Rotor Patents (Class 29/598)
  • Patent number: 11801648
    Abstract: A sheet-shaped insulating member including a thermoplastic resin fiber and an inorganic fiber is arranged on a surface of a magnet body. The insulating member is compressed while being heated to a temperature higher than or equal to a glass transition temperature of the thermoplastic resin fiber, so that the insulating member is thermocompression-bonded to the magnet body in a state in which the inorganic fiber is elastically compressed. A magnet is thus formed. With the magnet arranged in a slot of a rotor core, the magnet is heated to a temperature higher than or equal to the glass transition temperature of the thermoplastic resin fiber. This causes the inorganic fiber to restore elasticity, so that the magnet is fixed to the rotor core.
    Type: Grant
    Filed: July 21, 2021
    Date of Patent: October 31, 2023
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventor: Kenta Takeshima
  • Patent number: 11795917
    Abstract: A main rotor shaft of a wind turbine configured to reducing contact pressure at a hub joint connection includes a flanged portion and a rod portion. The flanged portion includes an outer circumferential edge, an outer radial area, and an inner radial area. The outer radial area includes holes placed around the outer radial area for attachment to a wind turbine hub. The outer circumferential edge includes a groove placed atop the outer circumferential edge. The rod portion is formed with the inner radial area and configured for connection to a gearbox of a wind turbine.
    Type: Grant
    Filed: March 23, 2022
    Date of Patent: October 24, 2023
    Assignee: General Electric Renovables Espana, S.L.
    Inventors: Hemant Bhimrao Pawar, Bradley Graham Moore, Vinay Bawane, Christopher Michael Bean
  • Patent number: 11799367
    Abstract: A rotor manufacturing method is a method that allows magnetized magnets inserted in second magnet holes of a second rotor core to be inserted, while retaining magnetism, into first magnet holes of a first rotor core. This method includes a placing step of placing the second rotor core on a first end surface, in a stack thickness direction, of the first rotor core such that the second magnet holes overlap the first magnet holes, and an extruding step of extruding the magnetized magnets from the second magnet holes toward the first magnet holes using a non-magnetic jig.
    Type: Grant
    Filed: August 4, 2021
    Date of Patent: October 24, 2023
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Shinya Sano, Kensuke Komori
  • Patent number: 11791679
    Abstract: A rotor includes magnets and a core including arcuately arranged pole segments. Each pole segment includes first and second prongs that extend away from the rotor axis and are at least in part arcuately spaced apart to define a cutout therebetween. Each pair of arcuately adjacent pole segments defines therebetween a respective magnet-receiving slot, with the first prong of one of the pole segments and the second prong of the other of the pole segments defining the slot. The magnets are received in slots, such that each of the magnets is at least in part interposed between one of the pairs of adjacent pole segments. The magnets and the pole segments are dimensioned and configured so that at least one of the first and second prongs is deflected by the magnet received in the respective slot, such that the prongs cooperatively apply a clamping force on the magnet.
    Type: Grant
    Filed: August 19, 2021
    Date of Patent: October 17, 2023
    Assignee: Nidec Motor Corporation
    Inventors: John M. Tucker, Lunjie Lu
  • Patent number: 11781854
    Abstract: The rotation sensing device comprises a magnet, magnetic sensors, and yokes, which are secured to the base and control the magnetic flux of the magnetic field formed by the magnet; each magnetic sensor comprises a magnetic wire, a coil, and a bobbin; each yoke comprises a left yoke piece and a right yoke piece partially covering the left portion and the right portion of the magnetic sensor; the left yoke piece has a left front plate portion, the left front plate portion, which extends linearly from the front of the left portion of the bobbin, which is to the left of the section where the coil is provided, all the way to the front of the coil, and is inclined with respect to the direction of extension of the magnetic wire such that the right end thereof is located rearwardly of left end thereof.
    Type: Grant
    Filed: January 25, 2022
    Date of Patent: October 10, 2023
    Assignee: Hirose Electric Co., Ltd.
    Inventor: Kosuke Egawa
  • Patent number: 11777348
    Abstract: A rotor core for an electric machine of an automobile includes a core stack including a plurality of lamination plates. Each lamination plate includes a plurality of apertures formed therein. The plurality of apertures of each of the lamination plates are axially aligned and define and a slot extending through the core stack and shaped to receive a corresponding insert. The rotor core also includes at least one insert received by the slot that provides radial structural stability to the plurality of lamination plates to prevent portions of the plurality of lamination plates adjacent the plurality of magnet slots from flexing due to radial forces exerted on the plurality of lamination plates during operation of the rotor core. The rotor core includes a load bearing polymer disposed within the aperture of the rotor core that provides contact between and the insert and the lamination plates.
