IP Library › Granted Patent US 12665476
Granted Patent B2
US 12665476 · App. 18/115,179 · Granted Jun 23, 2026

Method for manufacturing a rotor of an electric motor using a tool

Inventors: Florian Braunbeck (Stuttgart, DE); Patrick Knecht (Stuttgart, DE); Peter Wurster (Wiggensbach, DE); Tobias Engelhardt (Stuttgart, DE); Johannes Lange (Dettenheim, DE)
Assignee: Dr. Ing. h.c. F. Porsche Aktiengesellschaft
H02K15/03H02K1/28H02K15/12
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Quick Facts
Patent No.
US 12665476
App. No.
18/115,179
Granted
Jun 23, 2026
Kind
B2
Abstract

A method is provided for manufacturing a rotor ( 1 ) of an electric motor. The rotor ( 1 ) has a rotor shaft ( 2 ), inner sheet metal packets ( 4 ), outer sheet metal packets ( 4 ), buried magnets ( 5 ) arranged in the assembled state between the inner sheet metal packets ( 3 ) and the outer sheet metal packets ( 4 ), and surface magnets ( 6 ) arranged in the assembled state on the outer sheet metal packets ( 4 ). The method includes pushing the inner sheet metal packets ( 3 ) onto the rotor shaft ( 2 ) to achieve alignment rectangularly and coaxially. The rotor ( 1 ) is constructed by placing the buried magnets ( 5 ) and the outer sheet metal packets ( 4 ) on the inner sheet metal packets ( 3 ) and the surface magnets ( 6 ) on the outer sheet metal packets ( 4 ). A total run-out of the rotor ( 1 ) thus is set to a predetermined acceptable amount.

Claims (24)

1 . A method for manufacturing a rotor ( 1 ) of an electric motor using a two-part tool ( 7 ) having a first part ( 10 ) and a second part ( 13 ), the method comprising:

providing a rotor shaft ( 2 ), inner sheet metal packets ( 3 ), outer sheet metal packets ( 4 ), buried magnets ( 5 ), and surface magnets ( 6 );

pushing the inner sheet metal packets ( 3 ) onto the rotor shaft ( 2 );

placing the buried magnets ( 5 ) and the outer sheet metal packets ( 4 ) on the inner sheet metal packets ( 3 ) and placing the surface magnets ( 6 ) on the outer sheet metal packets ( 4 );

inserting a first end of the rotor shaft ( 2 ) having at least one of the inner sheet metal packets ( 3 ) into the first part ( 10 ) of the two-part tool ( 7 ) by positioning the first end of the rotor shaft ( 2 ) within a first receptacle ( 11 ) of the first part ( 10 ) and positioning the at least one of the inner sheet metal packets ( 3 ) within a second receptacle ( 12 ) of the first part ( 10 );

inserting the second part ( 13 ) of the two-part tool ( 7 ) onto a second end of the rotor shaft ( 2 ) having the inner sheet metal packets ( 3 ) by positioning the second end of the rotor shaft ( 2 ) within a third receptacle ( 14 ) of the second part ( 13 ) and positioning at least a second one of the inner sheet metal packets ( 3 ) that is not inserted into the second receptacle ( 12 ) within a fourth receptacle ( 15 ) of the second part ( 13 );

connecting the first part ( 10 ) and the second part ( 13 ) of the two-part tool ( 7 ) by inserting pins ( 17 ) of one of the first part ( 10 ) and the second part ( 13 ) into openings ( 18 ) of the other of the first part ( 10 ) and the second part ( 13 ).

2 . The method of claim 1 , connecting the first part ( 10 ) and the second part ( 13 ) of the two-part tool ( 7 ) forces a coaxial alignment between the inner sheet metal packets ( 3 ).

3 . A method for manufacturing a rotor ( 1 ) of an electric motor using a cuff tool ( 20 ), the method comprising:

providing a rotor shaft ( 2 ), inner sheet metal packets ( 3 ), outer sheet metal packets ( 4 ), buried magnets ( 5 ), and surface magnets ( 6 );

pushing the inner sheet metal packets ( 3 ) onto the rotor shaft ( 2 );

placing the buried magnets ( 5 ) and the outer sheet metal packets ( 4 ) on the inner sheet metal packets ( 3 ) and placing the surface magnets ( 6 ) on the outer sheet metal packets ( 4 );

placing the cuff tool ( 20 ) around the rotor ( 1 ), the rotor shaft ( 2 ), the inner sheet metal packets ( 3 ), the buried magnets ( 5 ), the outer sheet metal packets ( 4 ), and the surface magnets ( 6 );

reducing an inner diameter of the cuff tool ( 20 );

overmolding the rotor ( 1 ) with plastic and thereby filling interstices ( 9 ) between the inner sheet metal packets ( 3 ), the buried magnets ( 5 ), the outer sheet metal packets ( 4 ), and the surface magnets ( 6 ) with the plastic; and

increasing an inner diameter of the cuff tool ( 20 ) and then removing the cuff tool ( 20 ) from the rotor ( 1 ).

4 . A method for manufacturing a rotor ( 1 ) of an electric motor using a cylinder ( 19 ′) with radially inwardly adjustable punches ( 21 ), the method comprising:

providing a rotor shaft ( 2 ), inner sheet metal packets ( 3 ), outer sheet metal packets ( 4 ), buried magnets ( 5 ), and surface magnets ( 6 ),

pushing the inner sheet metal packets ( 3 ) onto the rotor shaft ( 2 ),

placing the buried magnets ( 5 ) and the outer sheet metal packets ( 4 ) on the inner sheet metal packets ( 3 ) and placing the surface magnets ( 6 ) on the outer sheet metal packets ( 4 ),

inserting the rotor ( 1 ) with the rotor shaft ( 2 ), the inner sheet metal packets ( 3 ), the buried magnet ( 5 ), the outer sheet metal packets ( 4 ), and the surface magnets ( 6 ) into the cylinder ( 19 ′),

radially inwardly adjusting the punches ( 21 ),

overmolding the rotor ( 1 ) with plastic and thereby filling the plastic into interstices ( 9 ) between the inner sheet metal packets ( 3 ), the buried magnets ( 5 ), the outer sheet metal packets ( 4 ), and the surface magnets ( 6 ), and

adjusting the punches ( 21 ) radially outwardly, and removing the rotor ( 1 ) from the cylinder ( 19 ′).