A star disc, for a rotor of an electric machine, comprising a plurality of pole arms configured to wind a wire around a winding; a switching ring having protruding contacts, the switching ring being held in a rotationally fixed manner in a recess of the star disc; and an external plastic overmolding structured to hold the switching ring to the star disc in an axially form-fitting manner.

A manufacturing device includes: an upper plate on which a plunger is mounted; a lower plate arranged under the upper plate; and a tray placed on it, on which a laminated core body is mounted. The tray includes: a cylindrical section inserted in a shaft hole of the laminated core body; and a brim section contacting the lower plate from above and an outer portion of the laminated core body from below. The cylindrical section has a resin arrangement hole in which a resin tablet is arranged and the plunger for pressing it is inserted. The brim section has: a plurality of resin flow path grooves extending radially from the arrangement hole on a lower surface opposing the lower plate; and a plurality of gates, each of which extends upward from each of the plurality of flow path grooves and communicates with each of a plurality of magnet insertion holes.

A manufacturing device includes: an upper plate on which a plunger is mounted; a lower plate arranged under the upper plate; and a tray placed on it, on which a laminated core body is mounted. The tray includes: a cylindrical section inserted in a shaft hole of the laminated core body; and a brim section contacting the lower plate from above and an outer portion of the laminated core body from below. The cylindrical section has a resin arrangement hole in which a resin tablet is arranged and the plunger for pressing it is inserted. The brim section has: a plurality of resin flow path grooves extending radially from the arrangement hole on a lower surface opposing the lower plate; and a plurality of gates, each of which extends upward from each of the plurality of flow path grooves and communicates with each of a plurality of magnet insertion holes.

A method produces an electric motor having a motor housing and a stator that has a stator carrier and a number of phase connections. An electronics housing is joined to the motor housing and has a connection side. A substantially pot-shaped rotor bell is produced by way of a deep-drawing process such that a bell base runs oblique to a peripheral bell wall, and that the bell base has a larger wall thickness than the bell wall. The rotor bell and the stator are inserted into a receptacle in the motor housing, wherein the rotor bell and the stator are added into the motor housing by a stamping unit so as to produce an electrical connection between the phase connections and the connection side.

A method produces an electric motor having a motor housing and a stator that has a stator carrier and a number of phase connections. An electronics housing is joined to the motor housing and has a connection side. A substantially pot-shaped rotor bell is produced by way of a deep-drawing process such that a bell base runs oblique to a peripheral bell wall, and that the bell base has a larger wall thickness than the bell wall. The rotor bell and the stator are inserted into a receptacle in the motor housing, wherein the rotor bell and the stator are added into the motor housing by a stamping unit so as to produce an electrical connection between the phase connections and the connection side.

In a motor and a method of assembling a motor, a coupling hole is formed in one of a housing and a fixing bracket and a plastic deformation part is formed in the other, and then stacked and fixed by caulking, so that the joining is maintained in a firm state and the defect rate can be drastically reduced, and the number of parts can be reduced and productivity can be increased without a separate fastening means.

In a motor and a method of assembling a motor, a coupling hole is formed in one of a housing and a fixing bracket and a plastic deformation part is formed in the other, and then stacked and fixed by caulking, so that the joining is maintained in a firm state and the defect rate can be drastically reduced, and the number of parts can be reduced and productivity can be increased without a separate fastening means.

A fully-sealed brushless motor includes a motor casing body, a motor rotor, a stator core, a moving impeller, an air guide enclosure, a circuit board, and a circuit board end cover. The motor casing body includes upper and lower aluminum casing bodies connected together. The motor rotor is enclosed by the aluminum casing bodies and transmits heat to the aluminum casing bodies by the stator core. A rotating shaft of the motor rotor extends out from the lower aluminum casing body. The moving impeller is installed at the rotating shaft. The air guide enclosure is installed on the lower aluminum casing body at an outer side of the moving impeller. A gas flow discharged by the moving impeller is blown towards the motor casing body by the air guide enclosure. The circuit board is enclosed by the circuit board end cover and upper aluminum casing body.

A fully-sealed brushless motor includes a motor casing body, a motor rotor, a stator core, a moving impeller, an air guide enclosure, a circuit board, and a circuit board end cover. The motor casing body includes upper and lower aluminum casing bodies connected together. The motor rotor is enclosed by the aluminum casing bodies and transmits heat to the aluminum casing bodies by the stator core. A rotating shaft of the motor rotor extends out from the lower aluminum casing body. The moving impeller is installed at the rotating shaft. The air guide enclosure is installed on the lower aluminum casing body at an outer side of the moving impeller. A gas flow discharged by the moving impeller is blown towards the motor casing body by the air guide enclosure. The circuit board is enclosed by the circuit board end cover and upper aluminum casing body.

An electric propulsion system for a vertical takeoff-and-landing aircraft having an inverter assembly, a gearbox assembly, an electric motor assembly. The inverter assembly, the gearbox assembly, and the electric motor assembly may be substantially aligned along an axis. The inverter assembly, a gearbox assembly, and electric motor assembly may each abut at least one of the others. The electric engine may use a liquid, such as oil, for cooling and lubricating components of the inverter assembly, gearbox assembly, and electric motor assembly. Further, the electric engine may use volumes of oil for cooling and lubricating components below a threshold volume so that the electric engines do not require a fire protective barrier.