    Type: Grant
    Filed: August 3, 2021
    Date of Patent: October 3, 2023
    Assignee: GM GLOBAL TECHNOLOGY OPERATIONS LLC
    Inventors: Derek Frei Lahr, Alireza Fatemi, Anthony Michael Coppola
  • Patent number: 11766855
    Abstract: A method for connecting lamination parts to form lamination stacks. In order to ensure a versatile applicability of the lamination stacks, it is proposed that first cut-outs are stamped out identically in the first sub-region and in a second sub-region of the electric strip, additional second cut-outs are stamped into the second sub-region in accordance with the number of spacers, which second cut-outs are embodied to accommodate the spacers, and a second lamination part stamped out from the second sub-region is stacked either before or after the first lamination part in such a way that when spacers of the first lamination part are resting against this second lamination part, the second cut-outs are positioned offset from these spacers.
    Type: Grant
    Filed: January 18, 2019
    Date of Patent: September 26, 2023
    Assignee: voestalpine Automotive Components Dettingen GmbH & Co. KG
    Inventors: Jochen Lanksweirt, Axel Nann
  • Patent number: 11770056
    Abstract: A manufacturing method of a laminated iron core by laminating a plurality of blanked members to form a laminate, the laminate including a pair of first and second end surfaces and the plurality of blanked members being interlocked by a caulk in a lamination direction of the laminate, includes: forming the laminate such that a protrusion of the caulk protrudes downward from the first end surface being in a downward state; placing the laminate on support such that the protrusion is not in contact with a support surface of the support; and processing the laminate in a state where the laminate is placed on the support.
    Type: Grant
    Filed: March 5, 2019
    Date of Patent: September 26, 2023
    Assignee: MITSUI HIGH-TEC, INC.
    Inventors: Shigeru Nagasugi, Takashi Fukumoto, Jin Oda
  • Patent number: 11752544
    Abstract: A centrifugal casting apparatus comprising an upper portion into which molten material is poured, the upper portion having a central rotational axis about which the apparatus is rotated; at least one block runner is connected to the upper portion at the proximal end of the block runner and to at least one mould at the distal end of the block runner, the block runner being mounted substantially perpendicular to the axis of rotation; and wherein the moulds are oriented substantially parallel to the axis of rotation of the centrifugal casting apparatus.
    Type: Grant
    Filed: November 4, 2021
    Date of Patent: September 12, 2023
    Assignee: ROLLS-ROYCE plc
    Inventors: Rui Yang, Yuyou Cui, Paul A Withey, Nicholas Green, Feiyang Liu
  • Patent number: 11757317
    Abstract: A spoked rotor is rotatable about an axis. The rotor includes a core. The core includes a plurality of pole segments arranged arcuately about the axis. The rotor includes a plurality of arcuately arranged magnets alternating arcuately with the pole segments, such that each of the magnets is at least in part interposed between a pair of adjacent pole segments. Each of the magnets includes a curved section extending arcuately between radially inner and outer curved section ends. An effective rotor pole location is defined on each of the pole segments. Each of the pole segments has an end opposite the effective rotor pole location. A center point is defined at the pole segment end. Each of the effective rotor pole locations is arcuately offset from a corresponding one of the center points by between about five tenths (0.5) rotor poles and about two (2.0) rotor poles.
    Type: Grant
    Filed: September 28, 2022
    Date of Patent: September 12, 2023
    Assignee: Nidec Motor Corporation
    Inventors: Ryan M. Bastien, Lunjie Lu
  • Patent number: 11750052
    Abstract: A rotating electric machine rotor according to the present disclosure includes: a rotor shaft extending in a direction of an axis of rotation; and a rotor core fixedly fitted to an outer circumference of the rotor shaft and formed of laminated steel sheets. Further, an inner diameter of the rotor core is smaller than an outer diameter of the rotor shaft. Furthermore, an inner edge part of each laminated steel sheet is made thinner than an outer edge part thereof, and the inner edge part abuts on an outer peripheral surface of the rotor shaft and is curved along the outer peripheral surface of the rotor shaft in the direction of the axis of rotation.
    Type: Grant
    Filed: January 6, 2022
    Date of Patent: September 5, 2023
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Koichi Ono, Hiroaki Kodera, Keiichi Kaneshige
  • Patent number: 11750076
    Abstract: Apparatus, systems, and methods used to produce linear and rotational motion, acceleration, and actuation by the use of mobile ferromagnetic or permanent magnets subjected to asymmetric electromagnetic field distributions are disclosed herein. A variety of exemplary embodiments and applications are described, involving different coil and actuator geometries to include and allow for both stationary and moving magnets, electric fields, and magnetic fields.
    Type: Grant
    Filed: May 25, 2022
    Date of Patent: September 5, 2023
    Inventor: Thomas Alexander Johnson
  • Patent number: 11742721
    Abstract: A rotor assembly for a permanent magnet motor, including: a rotor shaft comprising an internal cavity having an inlet and an outlet; and a rotor core disposed about the rotor shaft, comprising an internal channel having an inlet and an outlet; wherein the outlet of the internal cavity of the rotor shaft is coupled to the inlet of the internal channel of the rotor core; and wherein the internal cavity of the rotor shaft and the internal channel of the rotor core are configured to circulate a cooling fluid through the rotor shaft and the rotor core. The rotor core includes a plurality of permanent magnets adapted to interact with a stator assembly disposed about/adjacent to the rotor core.
