Abstract: A rotor core for an induction motor. The rotor core includes a body that at least (i) extends axially from an outer surface of the body inward toward a central axis, (ii) extends from a first axial end to a second axial end, and (iii) defines a plurality of internal grooves. Further, each groove at least (iv) includes an opening at the outer surface of the body, (v) is defined by two opposing walls, (vi) extends from the first axial end to the second axial end, (vii) extends axially between the opening at the exterior surface and an inward end, and (viii) includes a body section. And wherein (ix) at least one wall of the opposing walls of the groove includes, in the body section of the groove, an extended segment forming a portion of increased breadth for the groove.

Abstract: A method for forming a rotor for an induction motor includes providing a rotor core including a plurality of conductor bar grooves having first and second ends corresponding to first and second ends of the rotor core wherein the conductor bar grooves are progressively larger closer to the ends of the conductor bar grooves. The rotor core is placed into a casting mold, and molten metal is introduced into a first end of the casting mold. The molten metal flows from the first end of the casting mold through the plurality of conductor bar grooves to a second end of the casting mold. The molten metal solidifies to form conductor bars in the plurality of conductor bar grooves and to form shorting rings across exterior portions of the end elements within the first and second ends of the casting mold.

Abstract: A billet of an aluminum alloy or magnesium alloy is formed by a combination of forming operations into a desired article of complex, but open shape. In a first step a billet is heated and extruded to form an extruded workpiece profile having at least first and second sections of different thicknesses. The extruded workpiece may be shaped so that the respective sections are at an angle to each other. The extruded workpiece is then further formed against a forming surface so that the shape of least one of the sections is further formed toward the shape of the article. The methods are suitable for efficient manufacture of many like complex shapes such as brackets and reinforcement members, and even container pans for computers and other electronic devices.

Abstract: A rotor core of an induction motor fabricating method includes a cylindrically shaped steel laminate stack having a plurality of longitudinal grooves distributed around the periphery of the steel laminate stack. A plurality of conductor bars are each located in one of the plurality of longitudinal grooves and each includes a first end projecting from a first end of the steel laminate stack. A shorting end ring includes a plurality of grooves aligned with and mated to the first ends of the conductor bars. The shorting end ring is affixed to the rotor core assembly by a lock ring assembled when at a thermally expanded condition to the rotor core when at a thermally contracted condition.

Abstract: A method for fabricating a rotor assembly for an induction motor includes assembling a shorting end ring onto the rotor assembly which includes a steel laminate stack and a plurality of conductor bars. The shorting end ring includes a plurality of grooves aligned with corresponding portions of the conductor bars extending from a first end of the steel laminate stack. Assembling includes inserting the corresponding portions of the conductor bars into the grooves of the shorting end ring. The shorting end ring is affixed to the rotor assembly by applying a compressive force around a perimeter of the shorting end ring to deform the conductor bars.

Abstract: One embodiment includes a method including providing a first portion of a product, the first portion of the product having a body and a flange extending therefrom; and casting a material around at least a portion of the flange to enclose the same and to provide a second portion of the product and wherein the at least the portion of the flange is constructed and arranged to provide frictional damping of the product.

Abstract: A method of preparing a plurality of bar-wound stator conductors for electrical interconnection includes inserting the plurality of conductors into a stator, twisting a conductor such that a first conductor of a first row is adjacent to a second conductor of a second row; trimming the adjacent first and second conductors to a common length using a trimming device; and grinding the trimmed first and second conductors to a pre-determined surface profile using a rotary cutting tool.

Abstract: An end ring assembly for a rotor, wherein the rotor is rotatable about a central longitudinal axis, includes a plurality of annular sheets stacked adjacent one another. Each of the plurality of annular sheets has a first surface and a second surface spaced opposite the first surface. The end ring assembly also includes a braze material sandwiched between and joining only a first portion of the first surface of each of the plurality of annular sheets, and a corresponding second portion of the second surface of a respective adjacent one of the plurality of annular sheets without joining an entirety of the first surface of each of the plurality of annular sheets and the second surface of the respective adjacent one of the plurality of annular sheets. A method of forming the end ring assembly is also disclosed.

Abstract: An impact beam assembly includes a beam of high-strength steel, and a pair of end brackets constructed of a dissimilar material than the high-strength steel. The brackets are locally deformed onto the beam to thereby surround a portion of the beam. Once deformed, the brackets define a flat section suitable for welding to a vehicle door panel, as well as a section for retaining the beam. The beam can include a surface feature suitable for retaining the beam to the end brackets. A method of reinforcing a vehicle door assembly includes positioning the beam with respect to the end brackets such that the brackets surround a portion of the beam, and then activating a magnetic pulse coil (MPC) to deform an overlapping portion of the brackets onto the beam. The brackets are then attached to a surface of the door assembly to reinforce the door assembly.

