Abstract: A method of manufacturing a rotor for an electric motor comprises: positioning a permanent magnet within a magnet hole formed in a rotor body, the rotor body and the permanent magnet to form a rotor for an electric motor; providing an electrically insulating layer between the permanent magnet and a surface of the rotor body, the surface at least partially defines the magnet hole; performing an electrical continuity test on the permanent magnet and the rotor body while the permanent magnet is within the magnet hole and the electrically insulating layer is between the permanent magnet and the surface of the rotor body; determining whether the electrically insulating layer provides at least a threshold electric insulation to prevent of eddy currents circulating; and based on the electrically insulating layer providing at least the threshold electric insulation, approving the rotor for the electric motor.

Abstract: A dual axial cooling system for an electric motor includes a cover assembly provided at first and second axial ends of a stator of the electric motor. Each cover assembly includes a first side portion that is oriented so as to face an interior of the stator, with a plurality of holes formed in the first side portion. A second side portion is coupled to the first side portion, so that a passage is formed between the first and second side portions. A supply nozzle portion is in fluid communication with the plurality of openings via the passage defined between the first and second side portions. The plurality of openings receive cooling fluid from the supply nozzle portion, and discharge the cooling fluid in an axial direction, from each axial end portion of the stator, to provide axial cooling in two axial directions into the stator.

Abstract: An electric motor comprises: a rotor; a stator comprising a stack of laminations, wherein windings of the stator comprise wires that have individual insulation, the wires forming slot windings positioned in slots of the stator, the wires further forming end windings positioned outside the slots at each end of the stator; varnish in the slots of the stator, the varnish contacting the laminations and the slot windings, and wherein the varnish does not contact the end windings of at least one of the ends of the stator; and a cooling system to apply liquid coolant to at least the end windings, wherein the liquid coolant passes between the wires of the end windings.