    Type: Grant
    Filed: April 20, 2021
    Date of Patent: August 29, 2023
    Assignee: Rivian IP Holdings, LLC
    Inventors: Dang Dinh Dang, Larry Xiong
  • Patent number: 11735985
    Abstract: A method and apparatus for forming a rotor for an electric machine includes serially adding layers of material to form a rotor body having a radially-extending post configured to receive a set of electrically-conductive windings, and also having a radially-extending winding end turn support formed contiguously from the rotor body.
    Type: Grant
    Filed: August 7, 2020
    Date of Patent: August 22, 2023
    Assignee: GE Aviation Systems LLC
    Inventors: Veeraraju Vanapalli, Deepak Ghiya, Raghavendra Rao Adharapurapu, Hao Huang, James Patrick Mahle
  • Patent number: 11735983
    Abstract: A widening apparatus for a hairpin-type stator coil is provided to extend a distance between welding portions of hairpin-type stator coils inserted into slots of a stator core, and the widening apparatus includes, a coil support unit installed on a base frame, a tool driving unit installed on the base frame to be vertically movable below the coil support unit, and including a first gear operation part and a second gear operation part, a plurality of lower widening tools operably connected to the first gear operation part, and reciprocally movable along a layer direction of the stator coils, and a plurality of upper widening tools operably connected to the second gear operation part, and configured to be reciprocally movable above the plurality of lower widening tools.
    Type: Grant
    Filed: December 7, 2021
    Date of Patent: August 22, 2023
    Assignees: HYUNDAI MOTOR COMPANY, KIA CORPORATION
    Inventors: Yeongsu Yu, Myoung Gil Han, Jiwon Yu
  • Patent number: 11735976
    Abstract: Provided are a rotor shaft assembly, a rotor, and a motor. The rotor shaft assembly includes a magnetic core, a first end shaft, a second end shaft, and a protective sleeve. The protective sleeve is provided, in sequence, with a first through hole, a second through hole, and a third through hole; the first end shaft is disposed through the first through hole, at least part of the magnetic core is arranged inside the second through hole, and the second end shaft is disposed through the third through hole.
    Type: Grant
    Filed: December 17, 2018
    Date of Patent: August 22, 2023
    Assignee: GREE ELECTRIC APPLIANCES, INC. OF ZHUHAI
    Inventors: Liming Peng, Jinxin Jia, Xiaobo Zhang, Jianning Liu, Fang Zhang, Guanghai Li, Changguang Guo, Qiong Wei, Zhongyu Li, Jin Yan, Jiandong Liang, Bowen Xiong, Zeye Wang
  • Patent number: 11728701
    Abstract: This canned motor (10) is provided with a rotor (14); a cylindrical rotor can (42) that houses the rotor (14); an end plate (40) that covers an opening of the rotor can (42) in the axial direction and is joined to the rotor can (42); a rotating shaft (16) that passes through the rotor (14) and the end plate (40); and an annular wall (46) that surrounds the outer circumference of the rotating shaft (16), is joined to or integrated with the end plate (40), and is joined to the entire circumference of the rotating shaft (16) at an end thereof in the axial direction. The thickness of the end plate (40) is larger than the thickness of the annular wall (46).
    Type: Grant
    Filed: July 18, 2019
    Date of Patent: August 15, 2023
    Assignee: NIKKISO CO., LTD.
    Inventors: Kazuo Futatsugi, Osamu Watanabe, Yasushi Kubota, Yu Kodama, Masaaki Eguchi
  • Patent number: 11724311
    Abstract: Systems and methods form induction rotors by performing isostatic pressing (HIP) to weld clad to a shaft, which allows for scaling the manufacturing of solid steel rotors, as compared to conventional techniques. In examples, the rotors are designed for high-speed motors and may include recessed short circuit rings and/or end rings. An exemplary process molds an alloy powder into cladding such that heretofore unachievable rotor designs are achievable according to systems and methods described herein. In examples, a thin source-layer is introduced to welding zones, thereby enriching and strengthening the resulting joint at welding zones. The source-layer may be introduced by adding an intermediate layer comprising the source material between the materials being welded. The reduced alloy-depletion welding disclosed herein strengthens the welding area joints and provides for the manufacture of component designs, which were previously unachievable due to alloy-depletion weaknesses and environmental constraints.
    Type: Grant
    Filed: September 26, 2019
    Date of Patent: August 15, 2023
    Assignee: Ingersoll-Rand Industrial U.S., Inc.
    Inventors: Fredrik Boxberg, Juha T. Saari, Esa H. M. Vikman
  • Patent number: 11715999
    Abstract: A method to make a stator lamination of an axial flux motor for an automobile vehicle includes: constructing a stator having multiple stator stack members, including: providing a stator lamination with individual ones of the stator stack members; forming the stator lamination from a single lamination sheet of steel defining a sinuous-shaped assembly having multiple bends; compressing the stator lamination; and machining the stator lamination to create a first edge by removing a first portion of the multiple bends and to create a second edge opposite to the first edge by removing a second portion of the multiple bends.
