Abstract: A stacked plurality of alternating laminations and adhesive layers of a rotor are arranged such that each of the adhesive layers bonds an outer periphery of an adjacent pair of the laminations together. Each of the laminations includes a plurality of interlocks, disposed about a central region of the lamination radially inside the outer periphery and lacking presence of any of the adhesive layers, that engage a same adjacent one of the laminations.

Abstract: A rotor assembly for an electric motor includes a rotor core, a plurality of magnets, and a rotor core mold member. The rotor core defines a rotor bore and a plurality of cavities distributed about the rotor bore and extending through the rotor core. The plurality of magnets are disposed in the plurality of cavities. The rotor core mold member extends through the plurality of cavities to retain the plurality of magnets therein and, from the cavities, extends to a first end of the rotor core forming a containment ring at the first end. The containment ring forms a rim above a surface of the first end to restrict flow of a fluid to an outer side surface of the rotor core.

Abstract: A skewed rotor core assembly having a resin mold disposed in a plurality of longitudinal channels and a resin flow path is provided. The rotor core has a first and second magnet stack each defining a plurality of longitudinal channels. The plurality of longitudinal channels for the first stack are misaligned with the plurality of longitudinal channels for the second stack. Methods of making the same are also provided.

Abstract: A permanent magnet synchronous motor includes a shaft with an integrally formed flange and resolver rotor. The resolver rotor is formed by machining a set of cutouts in the flange. The rotor body, which includes the permanent magnets, is assembled onto the shaft from the end of the shaft opposite the flange and resolver rotor. Features, such as keyways on the shaft and keys on the rotor body establish a rotational position relationship between the shaft and the permanent magnets.

Abstract: A rotor assembly includes a plurality of laminations stacked to form a rotor core that defines a plurality of pockets and coolant passageways, a plurality of magnets disposed within the pockets, and a molded cage. The molded cage includes a plurality of columns securing the magnets within the pockets, and a pair of endcaps covering portions of the pockets on opposite ends of the rotor core such that the endcaps are connected with the columns. The endcaps define a plurality of apertures in fluid communication with the coolant passageways.

Abstract: A rotor includes a plurality of rotor cores arranged in a vertical stack, an end plate having a specified roughness on a surface engaging the vertical stack, and a binder material bonding the end plate to the vertical stack of rotor cores. The specified roughness is configured to allow venting of air beyond the end plate and to prevent passage of resin beyond the end plate.

Abstract: A stacked plurality of alternating laminations and adhesive layers of a rotor are arranged such that each of the adhesive layers bonds an outer periphery of an adjacent pair of the laminations together. Each of the laminations includes a plurality of interlocks, disposed about a central region of the lamination radially inside the outer periphery and lacking presence of any of the adhesive layers, that engage a same adjacent one of the laminations.

Abstract: A skewed rotor core assembly having a resin mold disposed in a plurality of longitudinal channels and a resin flow path is provided. The rotor core has a first and second magnet stack each defining a plurality of longitudinal channels. The plurality of longitudinal channels for the first stack are misaligned with the plurality of longitudinal channels for the second stack. Methods of making the same are also provided.

Abstract: Systems and methods for a wearable sensor system including a compressible material, a two-dimensional array of distance sensors, a support structure, and a controller. The compressible material is positionable relative to a tissue surface and the two-dimensional array of distance sensors is configured relative to the compressible material to detect compressive deformations of the compressible material. The support structure is configured to hold the compressible material in place relative to the tissue surface such that muscle movements at the tissue surface cause the compressive deformations of the compressible material and is also configured to restrict movement of the two-dimensional array during the muscle movements.