Wedge with auxiliary tool method for mechanical magnet retention in electric machines

A method for assembling a rotor configured for use in an electric motor for powering and electric vehicle, the rotor configured to rotate relative to a stator to drive a rotor shaft and at least one drive wheel of the electric vehicle, the rotor defining at least a first rotor slot configured to receive a magnet therein, the method comprising:

• arranging a plurality of first rotor laminations stacked upon each other, each having a first pattern;
• arranging a second rotor lamination between adjacent first rotor laminations of the plurality of first rotor laminations, the second rotor lamination having a second pattern distinct from the first pattern, the second pattern including a retention mechanism defined thereon that extends generally into the first rotor slot;
• inserting the magnet into the rotor slot;
• and
• advancing an auxiliary tool toward the first and second rotor laminations, wherein the plurality of second rotor laminations are deflected upon the advancing, the respective retention mechanisms deflecting into the magnet creating a retention load retaining the magnet within the rotor slot.

An electric machine for powering an electric vehicle, the electric machine comprising:

• a rotor configured to rotate relative to a stator to drive a rotor shaft and at least one drive wheel of the electric vehicle, the rotor defining at least a first rotor slot configured to receive a magnet therein;
• a plurality of rotor laminations stacked upon each other each having a first pattern, the plurality of rotor laminations each having a retention mechanism defined thereon;
• and
• wherein less than all of the plurality of rotor laminations are configured to deflect upon advancement of an auxiliary tool into the plurality of rotor laminations, the respective retention mechanisms deflecting into the magnet creating a retention load retaining the magnet within the rotor slot.