    Type: Grant
    Filed: December 18, 2020
    Date of Patent: August 1, 2023
    Assignee: GM GLOBAL TECHNOLOGY OPERATIONS LLC
    Inventors: Anil K. Sachdev, Chengwu Duan, Alireza Fatemi
  • Patent number: 11715986
    Abstract: A motor includes a rotor and a stator including a stator core and a winding including a first extension extending with respect to the stator core toward one side in a rotation-axis direction of the rotor, a second extension extending toward a rotation-radial direction outside of the rotor from an end of the first extension on the one side in the rotation-axis direction, and a third extension extending toward the one side in the rotation-axis direction from an end at the rotor rotation-radial direction outside of the second extension, and connected to a circuit device, and the winding forming a coil around the stator core, and such that an inner bent portion at a boundary between the first and second extensions is disposed at the one side in the rotation-axis direction with respect to an outer bent portion at a boundary between the second and third extensions.
    Type: Grant
    Filed: June 29, 2021
    Date of Patent: August 1, 2023
    Assignee: DENSO CORPORATION
    Inventors: Shinji Ikeda, Takumi Nagaya, Tatsuya Takagi, Kuniaki Matsumoto, Kazuhiro Hosotani, Yutaro Yagi, Yoshihiko Suga, Takuya Matsumoto, Shunichi Hiraoka
  • Patent number: 11699931
    Abstract: A rotor structure of a magnet motor includes a rotating shaft and an iron core on the rotating shaft. Magnet grooves are disposed inside the iron core along a circumferential direction with a magnet provided therein. A distance between an edge line of the magnet groove close to a circumferential edge of the iron core and the circumferential edge of the iron core varies so that a width of a flux barrier formed varies. One end of a long side of the magnet groove close to the circumferential edge is formed with an anti-demagnetization groove communicating with the magnet groove, and an edge line of the anti-demagnetization groove tilts toward the circumferential edge of the iron core. Process slots are provided between the magnet grooves and the circumferential edge of the iron core that are used to increase a salient rate and reluctance torque of the motor.
    Type: Grant
    Filed: June 30, 2021
    Date of Patent: July 11, 2023
    Assignee: Jing-Jin Electric Technologies Co., Ltd.
    Inventors: Xuan Zou, Liangliang Zhang, Chunshuang Feng, Chunxia Cai, Lei Han, Yang Zhang, Dandan Qi, Xin Xu, Kaihe Zhang, Biqing Sun
  • Patent number: 11682950
    Abstract: A manufacturing method of a rotor for an electric motor is disclosed herein. The rotor may include a rotor core having a through hole that extends along an axial direction of the rotor; a magnet inserted in the through hole; and a sheet disposed between an inner surface of the through hole and the magnet. The method may include inserting the sheet into the through hole such that the sheet extends through the through hole; and inserting the magnet into the through hole while the sheet is pulled at axial ends of the sheet in opposite directions to apply tension to the sheet and press the sheet against the inner surface.
    Type: Grant
    Filed: June 29, 2021
    Date of Patent: June 20, 2023
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventors: Kenta Takeshima, Shuzaburo Kita
  • Patent number: 11670994
    Abstract: A rotor manufacturing method comprises an arranging step for arranging a rotor core, which is formed by stacking electromagnetic steel plates, to direct the stacked electromagnetic steel plates toward a vertical direction, a guide inserting step for inserting a rod-like guide into a magnet insertion hole formed to extend in the stacked direction of the rotor core after the arranging step, a sheet inserting step for inserting a plurality of sheets from above the rotor core into the magnet insertion hole along different side surfaces of the guide after the guide inserting step, a guide pull-out step for pulling out the guide from the magnet insertion hole after the sheet inserting step, and a magnet inserting step for inserting a permanent magnet between the plurality of sheets within the magnet insertion hole after the guide pull-out step.
    Type: Grant
    Filed: May 2, 2022
    Date of Patent: June 6, 2023
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventor: Masayuki Akaishi
  • Patent number: 11654766
    Abstract: An electric motor includes a stator, a rotor and a rotor carrier radially inside of the rotor non-rotatably fixed to the rotor. The rotor carrier includes an axially extending cylindrical section including an outer circumferential surface having an annular groove formed therein. A method of forming a rotor carrier includes forming, by stamping, a rotor carrier including an axially extending cylindrical section including an outer circumferential surface having annular groove formed therein.
    Type: Grant
    Filed: May 4, 2018
    Date of Patent: May 23, 2023
    Assignee: Schaeffler Technologies AG & Co. KG
    Inventors: Timothy Simon, David Brucato
  • Patent number: 11646646
    Abstract: The continuous wires respectively have U-shaped parts and straight parts. The method includes: a transposition shape forming step of forming transposition shapes in each of which, among at least the two continuous wires belonging to an identical phase, the U-shaped part of one of the continuous wires is disposed inside the U-shaped part of the other one of the continuous wires; an inclined part forming step of causing the pairs of straight parts of the continuous wires respectively formed with the transposition shapes to be offset to form inclined parts on the continuous wires; and a folding step of folding the continuous wires formed with the inclined parts to form the turning parts and the slot disposition parts. The inclined part forming step and the folding step are alternately performed.
