arranged in slots in the laminated core. The conductors include at least two materials of different electrical conductivities, such that a material with a higher electrical conductivity surrounds a material with a lower electrical conductivity by at least 65% in a circumferential direction.

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.

An induction rotor assembly having an induction cage that is formed using a combination of liquid and solid materials. The first and second end plates of the induction cage may be fabricated before the casting of the conductors of the induction cage. According to certain embodiments, the first and second end plates may be assembled with first and second molds and a rotor core to form a casting assembly. A liquid casting material may be injected into the casting assembly, wherein the liquid casting material may solidify within one or more core passageways of the rotor core, thereby forming the conductors of the induction cage. The first and second end plates may also include flow channels that may be configured to facilitate the flow of the liquid casting material in the casting assembly, and increase the area of contact between the liquid casting material, when solidified, and the end plates.