Rotor Assembly with Electron Beam Welded End Caps

摘要

A rotor assembly and a method for fabricating the same are provided in which a pair of end caps, positioned at either end of the stack of laminated discs, are fusion welded to the rotor bars using an electron beam welder, thereby yielding improved electrical and mechanical characteristics in a low weight assembly.

主权项

1. A method of fabricating a rotor assembly for an electric motor, the method comprising:
inserting a plurality of rotor bars into a corresponding plurality of slots within a stack of laminated discs, wherein a first portion of each of said plurality of rotor bars protrudes from a first end surface of said stack of laminated discs, and wherein a second portion of each of said plurality of rotor bars protrudes from a second end surface of said stack of laminated discs; mounting a first end cap to said plurality of rotor bars, wherein said first portion of each of said plurality of rotor bars fits within a corresponding slot of a first plurality of slots in said first end cap; mounting a second end cap to said plurality of rotor bars, wherein said second portion of each of said plurality of rotor bars fits within a corresponding slot of a second plurality of slots in said second end cap; directing a first electron beam towards a circumferential side surface of said first end cap and fusing at least a region of said first portion of each of said plurality of rotor bars to said corresponding slot of said first plurality of slots of said first end cap; and directing a second electron beam towards a circumferential side surface of said second end cap and fusing at least a region of said second portion of each of said plurality of rotor bars to said corresponding slot of said second plurality of slots of said second end cap.