    Type: Grant
    Filed: March 24, 2021
    Date of Patent: May 9, 2023
    Assignee: HONDA MOTOR CO., LTD.
    Inventors: Takahiro Ide, Akihiro Watanabe
  • Patent number: 11641139
    Abstract: A lubricant supported electric motor includes an outer stator and an inner stator each extending around an axis in radially spaced relationship with one another. A rotor is rotatably disposed between the inner and outer stators to define an inner gap extending radially between the rotor and the inner stator and an outer gap extending radially between the rotor and the outer stator. A lubricant is disposed in both of the inner and outer gaps for supporting the rotor radially between the inner and outer stators. The lubricant supported motor with a two-sided radial flux configuration results in improved rotor-to-stator system stiffness to allow the lubricant supported electric motor to be used in high shock and high vibration environments, while also providing high torque in a small and lightweight design package.
    Type: Grant
    Filed: October 7, 2020
    Date of Patent: May 2, 2023
    Assignee: NEAPCO INTELLECTUAL PROPERTY HOLDINGS, LLC
    Inventors: Donald Remboski, Jacqueline Dedo, Mark Versteyhe
  • Patent number: 11637486
    Abstract: A guide device which is a rotor manufacturing device includes a pair of sheet guides and a holder. The holder is disposed between the pair of sheet guides and includes a magnet outlet through which a permanent magnet is inserted into the slot from above. The pair of sheet guides is linearly symmetrical in a front view in which a side of the pair of sheet guides is located at the front. The axis of symmetry of the pair of sheet guides and the center axis of the magnet outlet are aligned with each other in the front view.
    Type: Grant
    Filed: May 3, 2022
    Date of Patent: April 25, 2023
    Assignee: TOYOTA JIDOSHA KABUSHIKI KAISHA
    Inventor: Masayuki Akaishi
  • Patent number: 11632004
    Abstract: An electric motor includes a stator including four split cores, and a rotor having four magnetic poles. Each of the split cores includes a yoke and a tooth. An angle ?1 [degree] formed by a side surface of the tooth and a side surface of the yoke on an inner side in a radial direction of the stator satisfies 90 degrees ??1<180 degrees.
    Type: Grant
    Filed: December 30, 2020
    Date of Patent: April 18, 2023
    Assignee: Mitsubishi Electric Corporation
    Inventors: Kazuchika Tsuchida, Yuji Takayama, Keisuke Uemura
  • Patent number: 11605988
    Abstract: A method for manufacturing a laminated iron core includes providing a plurality of annular iron core piece rows, each of which is configured by annularly arranging a plurality of divided iron core pieces including yokes and teeth, and the yokes of the annularly-adjacent divided iron core pieces in the annular iron core piece row are mutually different in shape. In the method, the annular iron core piece rows are laminated by changing a rotational angle of the newly laminated annular iron core piece row relatively to the lastly laminated annular iron core piece row laminated so that the divided iron core piece with a shape different from that of the divided iron core piece is laminated on the lastly laminated divided iron core piece.
    Type: Grant
    Filed: January 18, 2018
    Date of Patent: March 14, 2023
    Assignee: MITSUI HIGH-TEC, INC.
    Inventors: Shuichi Nakamura, Daisuke Momota
  • Patent number: 11594927
    Abstract: Provided is a rotating electric machine capable of downsizing a coil end. The rotating electric machine includes an armature core and a plurality of coils. The plurality of coils each include a plurality of turn portions. The plurality of turn portions each include an inner-layer-side turn portion and an outer-layer-side turn portion. The inner-layer-side turn portion includes a first inner-layer-side bent portion, a first inner-layer-side oblique portion, and an inner-layer-side shift portion which is twisted. The outer-layer-side turn portion includes a first outer-layer-side bent portion, a first outer-layer-side oblique portion, and an outer-layer-side shift portion. The outer-layer-side shift portion has the inner-layer-side shift portion arranged between the outer-layer-side shift portion and the armature core.
    Type: Grant
    Filed: October 28, 2020
    Date of Patent: February 28, 2023
    Assignee: Mitsubishi Electric Corporation
    Inventors: Tatsuro Hino, Katsuya Ito, Hiroyuki Yasuda, Tatsuki Kawashima, Kazuya Hasegawa
  • Patent number: 11565504
    Abstract: A method for connecting lamination parts to form a lamination stack in which lamination parts are stamped out from an electrical strip that is coated with an activatable adhesive layer on at least one of its flat sides and the stamped-out lamination parts are stacked and glued to form lamination stacks, wherein before the lamination parts are stamped out, the electrical strip is embossed in a first sub-region, which produces multiple protruding spacers on at least one flat side of the electrical strip, which spacers, after a first lamination part is stamped out from this first sub-region, facilitate a detachment of the stacked and glued lamination parts into lamination stacks.
