Method of manufacturing the rotor assembly for an electric motor

1. A method of fabricating a rotor assembly for an electric motor, comprising:

assembling a lamination stack, wherein said lamination stack is comprised of a plurality of lamination discs, wherein each of said lamination discs is comprised of a first plurality of slots, and wherein each of said lamination discs is further comprised of a central bore;

inserting a plurality of pre-fabricated conductive rotor bars into said first plurality of slots corresponding to said lamination stack, wherein a first end portion of each of said plurality of pre-fabricated conductive rotor bars extends beyond a first end surface of said lamination stack, and wherein a second end portion of each of said plurality of pre-fabricated conductive rotor bars extends beyond a second end surface of said lamination stack;

locating a shaft within said central bore of said lamination stack;

locating a first member adjacent to said first end surface of said lamination stack, wherein at least a portion of said first member is encircled by said first end portion of each of said plurality of pre-fabricated conductive rotor bars, and wherein said first member at least partially defines a first end ring of said rotor assembly;

locating a second member adjacent to said second end surface of said lamination stack, wherein at least a portion of said second member is encircled by said second end portion of each of said plurality of pre-fabricated conductive rotor bars, and wherein said second member at least partially defines a second end ring of said rotor assembly;

die casting said first end ring and said second end ring of said rotor assembly, wherein said first end ring is comprised of said first end portion of each of said plurality of pre-fabricated conductive rotor bars, and wherein said second end ring is comprised of said second end portion of each of said plurality of pre-fabricated conductive rotor bars; and

removing said shaft, said first member and said second member from said rotor assembly.

2. The method of claim 1 , further comprising:

fitting a first containment ring around said first end portion of each of said plurality of pre-fabricated conductive rotor bars, wherein said step of fitting said first containment ring is performed prior to said step of die casting said first end ring and said second end ring of said rotor assembly; and

fitting a second containment ring around said second end portion of each of said plurality of pre-fabricated conductive rotor bars, wherein said step of fitting said second containment ring is performed prior to said step of die casting said first end ring and said second end ring of said rotor assembly.

3. The method of claim 2 , further comprising fabricating said first containment ring and said second containment ring from a material selected from the group consisting of a stainless steel, a beryllium copper alloy, and a metal matrix composite.

4. The method of claim 1 , further comprising:

machining said first end ring to remove a first circumferential portion corresponding to said first end ring, wherein said step of machining said first end ring is performed after completion of said die casting step;

fitting a first containment ring around said first end ring, wherein said first containment ring encircles said first end portion of each of said plurality of pre-fabricated conductive rotor bars, and wherein said first containment ring is positioned where said first circumferential portion of said first end ring was removed during said step of machining said first end ring;

machining said second end ring to remove a second circumferential portion corresponding to said second end ring, wherein said step of machining said second end ring is performed after completion of said die casting step; and

fitting a second containment ring around said second end ring, wherein said second containment ring encircles said second end portion of each of said plurality of pre-fabricated conductive rotor bars, and wherein said second containment ring is positioned where said second circumferential portion of said second end ring was removed during said step of machining said second end ring.

5. The method of claim 4 , further comprising fabricating said first containment ring and said second containment ring from a material selected from the group consisting of a stainless steel, a beryllium copper alloy, and a metal matrix composite.

6. The method of claim 4 , further comprising holding said first containment ring in place around said first end ring and holding said second containment ring in place around said second end ring utilizing one of the following steps:

a step of forming a first interference fit between said first containment ring and said first end ring and forming a second interference fit between said second containment ring and said second end ring;

a step of soldering said first containment ring to said first end ring and soldering said second containment ring to said second end ring;

a step of welding said first containment ring to said first end ring and welding said second containment ring to said second end ring; and

a step of bonding said first containment ring to said first end ring and bonding said second containment ring to said second end ring.

7. The method of claim 1 , further comprising fabricating said plurality of pre-fabricated conductive rotor bars from an oxygen-free electrolytic copper.

8. The method of claim 1 , further comprising:

fabricating said shaft, said first member and said second member from steel; and

coating said shaft, said first member and said second member with a non-stick coating to prevent adhesion between said steel and a casting material.

9. The method of claim 1 , further comprising fabricating said shaft and said first member as a single component.

10. The method of claim 1 , said step of assembling said lamination stack further comprising:

stamping each of said plurality of lamination discs from a metal; and

coating each of said plurality of lamination discs with an electrically insulating coating.

11. The method of claim 1 , said step of assembling said lamination stack further comprising:

fabricating each of said plurality of lamination discs from a metal;

fabricating a plurality of electrically insulating spacer discs; and

interposing one of said plurality of electrically insulating spacer discs between adjacent lamination discs of said plurality of lamination discs.

12. The method of claim 1 , said step of assembling said lamination stack further comprising:

locating a first end stack lamination disc at a first end of said lamination stack; and

locating a second end stack lamination disc at a second end of said lamination stack, wherein a first thickness corresponding to said first end stack lamination disc is thicker than a third thickness corresponding to each of said plurality of lamination discs interposed between said first end stack lamination disc and said second end stack lamination disc, and wherein a second thickness corresponding to said second end stack lamination disc is thicker than said third thickness corresponding to each of said plurality of lamination discs interposed between said first end stack lamination disc and said second end stack lamination disc.

13. The method of claim 12 , said first and second end stack lamination discs comprised of a second plurality of slots, wherein each of said second plurality of slots is of an approximately equivalent size to each of said first plurality of slots.

14. The method of claim 12 , said first and second end stack lamination discs comprised of a second plurality of slots, wherein each of said second plurality of slots is larger than each of said first plurality of slots.

15. The method of claim 1 , further comprising:

inserting a rotor shaft within said central bore of said lamination stack, wherein said step of inserting said rotor shaft is performed after completion of said die casting step and after completion of said removing step;

mounting a first bearing assembly to said rotor shaft, wherein said first bearing assembly is proximate to said first end ring; and

mounting a second bearing assembly to said rotor shaft, wherein said second bearing assembly is proximate to said second end ring.

16. The method of claim 1 , wherein each of said first plurality of slots is sized larger than a cross-section corresponding to each of said plurality of pre-fabricated conductive rotor bars, and wherein said die casting step further comprises forcing a casting material through said first plurality of slots corresponding to said lamination stack.

17. The method of claim 16 , wherein after completion of said inserting step, a portion of each of said first plurality of slots extends inwardly towards said central bore past an innermost edge of a corresponding one of said plurality of pre-fabricated conductive rotor bars, and wherein said casting material is forced through said portion of each of said first plurality of slots during said die casting step.

18. The method of claim 1 , wherein after completion of said die casting and removing steps, said first end ring is defined by a first ring inner cylindrical surface and a first ring outer cylindrical surface and said second end ring is defined by a second ring inner cylindrical surface and a second ring outer cylindrical surface.

19. The method of claim 1 , wherein after completion of said die casting and removing steps, said first end ring is defined by a first ring inner sloped surface and a first ring outer cylindrical surface and said second end ring is defined by a second ring inner sloped surface and a second ring outer cylindrical surface.

20. The method of claim 1 , wherein after completion of said die casting and removing steps, said first end ring is defined by a first ring inner stepped surface and a first ring outer cylindrical surface and said second end ring is defined by a second ring inner stepped surface and a second ring outer cylindrical surface.