Gm Global Technolgoy Operations, Inc.

Michael D Hanna

James Gregory Schroth

Mohan Sundar

Richard Murray Kleber

Mark T Riefe

Brent D Lowe

Omar S Dessouki

Andrew Schertzer

John Stilianos Agapiou

Richard Harry Hammar

Michael J Walker

Jeremy W Short

Mark William Verbrugge

Anil Kumar Sachdev

John C Ulicny

Mark A Golden

James A Webster

Moinuddin S Rashid

Thomas C Zebehazy

Ronnie T Brown

Andrew Leslie Bartos

Jon T Carter

Bob Ross Powell

John C Morgante

Peter H Foss

John P Miller

Michael L Holly

Shung H Sung

Stephen R Koshorek

Rao Mallikarjuna Chalasani

Matthew T Doescher

Kee Hyuk Im

Robert B Ruokolainen

Charon L Morgan

Lisa G Devoe

Donna Y Sekulovski

A lamination pack for a motor and method of forming the lamination pack is provided. The method includes inserting a plurality of conductor bars into a plurality of rotor slots defined by a lamination stack such that opposing bar ends of the conductor bars extend from opposing end faces of the lamination stack, skewing the lamination stack and the conductor bars to a skew angle relative to a rotation axis of the lamination stack, and subsequently bending the bar ends of the conductor bars in opposing radial directions to a locking angle greater than the skew angle, to lock each of the conductor bars in its respective rotor slot. The bent bar ends exert a compressive axial locking force on the lamination stack to prevent axial and radial movement of the laminations in the lamination stack and to prevent axial movement of the conductor bars relative to the lamination stack.

Lamination pack and method of forming same

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.

Rotor and method of forming

Rotor casting

A method of forming a rotor includes inserting a conductor bar into a slot defined by a lamination stack to define a gap between the conductor bar and the lamination stack. The method further includes, after inserting, swelling the conductor bar within the slot to fill the gap and form the rotor. A rotor is also disclosed.

Rotor and method of forming same

A ferritically nitrocarburized rotational member of a vehicle brake is disclosed, including a rotational member having a friction surface configured for braking engagement with a corresponding friction material. A compound zone is disposed at the friction surface. An exposed surface of the compound zone is exposed to an atmosphere. The area of the exposed surface includes from about 0 percent to about 14 percent graphite.

Friction brake component and method for manufacturing the same

Lamination pack for skewed conductor bars and method of forming same

One embodiment of the invention includes a frictional damping insert including a body constructed and arranged to be incorporated into a product and to provide frictional damping of the product, the body including lines of weakness constructed and arranged to segment the body into separate sections upon exposure to a molten material.

Inserts with holes for damped products and methods of making and using the same

One embodiment includes a damped product including a first portion, a second portion, a first cavity formed in one of the first portion or the second portion, and a frictional damping insert at least partially received in the first cavity so that the first portion and the second portion completely enclose the frictional damping insert and so that vibration of the product is damped by the insert.

Method of manufacturing a damped part

A method including positioning an insert in a vertical mold including a first mold portion and a second mold portion; and casting a material including a metal around at least a portion of the insert.

Method of casting damped part with insert

One exemplary embodiment may include a product including a first brake rotor cheek having a first body and at least a first outer surface. A first hardened region may extend from the first outer surface towards the center of the body. In one embodiment, the first hardened region may include a nitro-carburized ferrous metal.

Mass reduction of brake rotors

A method is disclosed for forming a brake rotor including a desired custom marking having a predetermined size and shape. The method includes applying a chemical treatment to a marking portion of a surface of the rotor. The marking portion has a size and shape corresponding to the predetermined size and shape of the desired custom marking. The chemical treatment is configured to affect, in a predetermined manner, an ability of a stimulus, to which the rotor is to be exposed, to alter properties of the rotor. The method also includes exposing the rotor, having the chemical treatment applied thereto, to the stimulus. The stimulus alters properties of the rotor at the marking portion differently than the stimulus alters properties of the rotor at other portions of the rotor adjacent the marking portion, thereby forming physical differences in the rotor, which, being visually perceptible, form the custom marking.

Brake rotors having a custom designer feature and methods for forming the same

A method for fabricating a rotor for an induction motor includes disposing a first flux material on a plurality of first exposed ends of a respective plurality of conductor bars of a rotor core. A second flux material is disposed on a first end face of the rotor core. A first portion of a conductive material is cast over the plurality of first exposed ends to form a first shorting end ring to electrically and mechanically connect the plurality of conductor bars.

Method for fabricating rotor for induction motor

A multi-piece sound dampened brake rotor comprises a relatively light weight hub with a hub flange and a heavier rotor body with a sound damping insert and a rotor body flange. The hub and rotor body are attached at their flanges. The flanges may be mechanically attached such as with bolts. Or the hub and rotor may be attached by casting the hub of a lower melting metal alloy against the rotor body and rotor body flange. The rotor body may have vanes for air cooling and a sound damping insert may be incased in either or both body portions sandwiching the vanes.

Low mass multi-piece sound dampened article

One exemplary embodiment of a brake rotor includes a cheek member, an intermediate portion, and a hub member. The intermediate portion may be located between the cheek and hub members, and may extend from either the cheek member or the hub member. The intermediate portion may have an exposed section with multiple openings located in the exposed section. The intermediate portion may also have multiple blades extending from inner surfaces of all or some of the openings. The blades cause airflow to pass through the openings to cool the intermediate portion.

Brake rotor with intermediate portion

A light-weight, sound-damped, composite brake rotor for a vehicle braking system includes a rotor hat and an annular rotor cheek supported by, and cast around, the rotor hat. The rotor hat includes an axially-protruding central hub and an integral flange that extends radially from and circumferentially around the central hub. The rotor cheek includes a top ledge and a bottom ledge that overly a top annular surface and a bottom annular surface, respectively, of the integral flange. An annular interfacial boundary present between an underside of the top and/or bottom ledges and their respective adjacent annular surfaces of the integral flange includes a vibration damping interface. The brake rotor derives its vibration-deadening and sound-damping effects from the vibration damping interface through the occurrence of relative frictional contacting movement.

Light-weight and sound-damped brake rotor and method of manufacturing the same

Growing community of inventors

West Bloomfield, MI, United States of America

Michael D Hanna