    Type: Grant
    Filed: January 18, 2019
    Date of Patent: January 31, 2023
    Assignee: Voestalpine Automotive Components Dettingen GmbH & Co. KG
    Inventors: Jochen Lanksweirt, Axel Nann
  • Patent number: 11552541
    Abstract: An induction motor includes a stator and a rotor. The stator is configured to generate a rotating magnetic field. The rotor is disposed inside the stator, separated from the stator by an air gap, and is configured to rotate around an axis in response to the rotating magnetic field. The rotor includes a rotor core, multiple end rings, and multiple collars. The end rings are attached at opposite ends of the rotor core. Each end ring has one of multiple regions disposed outside the air gap. Each region has an outer surface. The collars are attached in a prestressed condition around the outer surface of each region. The prestressed condition is configured to maintain a compressive stress in the end rings at a maximum-designed rotational speed of the rotor.
    Type: Grant
    Filed: January 18, 2021
    Date of Patent: January 10, 2023
    Assignee: GM Global Technology Operations LLC
    Inventors: John S. Agapiou, Edwin H. Chang, Yew Sum Leong
  • Patent number: 11522422
    Abstract: A method to produce rotors or stators of electric machines having radial grooves into which webs of flat windings having parallel webs and winding heads connecting said webs being pulled, wherein a winding is produced on a rotating, strip-shaped flat former shorter than the winding such that windings are pulled off the former and transferred into a linear transfer device, which transports the windings to a removal position at which the windings are transferred into radial grooves of a rotor or of the transfer tool for transfer into radial grooves of a stator, wherein the former, the transfer device, and the rotor or the transfer tool being jointly rotated about an axis of rotation of the former when rotated to form windings.
    Type: Grant
    Filed: March 24, 2021
    Date of Patent: December 6, 2022
    Assignee: Schaeffler ELMOTEC STATOMAT GmbH
    Inventors: Sadik Sadiku, Keith Alan Witwer
  • Patent number: 11522409
    Abstract: Shaft for an electric machine, includes a core seat for a laminated core and two shaft ends extending axially outwardly from the core seat in opposite directions, wherein the core seat has at least one core seat portion extending in the axial direction with a polygonal profile for forming a polygonal connection to the laminated core.
    Type: Grant
    Filed: August 26, 2020
    Date of Patent: December 6, 2022
    Assignee: VALEO SIEMENS EAUTOMOTIVE GERMANY GMBH
    Inventor: Regina Bach
  • Patent number: 11482897
    Abstract: A rotor includes an assembly of laminations including a plurality of radially-projecting poles, a winding of electrically conductive wires to be wound around each pole by means of wire-guiding heads arranged axially on either side of the lamination assembly. A guiding head support is inserted between the lamination assembly and each guiding head such that: an internal radial face of the support abuts against an external radial face at an axial end of the lamination assembly; and a peripheral surface of the support, which projects axially outward from the internal radial face of the support, is in contact with a contact face of the guiding head that is orientated radially outward from same, the guiding head abutting against the peripheral surface of the support.
    Type: Grant
    Filed: April 4, 2019
    Date of Patent: October 25, 2022
    Assignees: Renault s.a.s., NISSAN MOTOR CO., LTD.
    Inventors: Shahab Tavakoli, Joel Pressoir
  • Patent number: 11469653
    Abstract: A method of manufacturing a rotating body includes disposing an end plate on an end surface of the core body in a height direction, and forming the rotating body by welding the end plate and the core body together. The rotating body is formed by welding the end plate and the core body together while a temperature of the core body and the end plate is within a predetermined operational a temperature range associated with rotation of the rotating body in a manufactured state of operation.
    Type: Grant
    Filed: September 10, 2020
    Date of Patent: October 11, 2022
    Inventors: Kenji Katsuki, Takashi Fukumoto, Yasutaka Oba, Go Kato, Masashi Matsumoto
  • Patent number: 11456649
    Abstract: A rotating electrical machine includes a coil, a rotor including a shaft, a rotor core, a commutator including plural hooks being provided with a first hook to which an end of the coil is connected, the coil wound on a predetermined tooth of plural teeth, and an insulator attached to the rotor core, and a stator. The insulator includes an annular portion provided to surround the plural hooks which are aligned along a circumferential direction of the shaft, and a protrusion protruding opposite to the rotor core. The protrusion is arranged on a path where an end part of the coil passes through, the end part corresponding to an area from a part connected to the predetermined tooth to the end of the coil connected to the first hook, the protrusion being hooked by the end part.
    Type: Grant
    Filed: June 10, 2020
    Date of Patent: September 27, 2022
    Assignee: AISIN CORPORATION
    Inventor: Junichi Hashimoto
  • Patent number: 11435092
    Abstract: A rotor includes a rare-earth magnet magnetized in a radial direction, a rotor core, and a thermal conduction sheet formed of a deformable material. The rotor core includes a first part, a thin-wall part including a second part that is harder than the first part, and a magnet insertion hole. The thin-wall part is situated between a region of end of the magnet insertion hole in a circumferential direction and an outer edge of the rotor core.
