An electric motor includes a rotor mounted rotatably about an axis of rotation in a bearing accommodated in an end shield, and a stator including wound coils such that windings are defined by at least one winding wire with winding wire ends electrically connected to busbars of a busbar unit. The busbar unit is on an upper side of the stator and the end shield is seated on an upper side of the busbar unit. A magnetic shield is integrated into the end shield.

A rotor of a rotary dynamoelectric machine incudes a magnetically conductive body, having substantially axially running slots distributed around the circumference. A squirrel cage includes electrical conductors which are arranged in the slots. The electrical conductors are electrically contacted at the two end faces of the rotor by short-circuit rings. The magnetically conductive body includes a base body and at least two further additional bodies, which axially adjoin the base body. A first one of the at least two additional bodies directly axially adjoins the end face of the base body, and a second one of the at least two additional bodies and optionally any further additional body axially adjoin the first additional body. The slots have radially exposed slot portions in the axial end regions of the rotor such that the conductors can be moved radially outward.

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.

Methods are provided for manufacturing a component. In one method, first 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 heat-sink base provided with heat-sink fin portions, a manufacturing method and a motor provided with the heat-sink base. The base is produced by pouring cast metal into a mold cavity to replace a pattern having a predetermined sublimation temperature. The base includes a preformed heat-sink member comprising a plurality of heat-sink fin portions and at least one anchor portion embedded at least partially in the pattern, and a base body comprising an enclosed base portion and a holder portion for receiving and holding the at least one anchor portion. By virtue of the invented method, the heat-sink member having an extremely thin thickness can be mounted on the base body and the overall surface area of the heat-sink base is increased considerably.

A method for casting aluminum on a rotor, comprising: installing casting equipment on a casting workbench and storing enough molten aluminum in the casting equipment, wherein the casting equipment comprises an heat preserving furnace and an electromagnetic pump arranged at a side of the heat preserving furnace; assembling a plurality of rotor iron cores with a plurality of dies respectively and preheating outside the casting workbench; installing the plurality of preheated dies on a plurality of liquid outlet gates at a top end of the electromagnetic pump, wherein each liquid outlet gate is matched with a liquid inlet gate of the dies; heating and keeping the installed die in a multi-stage heating mode; controlling the pressurizing pressure of the electromagnetic pump in time-period when the electromagnetic pump is used for casting; and after completing casting, moving the plurality of dies out of the casting workbench to be cooled. According to the method for casting aluminum through the rotor, the casting efficiency is improved by reasonably distributing the heating time and the one-time multi-casting mode; the top-down temperature gradient is matched with accurate pressure control, so that the compensation capacity is improved.

A method includes: forming a sand core including a main portion and core-head members connecting the main portion; applying a casting process to produce a frame casting having a first end, a first-end inner wall, a second end, a second-end inner wall, a closed water channel between the first-end inner wall and the second-end inner wall, a water inlet, a water outlet and sand-expelling holes at the first end; shaking the frame casting to have part of the sand core to leave the closed water channel via the water inlet, the water outlet and the sand-expelling holes; pressurizing a fluid into the closed water channel via the water inlet to carry the rest of the sand core to leave the closed water channel via the sand-expelling holes and the water outlet; and applying screw bolts to lock the sand-expelling holes to manufacture a closed-type and liquid-cooling motor frame.

A method of manufacturing a stator for a rotary electric machine includes: a step of preparing a stator core formed from a first metal material that is magnetic, the stator core having a space provided on a radially inner side and in which a rotor is to be disposed; a blocking step of covering at least a part of an end surface of the stator core in an axial direction and blocking the space using a blocking member; and a casting step of pouring a second metal material that is non-magnetic to a radially outer side of the stator core with at least a part of the end surface of the stator core covered and with the space blocked through the blocking step in a die.

A rotating electrical machine for vehicle driving that includes a stator core made of a first metal material which is a magnetic material; and a case part that is integrally joined to the stator core and made of a second metal material which is a non-magnetic material, and a joint surface between the case part and the stator core forms a heat receiving surface where the case part receives heat from the stator core.

A method includes: forming a sand core including a main portion and core-head members connecting the main portion; applying a casting process to produce a frame casting having a first end, a first-end inner wall, a second end, a second-end inner wall, a closed water channel between the first-end inner wall and the second-end inner wall, a water inlet, a water outlet and sand-expelling holes at the first end; shaking the frame casting to have part of the sand core to leave the closed water channel via the water inlet, the water outlet and the sand-expelling holes; pressurizing a fluid into the closed water channel via the water inlet to carry the rest of the sand core to leave the closed water channel via the sand-expelling holes and the water outlet; and applying screw bolts to lock the sand-expelling holes to manufacture a closed-type liquid-cooling motor frame.