US 11,070,117 B2Granted

Apparatus and method to centrifugally cast copper rotor assemblies for induction motor of electric vehicle

AssigneeSF Motors, Inc.

InventorsJustin Chen, Zhichun Ma, Duanyang Wang, Yifan Tang, Yin Wang

Life of this patent

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Abstract

Provided herein are systems, apparatuses, and methods of providing a centrifugally cast rotor assembly for an induction motor of an electric vehicle. The rotor assembly includes a rotor lamination stack with a cylindrical shape that terminates in a first end surface and a second end surface. The rotor lamination stack has multiple lamination discs, and each lamination disc has multiple rotor slots. The rotor assembly further includes copper bars disposed within the rotor slots, a first intermediary end ring disposed at the first end surface, and a second intermediary end ring disposed at the second end surface. A centrifugally cast first copper end ring that electrically and mechanically couples each of the copper bars is located proximate the first end surface, and a centrifugally cast second copper end ring that electrically and mechanically couples each of the copper bars is located proximate the second end surface.

Claims20

Dependent claims

An apparatus to centrifugally cast copper rotor assemblies for induction motors of electric vehicles, comprising:

a rotor assembly with a cylindrical shape that defines a central axis, the rotor assembly terminates in a first end and a second end;
an inner die component;
an outer die component, each of the inner die component and the outer die component disposed at the first end of the rotor assembly;
a spinner assembly, comprising:
a lower structure disposed beneath the rotor assembly, comprising:
a base plate;
a spindle component to mate with the outer die component;
a first bearing assembly having a first inner ring component and a first outer ring component, the first outer ring component fixedly coupled with the base plate and the first inner ring component fixedly coupled with the spindle component such that the spindle component is permitted to rotate with the rotor assembly about the central axis relative to the base plate;
an upper structure disposed above the rotor assembly, comprising:
an upper plate;
a drive wheel component to mate with the rotor assembly;
a second bearing assembly having a second inner ring component and a second outer ring component, the second outer ring component fixedly coupled with the upper plate and the second inner ring component fixedly coupled with the drive wheel component such that the drive wheel component is permitted to rotate with the rotor assembly about the central axis relative to the upper plate;
and
a sidewall structure that couples the lower structure with the upper structure;
and
a motor to drive rotation of the drive wheel component.

13 more elements

A spinner assembly of a centrifugal casting process of a rotor assembly used in an induction motor of an electric vehicle, comprising:

a lower structure disposed beneath the rotor assembly, comprising:
a base plate;
a spindle component to mate with an outer die component of the rotor assembly;
a first bearing assembly comprising a first inner ring component and a first outer ring component, the first outer ring component fixedly coupled with the base plate and the first inner ring component fixedly coupled with the spindle component such that the spindle component is permitted to rotate with the rotor assembly relative to the base plate;
an upper structure disposed above the rotor assembly, comprising:
an upper plate;
a drive wheel component to mate with the rotor assembly;
a second bearing assembly comprising a second inner ring component and a second outer ring component, the second outer ring component fixedly coupled with the upper plate and the second inner ring component fixedly coupled with the drive wheel component such that the drive wheel component is permitted to rotate with the rotor assembly relative to the upper plate;
and
a sidewall structure coupling the lower structure to the upper structure.

7 more elements

Dependencies are inferred from the claim text.

Facts

Application: 16/388,515Filed 18 Apr 2019 · continuation
Priority: 16 Apr 2019
Published: US 2020/0336055 A122 Oct 2020
Granted: 20 Jul 2021
Term ends: Not estimatedThe source records don’t support an estimate.

Classification15 codes

B22D 19/0054
Casting in, on, or around objects which form part of the product: rotors, stators for electrical motors
B22D 13/026
Of elongated solid or hollow bodies, e.g. pipes, in moulds rotating around their longitudinal axis: the longitudinal axis being vertical
B60L 50/51
Using propulsion power supplied by batteries or fuel cells: characterised by AC-motors
H02K 1/02
Details of the magnetic circuit: characterised by the magnetic material

Family

Application16/385,992Parent of this continuation · filed 16 Apr 2019
US 2020/0336056 A1Pre-grant publication · published 22 Oct 2020
US 10,855,153 B2Parent of this continuation
US 2020/0336055 A1Published application
US 11,070,117 B2This patent

From the US filing history. Foreign family members aren’t listed.