    Type: Grant
    Filed: December 7, 2017
    Date of Patent: September 6, 2022
    Assignee: Mitsubishi Electric Corporation
    Inventor: Naohiro Oketani
  • Patent number: 11415676
    Abstract: In one embodiment, a lidar system includes a light source configured to emit pulses of light and a scanner configured to scan at least a portion of the emitted pulses of light along an interlaced scan pattern. The scanner includes a first scanning mirror configured to scan the portion of the emitted pulses of light substantially parallel to a first scan axis to produce multiple scan lines of the interlaced scan pattern, where each scan line is oriented substantially parallel to the first scan axis. The scanner also includes a second scanning mirror configured to distribute the scan lines along a second scan axis that is substantially orthogonal to the first scan axis, where the scan lines are distributed in an interlaced manner.
    Type: Grant
    Filed: October 9, 2018
    Date of Patent: August 16, 2022
    Assignee: Luminar, LLC
    Inventor: Eric C. Danziger
  • Patent number: 11418073
    Abstract: A rotor of an electric machine, in particular an electric motor, comprising a rotor body which circumferentially surrounds a shaft, and with a plurality of magnets. Each of the magnets is in each case arranged within a radially extending pocket of the rotor body, and each of the pockets is connected by means of an axially extending slot, each with a radially inner chamber of the rotor body. An electric machine is also provided.
    Type: Grant
    Filed: April 13, 2020
    Date of Patent: August 16, 2022
    Assignee: Baumueller Nuernberg GmbH
    Inventors: Jiri Kurfuerst, Matthias Swarte, Florian Tafelmayer
  • Patent number: 11393623
    Abstract: According to one embodiment, a method for manufacturing an iron core product includes providing an iron core body which includes a magnet insertion hole in which a permanent magnet is disposed, injecting a molten resin into the magnet insertion hole of the iron core body at a first pressure, and setting a pressure applied to the molten resin to a second pressure lower than the first pressure after the molten resin is injected into the magnet insertion hole and before the molten resin is cured.
    Type: Grant
    Filed: July 17, 2019
    Date of Patent: July 19, 2022
    Assignee: MITSUI HIGH-TEC, INC.
    Inventors: Takashi Fukumoto, Kohei Yoshida, Junya Satake
  • Patent number: 11394281
    Abstract: A method and device for manufacturing winding mats for manufacturing a coil winding of an electric machine. The winding mat is composed of wave winding wires bent as a flat winding in one plane. To be able to manufacture different coil mats with improved electrical characteristics easily and reliably in large series, it is proposed not to interlace or twist the wave winding wires, but to plug them at least partially. In addition, a method and a device for manufacturing a coil mat from several winding mats designed as individual mats are proposed. The device preferably comprises an offsetting device for introducing height offsets into winding heads of the wave winding wires.
    Type: Grant
    Filed: February 27, 2019
    Date of Patent: July 19, 2022
    Assignee: GROB-WERKE GMBH & CO. KG
    Inventors: Frederik Schmid, Ralf Rauscher
  • Patent number: 11349367
    Abstract: A support device for a rotor of an internal-rotor synchronous machine of a motor vehicle includes a star disk, which is able to be arranged on the laminated core of the rotor between an end side of the laminated core and end windings of the rotor windings, and a support ring for encasing the star disk. The star disk has a ring carrier for arranging on a rotor yoke of the laminated core, supporting teeth, protruding radially from the ring carrier, for arranging on rotor teeth of the laminated core, and collar-type end pieces, protruding axially from ends of the supporting teeth, for arranging on pole shoes of the rotor laminated core. The end pieces of the star disk and the support ring have mutually complementary bayonet joint regions, which are designed to connect the star disk and the support ring in a form-fitting manner.
    Type: Grant
    Filed: October 15, 2019
    Date of Patent: May 31, 2022
    Assignee: Bayerische Motoren Werke Aktiengesellschaft
    Inventor: Daniel Loos
  • Patent number: 11336159
    Abstract: The manufacturing method of a rotor includes: a step of preparing a plate that is composed of an austenitic material and that has a projected portion and a part with a width in a rotational axis direction smaller than a width of the projected portion in the rotational axis direction; and a step of forming a welded portion across the projected portion of the plate and a rotation transmitting member by emitting an energy beam on at least a part of the projected portion to melt at least a part of the projected portion.
