A rotor assembly includes a plurality of rotor laminations arranged in a stacked configuration, and a plurality of apertures formed in each of the rotor laminations, where the plurality of apertures of the plurality of rotor laminations are aligned to form a plurality of passages in the stacked configuration. A conductive rotor bar is disposed in each passage of the plurality of passages, and each conductive rotor bar includes at least one coolant channel formed therein and configured to receive a flow of coolant for cooling the conductive rotor bar.

An induction rotor assembly is provided. The induction rotor assembly includes a laminated stack, a plurality of foils, a plurality of conductor bars, a first end ring, and a second end ring. The laminated stack includes a body with an outer circumferential surface with a plurality of grooves extending from the first end to the second end. Each one of the plurality of foils is disposed within one of the grooves. Each of the foils is disposed between each of the conductor bars and each of the grooves. Each of the plurality of conductor bars includes a first conductor end and a second conductor end. The first end ring mates with a surface of each first conductor end. The second end ring mates with a surface of each second conductor end, and the plurality of conductor bars extends between the first end ring and the second end ring.

In a method for producing a squirrel-cage rotor of an asynchronous machine, conductor bars of a first conductive material are inserted into slots of a magnetically conductive body such as to project out of at least one end side to form a projection. A short-circuiting disc of a second conductive material is positioned under pressure on the projection with a clearance fit of approximately 0.1 mm relative to a radially outwardly open recess of the short-circuiting disc. The short-circuiting disc is heated while the conductor bars virtually contact the short-circuiting disc. At least the projection of the conductor bars is coated with a third material at a layer thickness to form an alloy with the first and second materials after heating so that the third material is fully dispersed in the first and second materials as a result of the third material being diffused into the first and second materials.

In a method for producing a squirrel-cage rotor of an asynchronous machine, conductor bars of a first conductive material are inserted into slots of a magnetically conductive body such as to project out of at least one end side to form a projection. A short-circuiting disc of a second conductive material is positioned under pressure on the projection with a clearance fit of approximately 0.1 mm relative to a radially outwardly open recess of the short-circuiting disc. The short-circuiting disc is heated while the conductor bars virtually contact the short-circuiting disc. At least the projection of the conductor bars is coated with a third material at a layer thickness to form an alloy with the first and second materials after heating so that the third material is fully dispersed in the first and second materials as a result of the third material being diffused into the first and second materials.

A device for manufacturing a rotor for an induction motor includes an upper mold formed at a center of a bottom surface of a base portion, a lower mold formed in a center of an upper surface of the base portion, a sleeve formed on an inner surface of the lower mold, a biscuit which is formed inside the sleeve and into which a molten metal is injected, and a plunger disposed inside the sleeve, wherein the rotor assembly is pressurized in a vertical direction and an outer peripheral surface of a core of the rotor assembly is filled with the molten metal to manufacture a rotor. According to the present disclosure, it is possible to cast the rotor in a vertical manner and pressurize both ends of the rotor to achieve zero porosity and prevent contraction and deformation of the core.

A rotor of a squirrel-cage motor and a method for producing the same, wherein the rotor has a squirrel cage winding, and rotor bars of the squirrel cage winding extend in the axial direction through a cylindrical rotor body and are interconnected by end rings at respective end faces of the rotor body, and where the end rings are applied directly to the end faces of the cylindrical rotor body via an additive manufacturing method.

A rotor of a squirrel-cage motor and a method for producing the same, wherein the rotor has a squirrel cage winding, and rotor bars of the squirrel cage winding extend in the axial direction through a cylindrical rotor body and are interconnected by end rings at respective end faces of the rotor body, and where the end rings are applied directly to the end faces of the cylindrical rotor body via an additive manufacturing method.

A rotor assembly is configured to rotate relative to a stator to drive a rotor shaft and at least one drive wheel of an electric vehicle. The rotor assembly includes a rotor core, and first and second bar assemblies. The rotor core includes a core body that defines a plurality of circumferentially arranged bar passages including a plurality of first bar passages and a plurality of second bar passages. The first bar assembly includes a plurality of first bars, each of the first bars having a first elongated blade portion and a first end body portion. The second bar assembly includes a plurality of second bars, each of the second bars having a second elongated blade portion and a second end body portion. the first bars and the second bars are alternately received at the respective plurality of first bar passages and second bar passages in the core body.

An induction motor rotor includes a magnetic metal core; and an electrically conductive metal contiguous with the magnetic metal core. The electrically conductive metal includes rotor bars extending along the magnetic metal core and end segments formed onto opposite ends of the rotor bars. Each of the end segments includes a base section extending a first axial distance from the magnetic metal core and a protrusion extending a second axial distance from the magnetic metal core. The second axial distance is greater than the first axial distance. The induction motor rotor also includes a metal ring positioned on an outer circumferential surface of each of the end segments to prevent the end segments from separating from the rotor bars.

An induction motor rotor includes a magnetic metal core; and an electrically conductive metal contiguous with the magnetic metal core. The electrically conductive metal includes rotor bars extending along the magnetic metal core and end segments formed onto opposite ends of the rotor bars. Each of the end segments includes a base section extending a first axial distance from the magnetic metal core and a protrusion extending a second axial distance from the magnetic metal core. The second axial distance is greater than the first axial distance. The induction motor rotor also includes a metal ring positioned on an outer circumferential surface of each of the end segments to prevent the end segments from separating from the rotor bars.