Abstract: A method of repairing a damaged combustion gas transition liner for a gas turbine engine and an improved damage-resistant transition liner that mounts adjacent to the edge of one of the engine's combustion chambers. In a particular embodiment, the gas turbine engine is a reverse flow type and the transition liner has a scalloped, circular shape with a damaged outer edge portion. The outer edge portion of the liner is removed and replaced with a new ring-shaped edge portion. The new ring-shaped edge portion has a layer of damage-resistant material that is more robust than the original liner material. The layer of damage-resistant material is located such that it will be adjacent to the edge of the combustion chamber when the gas turbine engine is reassembled. A new transition liner assembly with the damage-resistant edge also is provided.

Abstract: An energy storage flywheel system includes a shaft, one or more primary bearing assemblies, and one or more secondary bearing assemblies. A secondary bearing control circuit determines the operability of the primary bearing assemblies and, based on this determination, selectively engages the secondary bearing assemblies to rotationally support the flywheel shaft.

Abstract: A highly reliable, multi-channel control, monitoring, and protection system includes at least three processors in each of the redundant channels, a main processor, and first and second monitor processors. The main processor performs the main control functions, and the monitor processors mirror one or more of the functions performed by the main processor. The processing performed in the main processor and the monitor processors is continuously compared to determine whether control needs to be shifted to one of the other redundant channels.

Abstract: A rotating electrical machine, such as an aircraft starter-generator, that includes an exciter that has its stator windings supplied with electrical power from a power supply. One or more switches are electrically coupled between the exciter stator winding and the power supply and are configured and controlled so that a capacitance may be selectively placed electrically in series with the exciter stator windings.

Abstract: A terminal block assembly for electrical generators, such as high speed AC generators used in aircraft, is made from components that are readily assembled and disassembled for ease of installation, maintenance, and repair. The terminal block assembly is formed of a terminal block and one or more terminal assemblies. The terminal block has a main body with at least an upper surface and a lower surface. A first cavity is formed in the main body lower surface, and an opening that extends through the main body between the upper surface and the first cavity. A threaded fastener is inserted into the opening and into the first cavity, and a bolt is coupled to the fastener to secure the fastener in the opening. Each terminal assembly is coupled to the terminal block and includes one or more electrically conductive terminal plates, feed-throughs, and slugs for connection to stator output leads, that are electrically and mechanically coupled together using electrically conductive fasteners.

Abstract: A high speed generator has its main rotor located within the main generator shaft assembly. The main rotor is mounted on a substantially hollow rotor shaft, which is also mounted within the main generator shaft assembly. The main stator surrounds at least a portion of the main generator shaft assembly. Main rotor cooling supply orifices extend through the rotor shaft. Main stator cooling supply orifices, which are in fluid communication with the main rotor cooling supply orifices, extend through the main generator shaft assembly. Cooling fluid is directed into the main generator shaft assembly, and flows through the main rotor cooling supply orifices and the main stator cooling supply orifices. The main rotor and main stator cooling supply orifices are configured to supply the main rotor and main stator with a cooling fluid spray. This configuration reduces the rotational fluid mass associated with flood-cooled rotors, which increases structural integrity, lowers material stresses, improves rotor dynamics.

Abstract: A flow control valve assembly, and a method of determining and controlling fluid flow through the valve, that is relatively simple in design, is relatively inexpensive, is accurate, and has a relatively wide measurement range. The flow control valve is relatively compact and includes all of the flow measurement and control components in a single, relatively compact assembly. Such components may include a differential pressure sensor, pressure sensor, a temperature sensor, a position sensor, and a processor. The differential pressure sensor senses differential pressure across the variable area flow orifice. The pressure sensor senses fluid pressure within the valve and supplies a fluid pressure signal. The temperature sensor senses fluid temperature and supplies a fluid temperature signal. The position sensor senses the position of the variable area flow orifice and supplies a position signal.

Abstract: An apparatus and method for centering a shaft (for an impeller or other rotating component) in a gas turbine engine, such as that used in aircraft or other vehicles. The apparatus includes a base, at least one arm and an actuator. The arm is connected to the base and the actuator is located on a predetermined axis and aligns the impeller shaft to that axis. The actuator also applies a force to the actuator to simulate actual operational forces in the engine so that proper tolerances can be measured. The method includes steps of coupling the apparatus to a locator surface, impeller shaft with the actuator and moving the actuator such that an axial load is provided on the shaft.

Abstract: An energy storage flywheel system that includes a power connector extending through the flywheel housing assembly and is hermetically sealed thereto. A circuit board, on which is mounted at least a motor/controller circuit, is coupled to the power connector adjacent to the flywheel housing assembly.

Abstract: The coil end-turn segments of a generator exciter rotor are retained using an end-turn retention assembly that includes an inner band and an outer band. The inner band is located around at least a portion of each of the end-turn segments and has two ends. The outer peripheral surface of the inner band is tapered such that the thickness of the inner band varies between its ends. The outer band is located around the inner band and also has two ends. The inner peripheral surface of the outer band is tapered in a fashion that is reverse to that of the inner band outer surface, and such that the outer band thickness varies between its ends. By forming oppositely configured tapers in the inner and outer bands, the outer bands will remain in place and not migrate axially away from the lamination core during exciter rotor rotation.