Abstract: A rotor core of an induction motor includes a cylindrically shaped steel laminate stack having a plurality of longitudinal grooves distributed around the periphery of the steel laminate stack. A plurality of conductor bars are each located in one of the plurality of longitudinal grooves and each includes a first end projecting from a first end of the steel laminate stack. A shorting end ring includes a plurality of grooves aligned with and mated to the first ends of the conductor bars. The shorting end ring is affixed to the rotor core assembly by a lock ring assembled when at a thermally expanded condition to the rotor core when at a thermally contracted condition.

Abstract: A method of manufacturing a rotor assembly includes placing a generally cylindrical rotor core in a die. The rotor core has axial grooves spaced about a perimeter of the rotor core. The grooves may be formed by stacked laminated disks. Material is cast around the annular rotor core in the die such that the cast material forms conductor bars that fill the grooves and first end ring portions at opposing ends of the rotor core connected with the conductor bars. Each of the first end ring portions has substantially a first axial width. The rotor core with cast conductor bars and cast first end ring portions is then removed from the die. A respective second end ring portion is welded to each of the cast first end ring portions to form end ring assemblies. Each second end ring portion has a second axial width greater than the first axial width.

Abstract: A method and system is provided to join the wire ends of a stator by placing a crimpable element on a wire end pair such that the wire ends of the wire end pair are surrounded by the crimpable element, and deforming the crimpable element using a crimping tool to form a crimped joint. The crimped joint is configured to provide an electrical connection between the wire ends of the wire end pair. The wire ends may be retained in substantial contact with each other by the crimpable element. The wire end portion of the stator may be immersed in a molten solder bath to form a solder joint joining the wire end pair comprising a crimped joint. The stator may be configured as a bar pin stator including a plurality of bar pins defining the wire ends.

Abstract: A welding apparatus for an induction motor includes a fixture operable to support a rotor and rotate the rotor about an axis of rotation of the motor, and a welding head supported adjacent the fixture and operable to weld conductor bars located about the surface of the rotor to the first shorting ring when the fixture supports the rotor. A controller controls the fixture to selectively rotate the rotor. The controller moves the welding head, the fixture, or both, so that the welding head is in a welding position, and causes the welding head to weld the conductor bars to the first shorting ring while remaining in the welding position, with the rotor rotating to create a substantially circular weld path along the first shorting ring. In some embodiments, the conductor bars are welded to both shorting rings simultaneously. A method of welding an induction motor is also provided.

Abstract: A method for fabricating a rotor assembly for an induction motor includes assembling a shorting end ring onto the rotor assembly which includes a steel laminate stack and a plurality of conductor bars. The shorting end ring includes a plurality of grooves aligned with corresponding portions of the conductor bars extending from a first end of the steel laminate stack. Assembling includes inserting the corresponding portions of the conductor bars into the grooves of the shorting end ring. The shorting end ring is affixed to the rotor assembly by applying a compressive force around a perimeter of the shorting end ring to deform the conductor bars.

Abstract: A rotor for an induction motor includes a rotor core having first and second ends and a plurality of conductor bars. Each conductor bar has a respective first end extending beyond the first end of said rotor core. Each first exposed end has a respective enclosed opening. The rotor also includes an end ring comprising a casting of material flowed between the respective first ends of the conductor bars and through the respective closed openings.

Abstract: A porous structure used to form a casted component. The casted component may include a visible design feature formed in part by the casted component and in part by a body material also forming other parts of the component. The casted component may be a brake rotor having a mixed-material composite formed in part by the casted component and in part by a body material also forming other parts of the rotor. The porous structure can include a ceramic foam or a metal mesh.

Abstract: A method and system is provided to join the wire ends of a stator by immersing a wire end portion of the stator in a molten solder bath to form a solder joint in each of a plurality of wire end pairs to provide an electrical connection between the respective wire ends of each wire end pair. The stator may be configured as a bar pin stator including a plurality of bar pins defining the wire ends. The solder joint may be defined by a portion of solder between the proximate surfaces of the wire ends of each wire end pair, and may be defined by a coating of solder in proximate contact with the perimeter surface of each respective wire end pair, wherein the portion of solder and the coating of solder each may provide an electrical connection between the respective wire ends.

Abstract: A method for fabricating a rotor assembly includes assembling shorting end rings onto conductor bars through a steel laminate stack. The ends of the steel laminate stack are immersed into a bath containing molten metal.

Abstract: A rotor core for an induction motor. The rotor core includes a body that at least (i) extends axially from an outer surface of the body inward toward a central axis, (ii) extends from a first axial end to a second axial end, and (iii) defines a plurality of internal grooves. Further, each groove at least (iv) includes an opening at the outer surface of the body, (v) is defined by two opposing walls, (vi) extends from the first axial end to the second axial end, (vii) extends axially between the opening at the exterior surface and an inward end, and (viii) includes a body section. And wherein (ix) at least one wall of the opposing walls of the groove includes, in the body section of the groove, an extended segment forming a portion of increased breadth for the groove.

Abstract: One embodiment includes a method for forming panels in which a particular shaping of the addendum contours of the formed panel to provide the functionality of the cooling fixture.