Abstract: An electric motor comprises a shaft, an interior magnet rotor core comprising a central bore and a pair of opposing ends faces, and at least one resilient structure inserted within the central bore between the pair of opposing end faces. The at least one resilient component is inserted within the central bore between the pair of opposing end faces such that the at least one resilient component does not extend beyond one of the opposing end faces. The resilient component comprises an outer rigid structure inserted within the central bore, a resilient component inserted within the outer rigid structure, and an inner rigid structure inserted within the resilient component, wherein the shaft is inserted through the inner rigid structure.

Abstract: A method for manufacturing an interior magnet rotor core motor is described herein. The method includes attaching a resilient material to an inner rigid structure configured to engage a shaft associated with the motor, engaging the structure with the motor shaft, positioning the shaft and structure assembly with respect to the rotor core, and affixing the resilient material to the rotor core.

Abstract: A permanent magnet rotor includes at least one permanent magnet and a rotor core including a first end and a second end. The rotor core includes a plurality of permanent magnet openings that are each configured to receive a permanent magnet. The permanent magnet rotor also includes a first rotor end lamination coupled to the first rotor core end. The first rotor end lamination includes a plurality of inner lamination walls defining a first lamination opening and a second lamination opening circumferentially adjacent the first lamination opening. At least one inner lamination wall includes at least one permanent magnet retention feature configured to secure the permanent magnet within a corresponding permanent magnet opening. The at least one permanent magnet retention feature includes at least one tab extending radially from at least one of the plurality of inner lamination walls within the first rotor end lamination.

Abstract: A permanent magnet rotor includes at least one permanent magnet and a rotor core including a first end and a second end. The rotor core includes a plurality of permanent magnet openings that are each configured to receive a permanent magnet. The permanent magnet rotor also includes a first rotor end lamination coupled to the first rotor core end. The first rotor end lamination includes a plurality of inner lamination walls defining a first lamination opening and a second lamination opening circumferentially adjacent the first lamination opening. At least one inner lamination wall includes at least one permanent magnet retention feature configured to secure the permanent magnet within a corresponding permanent magnet opening. The at least one permanent magnet retention feature includes at least one tab extending radially from at least one of the plurality of inner lamination walls within the first rotor end lamination.

Abstract: A method for securing a permanent magnet within a rotor core is described. The rotor core includes a first end and a second end and at least one permanent magnet opening configured to receive the permanent magnet. The method includes coupling a first rotor end lamination to the first end of the rotor core. The first lamination includes at least one inner wall that defines an opening within the first lamination that corresponds to the permanent magnet opening in the rotor core. The first lamination includes a bridge portion positioned between the at least one inner wall and an outer edge of the first rotor end lamination. The method also includes positioning a permanent magnet at least partially within the permanent magnet opening and mechanically deforming the bridge portion of the first lamination to secure the permanent magnet within the permanent magnet opening.

Abstract: An electric motor comprises a shaft, an interior magnet rotor core comprising a central bore and a pair of opposing ends faces, and at least one resilient structure inserted within the central bore between the pair of opposing end faces. The at least one resilient component is inserted within the central bore between the pair of opposing end faces such that the at least one resilient component does not extend beyond one of the opposing end faces. The resilient component comprises an outer rigid structure inserted within the central bore, a resilient component inserted within the outer rigid structure, and an inner rigid structure inserted within the resilient component, wherein the shaft is inserted through the inner rigid structure.

Abstract: A method for securing a permanent magnet within a rotor core is described. The rotor core includes a first end and a second end and at least one permanent magnet opening configured to receive the permanent magnet. The method includes coupling a first rotor end lamination to the first end of the rotor core. The first lamination includes at least one inner wall that defines an opening within the first lamination that corresponds to the permanent magnet opening in the rotor core. The first lamination includes a bridge portion positioned between the at least one inner wall and an outer edge of the first rotor end lamination. The method also includes positioning a permanent magnet at least partially within the permanent magnet opening and mechanically deforming the bridge portion of the first lamination to secure the permanent magnet within the permanent magnet opening.

Abstract: An electric motor is described that includes a mid-shield, a chassis, and a motor control unit configured to be mounted to the chassis. The chassis includes a plurality of clinches formed proximate a first end of the chassis and configured to provide axial positioning of the mid-shield with respect to the chassis.

Abstract: A method for manufacturing an interior magnet rotor core motor is described herein. The method includes attaching a resilient material to an inner rigid structure configured to engage a shaft associated with the motor, engaging the structure with the motor shaft, positioning the shaft and structure assembly with respect to the rotor core, and affixing the resilient material to the rotor core.

Abstract: An electric motor is described that includes a mid-shield, a chassis, and a motor control unit configured to be mounted to the chassis. The chassis includes a plurality of clinches formed proximate a first end of the chassis and configured to provide axial positioning of the mid-shield with respect to the chassis.

Abstract: A rotor assembly for an electric motor is described that includes a rotor shaft, a ferromagnetic core mounted on the rotor shaft, and at least one cylindrical shaped magnet configured to engage and substantially surround the length of the ferromagnetic core. The at least one magnet is fabricated utilizing neodymium.

Abstract: A method for making a core for one of a rotor and a stator for use in an electric motor, the core being formed from a plurality of laminations, includes forming a predetermined number of through-material slots in a first portion of a material stock, forming at least one angled interlocking projection in the material stock, the projection having a circumferential length and being formed so that at least a portion of the projection remains integral with the material stock, cutting the material stock to define a receiving opening corresponding to the interlocking projection, the receiving opening positioned relative to the projection at an angle &phgr; that is a whole number multiple of &bgr;, where &bgr; is an angle defined as a ratio of 360 degrees to the number of slots and cutting the material stock to form a first substantially circular lamination. Second and third laminations are formed in kind.

Abstract: A motor rotor or stator core is formed of a plurality of stacked generally circular laminations. The stack defines at least one inner lamination having laminations positioned adjacent to both sides of the lamination. Each lamination has a predetermined number of circumferentially equally spaced slots or bar elements extending radially at about an edge thereof. The inner laminations include at least one interlocking projection formed in one of the surfaces at a predetermined radial distance from the center of the lamination. The laminations further define at least one projection receiving region formed therein to engage the projection when the laminations arc in the stacked formation. The projection receiving region is spaced from the interlocking projection by an angle .phi. that is a whole number multiple of .beta., where .beta. is an angle defined as a ratio of 360 degrees to the number of slots. A method for making the stacked core is also disclosed.