Abstract: A method of making composite electric machine rotor assembly of a desired magnetic pattern. Magnetic segments and non-magnetic segments are separately formed to green strength, and then arranged adjacent to each other in a desired magnetic pattern. A small amount of powder material is added in-between the segments, and the whole assembly is then sintered to form a sinterbonded composite component of high structural integrity.

Abstract: A method of making composite electric machine components. Magnetic segments and non-magnetic segments are separately formed to green strength, and then arranged adjacent to each other in a desired magnetic pattern. A small amount of powder material is added in-between the segments, and the whole assembly is then sintered to form a sinterbonded composite component of high structural integrity.

Abstract: A composite powder metal disk for a rotor assembly in a circumferential type interior permanent magnet machine. The disk includes an inner ring of magnetically conducting powder metal compacted and sintered to a high density. The disk further includes an outer ring of permanent magnets separated by magnetically non-conducting powder metal compacted and sintered to a high density. The permanent magnets additionally are radially embedded by magnetically conducting powder metal compacted and sintered to a high density with optional intermediate non-conducting powder metal bridges extending radially from the permanent magnets to the outer surface of the disk. A rotor assembly is also provided having a plurality of the composite powder metal disks mounted axially along a shaft with their magnetic configurations aligned. A method for making the composite powder metal disks is further provided including filling a die with the powder metals, compacting the powders, and sintering the compacted powders.

Abstract: A composite powder metal disk for a rotor assembly in a circumferential type interior permanent magnet machine. The disk includes an inner ring of magnetically conducting powder metal compacted and sintered to a high density. The disk further includes an outer ring of permanent magnets separated by magnetically non-conducting powder metal compacted and sintered to a high density. The permanent magnets additionally are radially embedded by magnetically conducting powder metal compacted and sintered to a high density with optional intermediate non-conducting powder metal bridges extending radially from the permanent magnets to the outer surface of the disk. A rotor assembly is also provided having a plurality of the composite powder metal disks mounted axially along a shaft with their magnetic configurations aligned. A method for making the composite powder metal disks is further provided including filling a die with the powder metals, compacting the powders, and sintering the compacted powders.

Abstract: A method of making a composite powder metal disk for a rotor assembly in a synchronous reluctance machine. The method includes filling discrete regions of a disk-shaped die with ferromagnetic and non-ferromagnetic powder metals, compacting to powders, and sintering the compacted powders. By this method, a disk is formed that includes alternating regions of magnetically conducting powder metal and magnetically non-conducting powder metal compacted and sintered to a high density. The method may also include forming a rotor assembly by stacking a plurality of the composite powder metal disks axially along a shaft with their magnetic configurations aligned.

Abstract: A method of making a composite powder metal disk for a rotor assembly in a surface permanent magnet machine. The method includes filling inner and outer annular regions of a disk-shaped die with soft and hard ferromagnetic powder metals, compacting the powders, and sintering the compacted powders. By this method, a disk is formed that includes permanent magnets on the surface of an inner ring of magnetically conducting powder metal compacted and sintered to a high density. In one embodiment, non-ferromagnetic powder metal is filled into regions of the die such that the permanent magnets are separated by magnetically non-conducting powder metal compacted and sintered to a high density. The method may also include forming a rotor assembly by stacking a plurality of the composite powder metal disks axially along a shaft with their magnetic configurations aligned.

Abstract: A hybrid electrical machine generator having a permanent magnetic rotor field in addition to an electrically excited rotor field is disclosed. The generator rotor (120) has a wound field coil (124) mounted on the rotor shaft (122) between two opposing claw segments (126, 128). One or more permanent magnets (130) maybe provided about the periphery of the first and/or second claw segments.

Abstract: A hybrid electrical machine having a permanent magnetic rotor field in addition to an electrically excited rotor field is disclosed. The generator rotor (220) has two opposing claw segments (226, 228) mounted at opposite ends of a rotor shaft (222). A third, center claw segment (232) is mounted on the rotor shaft between the first and second claw segments. A first wound field coil (224) is mounted on the rotor shaft between the first and third claw segments, and a second wound field coil (234) is mounted between the second and third claw segments. One or more permanent magnets (230, 231) may be provided about the periphery of the first, second, and/or third claw segments.

Abstract: A hybrid electrical machine having a permanent magnetic rotor field in addition to an electrically excited rotor field is disclosed. The generator rotor (320) has a first claw segment (326) and a second claw segment (328) mounted at opposite ends of a rotor shaft (322). A third, center claw segment (332) is mounted on the rotor shaft, between the first and second claw segments. A wound field coil (324) is mounted on the rotor shaft (322) between the first and third claw segments, and a permanent, axial flux magnet (336) is mounted on the rotor shaft between the second claw segment and the third claw segment. In some embodiments, one or more permanent magnets may be provided about the periphery of the first, second, and/or third claw segments.

Abstract: A rotor for an interior magnet rotary machine, such as motors and generators, is mass produced by forming an elongated structure. This structure has channels in the periphery thereof which are parallel to the longitudinal axis of the structure. The elongated structure is cut into rotor frames of a predetermined length having channels extending from one end to the opposite end thereof. Magnets are placed in the channels. Pole pieces may be placed on the magnets in the channels.The interior magnet rotary machine produced by this method has a rotor of a structure made of a rotor frame with channels extending from one end to the opposite end, and at least one magnet in a respective one of the channels. Thus, an efficient, low cost, mass producible, and easily assembled rotor for an interior magnet rotary machine is provided.