Rotor and method of forming

Patent metadata

Field	Value
Publication number	US-10038359-B2
Application number	US-201815902618-A
Country	US
Kind code	B2
Filing date	Feb 22, 2018
Priority date	Apr 4, 2014
Publication date	Jul 31, 2018
Grant date	Jul 31, 2018

Abstract

A rotor casting includes a lamination stack and a cast structure including proximal and distal cast end rings respectively adjacent proximal and distal end faces of the lamination stack. Cast axial ribs are distributed radially on a peripheral surface of the lamination stack and extend between the proximal and distal cast end rings. Cast feed members extend axially from the proximal cast end ring and are respectively positioned radially between an adjacent pair of axial ribs. In one example, cast bar segments integral to the proximal and distal cast end rings are formed in axial slots of the lamination stack. In one example, a bar insert in each axial slot has insert ends that extend respectively from the proximal and distal end faces of the lamination stack and are fully encapsulated respectively in the proximal and distal cast end rings. A method of forming the rotor casting is provided.

First claim

The invention claimed is:

1. A method of forming a rotor casting, the method comprising:
inserting a lamination stack into a die cavity of a casting die;
the lamination stack including:
a distal end face and a proximal end face;
an axis of rotation; and
a plurality of axial slots distributed radially on an external peripheral surface of the lamination stack relative to the axis of rotation and extending between the proximal and distal end faces;

the die cavity having a proximal end and a distal end;
the die cavity defining a cast structure of the rotor casting including:
a proximal cast end ring;
a distal cast end ring; and
a plurality of cast axial ribs distributed radially on the external peripheral surface of the lamination stack relative to the axis of rotation;

wherein each of the plurality of cast axial ribs extends between the proximal and distal cast end rings;
wherein each of the plurality of axial ribs extends radially outward from the external peripheral surface of the lamination stack; and
wherein the cast structure incorporates the lamination stack.

2. The method of claim 1 , further comprising:
the casting die having a gating system including:
a plurality of side gates defined by the die cavity and distributed radially relative to the longitudinal axis;
each side gate defining a continuous gate opening extending axially between the proximal and distal ends of the die cavity such that the side gate opening is immediately adjacent the periphery, distal end face and proximal end face of the lamination stack;
the plurality of side gates configured to flow molten material from the proximal end of the die cavity to the distal end of the die cavity and to form the plurality of cast axial ribs;

the method further comprising:
flowing molten material into the die cavity via the plurality of side gates; and
solidifying the molten material to form the cast structure of the rotor casting.

3. The method of claim 2 , further comprising:
the gating system including a plurality of feeder gates distributed radially in fluid communication with the proximal end of the die cavity to receive the molten material into the die cavity;
the plurality of feeder gates in fluid communication with the plurality of side gates;
the method further comprising:
flowing molten material into the die cavity via the plurality of feeder gates.

4. The method of claim 1 , wherein the cast structure includes a plurality of cast bar segments formed in the plurality of axial slots of the lamination pack, each of the cast bar segments extending between and integral to the proximal and distal cast end rings.

5. The method of claim 1 , further comprising:
inserting a bar insert into each of the plurality of axial slots of the lamination stack prior to inserting the lamination stack into the die cavity;
wherein each bar insert includes first and second insert ends extending respectively from the proximal and distal end faces of the lamination stack after insertion to the lamination stack;
flowing molten material in contact with the first and second insert ends such that the first insert ends are fully encapsulated in the proximal cast end ring and the second insert ends are fully encapsulated in the distal cast end ring.

6. The method of claim 5 , wherein the first and second insert ends each define a hole;
the method further comprising:
flowing molten material through the hole during casting of the proximal and distal cast end rings.

7. The method of claim 5 , further comprising:
positioning the lamination stack in the die cavity to define a gap between the peripheral surface of the lamination stack and the die cavity; and
flowing molten material into the gap to form a cast peripheral skin;
wherein the cast peripheral skin at least partially encapsulates the peripheral surface of the lamination stack.

8. A method of forming a rotor casting, the method comprising:
inserting a lamination stack into a die cavity of a casting die;
the lamination stack including:
a distal end face and a proximal end face;
an axis of rotation; and
a plurality of axial slots distributed radially on an external peripheral surface of the lamination stack relative to the axis of rotation and extending between the proximal and distal end faces;

the die cavity having a proximal end and a distal end;
the die cavity defining a cast structure of the rotor casting including:
a proximal cast end ring;
a distal cast end ring; and
a plurality of cast axial ribs distributed radially on the external peripheral surface of the lamination stack relative to the axis of rotation;

wherein each of the plurality of cast axial ribs extends between the proximal and distal cast end rings;
wherein the cast structure incorporates the lamination stack; and
wherein the cast structure further comprises a cast peripheral skin extending from the plurality of cast axial ribs to at least partially encapsulate the external peripheral surface of the lamination stack.

9. A method of forming a rotor casting, the method comprising:
inserting a lamination stack into a die cavity of a casting die;
the lamination stack including:
a distal end face and a proximal end face;
an axis of rotation; and
a plurality of axial slots distributed radially on an external peripheral surface of the lamination stack relative to the axis of rotation and extending between the proximal and distal end faces;

the die cavity having a proximal end and a distal end;
the die cavity defining a cast structure of the rotor casting including:
a proximal cast end ring;
a distal cast end ring; and
a plurality of cast axial ribs distributed radially on the external peripheral surface of the lamination stack relative to the axis of rotation;

wherein each of the plurality of cast axial ribs extends between the proximal and distal cast end rings;
wherein the cast structure incorporates the lamination stack; and
wherein the cast structure further comprises a plurality of cast feed members extending axially from the proximal cast end ring.

10. The method of claim 9 , wherein the plurality of cast feed members are distributed radially on the proximal cast end ring.

11. The method of claim 9 , wherein each respective cast feed member is positioned radially between a respective adjacent pair of cast axial ribs.

Assignees

• Gm Global Tech Operations Llc

Inventors

• Hanna Michael D
• Agapiou John S

Classifications

• B22D17/00

  Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure · CPC title

• H02K17/165 Primary

  Electricity · mapped topic

• B22D19/0054 Primary

  rotors, stators for electrical motors · CPC title

• H02K15/0012

  Electricity · mapped topic

• H02K15/023

  Cage rotors · CPC title