ROTOR ASSEMBLY AND METHOD OF MANUFACTURE FOR ELECTRIC MACHINES HAVING MULTIPLE MAGNET LENGTHS

摘要

An improved rotor assembly configured for magnets with differing lengths, and methods and systems for manufacturing the same. The rotor assembly may be created by selectively creating first and second tabs extending into apertures of lamination sheets. The first and second tabs may be selectively removed, depending on the different magnet lengths and the specific lamination sheet, according to one of a first finishing schedule and a second finishing schedule. The lamination sheets are stacked with any remaining first and second tabs, and other features, aligned.

主权项

1. A rotor assembly for an electric machine having a central axis, the rotor assembly comprising:
a plurality of standard lamination sheets; at least one tab lamination sheet; a plurality of recess lamination sheets, disposed opposite the tab lamination sheet from the standard lamination sheets;
wherein each of the standard lamination sheets, the tab lamination sheets, and the recess lamination sheets defines an aperture, andwherein the plurality of lamination sheets are disposed adjacent each other to define a laminated stack, such that the apertures align to define a slot extending substantially parallel with the central axis; a magnet disposed within the slot; a first tab formed on the tab lamination sheet, wherein the first tab extends into the slot and into abutting engagement with a proximal surface of the magnet, such that the first tab biases a distal surface of the magnet against the slot to secure the magnet in position relative to the laminated stack; a first recess groove defined in the recess lamination sheets axially adjacent to the first tab of the tab lamination sheet, wherein the first tab is at least partially disposed within the first recess groove; and a second tab formed on the tab lamination sheet and extending substantially perpendicularly into the slot relative to the slot, wherein the second tab abuts an end of the magnet but does not bias the magnet against the slot, and wherein the recess lamination sheets do not define a groove adjacent the second tab.