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 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 method for producing a component for an electrical machine, the component has a magnetic core with at least one groove which receives at least one wire winding, runs parallel to a longitudinal central axis of the component and completely penetrates the magnetic core. The component is aligned during introduction of an impregnating agent into the at least one groove in such a way that the impregnating agent is forced into the at least one groove in the direction of the longitudinal central axis by the influence of gravity. A temperature of the at least one wire winding is initially set to a lower first temperature selected to reduce a viscosity of the impregnating agent and then to a higher second temperature selected to increase the viscosity of the impregnating agent by applying an electric current during introduction of the impregnating agent into the at least one groove.

A rotor including, a core including a shaft center and a magnet hole, and a magnet material portion formed by injecting an injection molding material containing a magnetic powder into the magnet hole, in which the magnet material portion includes a magnet body inside the magnet hole, and a material end outside the magnet hole, and the material end encloses the magnet hole and is separated into a plurality of portions in a circumferential direction as viewed in an axial direction.

A rotor including, a core including a shaft center and a magnet hole, and a magnet material portion formed by injecting an injection molding material containing a magnetic powder into the magnet hole, in which the magnet material portion includes a magnet body inside the magnet hole, and a material end outside the magnet hole, and the material end encloses the magnet hole and is separated into a plurality of portions in a circumferential direction as viewed in an axial direction.

A rotating electrical machine rotor manufacturing method including a step of providing a first core and a second core, each having an axis and a magnet arrangement hole, a first setting step of setting the first core on a molding device, a first filling step of, after the first setting step, filling the magnet arrangement hole of the first core with an injection molding material including magnetic powder, a second setting step of, after the first filling step, setting the second core together with the first core on the molding device in a state where the second core is adjacent to the first core in an axial direction, and a second filling step of, after the second setting step, filling the magnet arrangement hole of the second core with the injection molding material.

A rotating electrical machine rotor manufacturing method including a step of providing a first core and a second core, each having an axis and a magnet arrangement hole, a first setting step of setting the first core on a molding device, a first filling step of, after the first setting step, filling the magnet arrangement hole of the first core with an injection molding material including magnetic powder, a second setting step of, after the first filling step, setting the second core together with the first core on the molding device in a state where the second core is adjacent to the first core in an axial direction, and a second filling step of, after the second setting step, filling the magnet arrangement hole of the second core with the injection molding material.

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.

Heating parts (212a to 212l, 222a to 222l) are brought into contact with planned heating regions (11a to 11l) of outermost electrical steel sheets (10a, 10b) of an electrical steel sheet group (100), to simultaneously pressurize and heat the planned heating regions (11a to 11l).