Scalable rotor

1. A rotor stack for connection to a shaft of a rotary electric machine, comprising:

a series of platters each centered about a centerline and including an opening for receiving the shaft such that the platters are stacked along the shaft, wherein passages extend through the platter and are arranged about the centerline;

permanent magnets positioned within the passages in abutted engagement therein, wherein a length of each permanent magnet is substantially the same as a length of its respective passage in a direction along the centerline;

wherein each permanent magnet includes a leading end having a tapered rectilinear surface extending at an angle of 10° relative the length of the permanent magnet, and the leading end having an opposing perpendicular edge; and

each platter associated with a respective hub separate therefrom, each respective hub securing each platter to the shaft via one or more projections that extend radially outward and engage a surface of the respective associated platter.

2. The rotor stack recited in claim 1 , wherein the platters abut one another.

3. The rotor stack recited in claim 1 , wherein the magnets have press-fit connections with inner surfaces defining the passages.

4. The rotor stack recited in claim 3 , wherein each magnet includes the leading end for engaging the inner surface to expand the passage and form the press-fit connection with the inner surface.

5. The rotor stack recited in claim 1 , wherein each platter includes an annular surface extending about the centerline, each magnet being spaced radially inwardly from the annular surface.

6. The rotor stack recited in claim 1 , wherein each magnet extends along a centerline parallel to the axis of the shaft, the magnet having a length extending parallel to the centerline and a thickness extending perpendicular to the centerline.

7. The rotor stack recited in claim 6 , wherein the thickness of each magnet is greater than a depth of the passage receiving the magnet.

8. The rotor stack recited in claim 1 , wherein each platter comprises a stack of laminations secured together through at least one of the passages.

9. The rotor stack recited in claim 8 , wherein the laminations have a welded connection with one another.

10. The rotor stack recited in claim 8 , wherein the laminations are mechanically held against one another.

11. The rotor stack recited in claim 1 , wherein a width of each permanent magnet extends perpendicular to the centerline.

12. The rotor stack recited in claim 11 , wherein the ratio between the length and the width of each permanent magnet is approximately 4:1.

13. A rotor stack for connection to a shaft of a rotary electric machine, comprising:

a series of platters each centered about a centerline and including an opening for receiving the shaft such that the platters are stacked along the shaft, wherein inner surfaces define passages extending through the platter and arranged about the centerline;

permanent magnets positioned in the passages in abutted engagement of the inner surfaces, each magnet including a leading end having a tapered surface for engaging the inner surface to expand the passage and form a press-fit connection with the inner surface; and

wherein:

a length of each permanent magnet is substantially the same as a length of its respective passageway in a direction along the centerline,

each platter comprises a stack of laminations secured together through at least one of the passages,

the laminations have a welded connection with one another in each given stack of laminations,

each of the welded connections contacted by one or more of the permanent magnets to electrically short the laminations together along the length of each platter;

each permanent magnet includes a leading end having a tapered rectilinear surface extending at an angle of 10° relative the length of the permanent magnet, and the leading end having an opposing perpendicular edge.

14. The rotor stack recited in claim 13 , wherein each platter includes an annular surface extending about the axis, each magnet being radially spaced inwardly from the annular surface.

15. The rotor stack recited in claim 13 , wherein each magnet extends along a centerline parallel to the axis of the shaft, the magnet having a length extending parallel to the centerline and a thickness extending perpendicular to the centerline.

16. The rotor stack recited in claim 15 , wherein the thickness of each magnet is greater than a depth of the passage receiving the magnet.

17. A subassembly for connection to a shaft of a rotary electric machine, comprising:

a platter centered about a centerline and including an opening for receiving the shaft, wherein inner surfaces define passages extending through the platter and arranged about the centerline;

each platter associated with a respective hub separate therefrom, each respective hub securing each platter to the shaft via one or more projections that extend radially outward and engage a surface of the respective associated platter; and

permanent magnets positioned in the passages and having a press-fit connection with the inner surfaces,

wherein a length of each permanent magnet is substantially the same as a length of its respective passageway in a direction along the centerline;

wherein each permanent magnet includes a leading end having a tapered rectilinear surface extending at an angle of 10° relative the length of the permanent magnet, and the leading end having an opposing perpendicular edge.

