Abstract: A method of manufacturing a bearing having improved cooling features is disclosed. A cooling coil is positioned in a casting mold for a bearing component. The cooling coil defines a conduit for the transmission of coolant through the coil. The bearing component is then cast within the mold to form a bearing component having an internal cooling coil. The cooling coil may be formed from any suitable material, such as copper. The cooling coil facilitates heat dissipation from the bearing during operation. Alternative methods of manufacturing a bearing with cooling features are also disclosed.

Abstract: A method of manufacturing an apparatus, such as a motor or other rotating machine, having a cooling coil is provided. The exemplary method includes disposing a cooling coil within a casting mold and casting a component of the device such that the cooling coil is embedded within the component. A coolant is routed through the cooling coil during the casting process to reduce or prevent melting of the cooling coil and preserve a fluid conduit within the cooling coil. A device component and apparatus having a cooling coil are also provided.

Abstract: According to one embodiment, the present invention provides a rotor assembly. The exemplary rotor assembly includes a plurality of rotor laminations, which cooperate to form a rotor core, capped at each end by end members. Extending through the rotor core and the end members, a plurality of rotor channels is configured to receive electrically conductive members therethrough. Each of the electrically conductive members has external portions, which extend beyond the rotor channel, and an interior portion that is housed within the rotor channel. By flexing the external portions, a compression force that secures the laminations and the end members with respect to one another may be provided. Advantageously, the external portions may be fused to one another and/or to the end members. As one example, the external portions may be fused through the introduction of a molten metal into the end member.

Abstract: In accordance with one exemplary embodiment, the present technique provides an electric motor having a stator core that is formed of a plurality of stator laminations and a rotor core that is formed of a plurality of rotor laminations. In the exemplary motor, the rotor laminations have mechanical and/or electrical characteristics that are different from the stator laminations. For example, the rotor laminations may have a different thickness than the stator laminations. Also, the rotor laminations may comprise a different material than the stator laminations. For example, the stator laminations may by alloyed with a certain percentage of an element, while the rotor laminations are alloyed with a different percentage of element.

Abstract: According to one embodiment, the present invention provides a rotor assembly. The exemplary rotor assembly includes a plurality of rotor laminations, which cooperate to form a rotor core, capped at each end by end members. Extending through the rotor core and the end members, a plurality of rotor channels is configured to receive electrically conductive members therethrough. Each of the electrically conductive members has external portions, which extend beyond the rotor channel, and an interior portion that is housed within the rotor channel. By flexing the external portions, a compression force that secures the laminations and the end members with respect to one another may be provided. Advantageously, the external portions may be fused to one another and/or to the end members. As one example, the external portions may be fused through the introduction of a molten metal into the end member.