    Type: Grant
    Filed: January 11, 2019
    Date of Patent: May 17, 2022
    Assignee: AISIN CORPORATION
    Inventors: Susumu Kato, Hideharu Ushida, Shohei Ohashi
  • Patent number: 11316416
    Abstract: A method of manufacturing a rotor includes forming plates each including a scrap portion that has a center hole and core plate portions that are disposed continuously with the scrap portion on an inner side of the center hole and that each defines a portion of a corresponding one of the outer cores forming a multilayer body including the outer cores by stacking the plates, setting at least a portion of the multilayer body and a portion of the inner core in a mold with a gap therebetween in the radial direction, forming a molded body by pouring a molten filling material into a gap in the mold and forming the filling section, at least a portion of the filling section being positioned between the outer cores, and separating the scrap portion and the core plate portions from each other.
    Type: Grant
    Filed: September 30, 2016
    Date of Patent: April 26, 2022
    Assignee: NIDEC CORPORATION
    Inventors: Yasuaki Nakahara, Keisuke Saito, Takeshi Honda, Hirofumi Muto, Osamu Fujimoto
  • Patent number: 11277045
    Abstract: In one embodiment, a permanent magnet rotor is provided. The permanent magnet rotor includes at least one permanent magnet and a substantially cylindrical rotor core including an outer edge and an inner edge defining a central opening. The rotor core includes a radius R, at least one pole, and at least one radial aperture extending radially though the rotor core from the outer edge to a predetermined depth less than the radius. The at least one radial aperture is configured to receive the at least one permanent magnet. The rotor further includes at least one protrusion extending into the at least one radial aperture, the at least one protrusion positioned substantially along a bottom of the at least one radial aperture and configured to facilitate retention of the at least one permanent magnet within the at least one radial aperture.
    Type: Grant
    Filed: March 30, 2020
    Date of Patent: March 15, 2022
    Assignee: Regal Beloit America, Inc.
    Inventors: Subhash Marutirao Brahmavar, Lester Benjamin Manz, Ludovic Andre Chretien, Changiz Rashidzadeh, Dan Mircea Ionel
  • Patent number: 11271462
    Abstract: An apparatus for manufacturing a heat sealing-type rotational laminated core enabling the automatic separation of a laminated core, wherein the apparatus for manufacturing a laminated core includes: a squeeze ring installed on the lower portion of a blanking die for the blanking process; a heating means installed on the outer portion of the squeeze ring; a rotating die having the squeeze ring and the heating means installed therein to rotate by a predetermined pitch with the squeeze ring and the heating means; a vertically-moving die installed on one side of the blanking die and having a plurality of protruding portions and recessed portions formed; and a fixed die installed in the upper mold on the upper side of the vertically-moving die and having a plurality of recessed portions and protruding portions formed.
    Type: Grant
    Filed: May 17, 2017
    Date of Patent: March 8, 2022
    Assignee: BMC CO., LTD.
    Inventor: In Gyu Jung
  • Patent number: 11239726
    Abstract: The embodiments of the present disclosure provide a shaft structure of a motor, comprising a housing, a stator disposed inside the housing, and a rotor rotatably disposed inside the stator. The stator may comprise a stator core and a coil wound around the stator core, and the rotor may comprise a rotor core and a rotational shaft coupled to the rotor core. The rotational shaft may comprise a plurality of adjusting portions formed on an outer circumferential surface of the rotational shaft to align a center of gravity of the rotor with a center of the rotational shaft.
    Type: Grant
    Filed: December 31, 2019
    Date of Patent: February 1, 2022
    Assignee: LG Electronics Inc.
    Inventors: Kyeonghwan Kim, Yangsoo Lee, Gyeongjae Park, Hojun Shin, Junho Ahn, Wonjung Sung
  • Patent number: 11223259
    Abstract: To effectively cover a coil end with a resin layer. A method for manufacturing a stator includes a first resin layer forming step (ii) of forming a first thermoset resin layer by impregnating the tip end side of a coil end with first thermoset resin, the coil end protruding from the core of the stator, the first thermoset resin having liquidity; a second resin layer forming step (iii) of forming a second thermoset resin layer on the first thermoset resin layer by dropping second thermoset resin from the core side of the coil end toward the tip end side; and a curing step of curing the first thermoset resin and the second thermoset resin.
    Type: Grant
    Filed: November 15, 2018
    Date of Patent: January 11, 2022
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, DENSO CORPORATION
    Inventors: Masashi Kawai, Yasushi Nishikuma, Hiroaki Takeda
  • Patent number: 11218059
    Abstract: In a case where a permanent magnet is inserted into each of a plurality of magnet-insert holes of a laminated iron core and then a resin is injected into the plurality of magnet-insert holes from a resin pool pot formed in one of an upper die and a lower die with the laminated iron core pinched and the resin is cured inside the plurality of magnet-insert holes to fix the permanent magnets to the laminated iron core, a dummy plate which abuts on the laminated iron core and includes a gate hole for allowing passage of the resin delivered from the resin pool pot and guiding the resin to the plurality of magnet-insert holes. The gate hole partially overlaps with at least two of the plurality of magnet-insert holes in a plan view of the dummy plate and the laminated iron core.
    Type: Grant
    Filed: December 20, 2017
    Date of Patent: January 4, 2022
    Assignee: MITSUI HIGH-TEC, INC.
    Inventor: Iwao Myojin