18. The subassembly recited in claim 17 , wherein each magnet includes a leading end having a tapered surface for engaging the inner surface to expand the passage and form a press-fit connection with the inner surface.

19. The subassembly recited in claim 17 , wherein each platter includes an annular surface extending about the centerline, each magnet being spaced radially inwardly from the annular surface.

20. The subassembly recited in claim 17 , wherein each magnet extends along a centerline parallel to the axis of the shaft, the magnet having a length extending parallel to the centerline and a thickness extending perpendicular to the centerline.

21. The subassembly recited in claim 17 , wherein a thickness of each magnet is greater than a depth of the passage receiving the magnet.

22. The subassembly recited in claim 17 , wherein each platter comprises a stack of laminations secured together through at least one of the passages.

23. A method of forming a rotor stack for connection to a shaft of a rotary electric machine, comprising:

securing a first stack of laminations together to form a first platter centered about a centerline, the first platter including an opening for receiving the shaft and passages arranged about the centerline;

positioning permanent magnets in the passages of the first platter;

mechanically securing the first platter to the shaft with a first hub separate from the first platter, the first hub securing the first platter to the shaft via one or more first projections that extend radially outward from the first hub and engage a first surface of the first platter;

securing a second stack of laminations together to form a second platter centered about a centerline, the second platter including an opening for receiving the shaft and passages arranged about the centerline;

positioning permanent magnets in the passages of the second platter; and

mechanically securing the second platter to the shaft with a second hub such that the first and second platters are stacked along the shaft, the second hub separate from the second platter and securing the second platter to the shaft via one or more second projections that extend radially outward from the second hub and engage a second surface of the second platter,

wherein a length of each permanent magnet is substantially the same as a length of its respective passageway in a direction along the centerline; wherein each permanent magnet includes a leading end having a tapered rectilinear surface extending at an angle of 10° relative the length of the permanent magnet, and the leading end having an opposing perpendicular edge.

24. A method of forming a rotor stack for connection to a shaft of a rotary electric machine, comprising:

securing, via at least one weld bead, a first stack of laminations together to form a first platter centered about a centerline, the first platter including an opening for receiving the shaft and passages arranged about the centerline;

mechanically securing the first platter to the shaft with a first hub separate from the first platter, the first hub securing the first platter to the shaft via one or more first projections that extend radially outward from the first hub and engage a first surface of the first platter;

positioning permanent magnets in the passages in abutted engagement therein of the first platter;

securing, via at least one weld bead, a second stack of laminations together to form a second platter centered about a centerline, the second platter including an opening for receiving the shaft and passages arranged about the centerline;

mechanically securing the second platter to the shaft with a second hub such that the first and second platters are stacked along the shaft, the second hub separate from the second platter and securing the second platter to the shaft via one or more second projections that extend radially outward from the second hub and engage a second surface of the second platter;

and

positioning permanent magnets in the passages of the second platter, wherein each permanent magnet includes a leading end having a tapered rectilinear surface extending at an angle of 10° relative the length of the permanent magnet, and the leading end having an opposing perpendicular edge.

25. A rotor stack for connection to a shaft of a rotary electric machine, comprising:

a first stack of laminations mechanically secured together via a first welded connection to form a first platter centered about a centerline, the first platter having an opening for receiving the shaft and passages arranged about the centerline;

a second stack of laminations mechanically secured together via a second welded connection to form a second platter centered about a centerline, the second platter having an opening for receiving the shaft and passages arranged about the centerline, wherein the first and second platters are rotatably secured to the shaft and without being directly secured to one another; and

wherein:

each passage is configured to receive one of a plurality of permanent magnets in abutted engagement therein,

at least one of the plurality of permanent magnets in the first platter contact the first welded connection to electrically short the first stack laminations together along the length of the first platter, and

at least one of the pluralities of permanent magnets in the second platter contact the second welded connection to electrically short the second stack laminations together along the length of the second platter,

a length of each permanent magnet is substantially the same as a length of its respective passageway in a direction along the centerline; wherein each permanent magnet includes a leading end having a tapered rectilinear surface extending at an angle of 10° relative the length of the permanent magnet, and the leading end having an opposing perpendicular edge.