Abstract: A valve actuator assembly is provided for selectively opening and closing a valve. The valve actuator assembly includes a primary motor and secondary motor both operatively coupled to an output shaft and adapted to receive valve position commands and operable, in response thereto, to selectively drive the output shaft in a valve open or close direction and a tertiary motor adapted to receive a flow of pressurized air and operable, in response thereto, to drive the output shaft in a valve close direction.

Abstract: A system and method for electrically coupling windings of a main generator rotor to a plurality of DC sources on an exciter that each have respective first-voltage and second-voltage terminals is disclosed. The system includes first and second conductive plates supported by the rotor that respectively define first and second apertures that surround a rotor shaft. The first plate includes a first rotor winding terminal by which the plate is electrically coupled to the windings, and a first plurality of terminals configured to be respectively coupled to the first-voltage terminals of the DC sources. The second plate is electrically insulated from the first plate, includes a second rotor winding terminal by which the second plate is electrically coupled to the windings, and includes a second plurality of terminals configured to be respectively coupled to the second-voltage terminals of the DC sources.

Abstract: A new improved system and method for end turn retention for wires on a generator rotor for use in high speed applications such as in aircraft applications. The rotor includes a shaft, spokes, supports, and wire winding coils, and at least one cap device. The spokes extend radially outwardly from the shaft, and each support is positioned on an associated spoke. Each coil wraps around an associated support and spoke. Each cap device is coupled to an end of its associated spoke to prevent the windings from moving radially outwardly while the rotor spins. Each support is coupled to an associated cap device, and includes at its radially inward edge a flange protruding away from the respective spoke. Because of the flange and the cap device, slack of the wire coil between the flange and the associated cap is taken up.

Abstract: An electro-hydraulic thrust reverser lock actuation system includes a hydraulic fluid source and a lock actuator assembly that is configured to selectively pressurize the hydraulic fluid. The lock actuator assembly is adapted to receive a lock control signal and, in response, pressurize the hydraulic fluid in the hydraulic fluid source. One or more lock assemblies are in fluid communication with the hydraulic fluid source and are configured, in response to the hydraulic fluid pressurization, to move to one of a locked or an unlocked position.

Abstract: A solenoid control circuit that includes two switching networks that are selectively opened and closed in a current limit cycle to control the magnitude of the current flowing through the solenoid. The configuration of the switching networks is such that current flows through an energy dissipating resistor only when the solenoid is commanded off by the solenoid control circuit, and not during the current limit cycle. Thus, the energy dissipated by this resistor is reduced relative to other solenoid control circuits, making it more efficient, and reducing EMI emissions from the circuit while providing for a fast solenoid response.

Abstract: A ground-based aircraft electrical power generation system for regulating the electrical power to an aircraft being serviced on the ground. The aircraft electrical power generation system may include a ground power cart, a power source located on the ground power cart and having an output terminal, and a power cable having a proximate end coupled to the output terminal of the power source and a distal end configured to be coupled to the aircraft. The aircraft electrical power generation system further may include a voltage regulator having a plurality of inputs and an output coupled to the power source. The voltage regulator monitors the voltage at the plurality of inputs representing the voltage sensed at multiple points of regulation. A contactor also may be coupled in series between the proximate end of the power cable and the distal end of the power cable.

Abstract: A prognostic health and fault management system and method that accurately determines the health and rate of degradation of one or more flywheel systems, by comparing actual and simulated responses of flywheel systems to supplied command signals. Based on the determined health status and degradation rate of the flywheel systems, one or more unhealthy, active flywheel systems are deactivated, and one or more healthy, deactivated flywheel systems are activated. The system can be used in terrestrial applications, or in vehicles such as satellites, spacecraft, or ships.

Abstract: An apparatus is provided for activating switches in a leading edge flap drive actuator. The apparatus comprises a mount plate having at least a first side, a second side, and an outer peripheral surface, an actuator arm rotationally coupled to the mount plate and rotationally moveable between at least an activate position and a deactivate position, and a spring arm coupled to the mount plate and extending away from the mount plate outer perpheral surface, the spring arm configured to supply a force that biases the actuator arm toward the deactivate position at least when the actuator arm is in the activate position.

Abstract: A flight control actuation system comprises a controller, electromechanical actuator and a pneumatic actuator. During normal operation, only the electromechanical actuator is needed to operate a flight control surface. When the electromechanical actuator load level exceeds 40 amps positive, the controller activates the pneumatic actuator to offset electromechanical actuator loads to assist the manipulation of flight control surfaces. The assistance from the pneumatic load assist actuator enables the use of an electromechanical actuator that is smaller in size and mass, requires less power, needs less cooling processes, achieves high output forces and adapts to electrical current variations. The flight control actuation system is adapted for aircraft, spacecraft, missiles, and other flight vehicles, especially flight vehicles that are large in size and travel at high velocities.

Abstract: Pressure powder metallurgy process for consolidating refractory or rhenium alloys using a reduced temperature and elevated pressure. Rhenium metal has high temperature strength and wear resistance but has a very high melting point as a pure metal and thus is difficult to use as a coating for many alloys having lower melting points. The reduced temperature and elevated pressure alloying process of the rhenium allows it to be used as a coating for other metal alloys, such as nickel and steel alloys, providing some high temperature and wear resistance due to the properties of the rhenium material in the coating.