Abstract: A generator system can include a generator control unit (GCU) configured to control a generator output of a generator. The GCU can be configured to monitor the generator output for overvoltage and attenuate an overvoltage by directing at least a portion of the generator output to a heater element. The GCU can be configured to cause voltage division of the generator output between the GCU and the heater element if an overvoltage is detected to protect one or more GCU electrical components.

Abstract: An electric machine assembly includes a rotor core. The rotor core includes a plurality of winding poles extending between a first axial face and a second axial face of the rotor core. A clench lock slot is defined in the first axial face. The clench lock slot includes a first channel section having a first channel width, a second channel section having a width equal to the first channel width, and a converging-diverging section connecting between the first channel section and the second channel section. A first end of the converging-diverging section connects to the first channel section and has a width equal to the first channel width. A second end of the converging-diverging section connects to the second channel section and has a width equal to the first channel width. A clench point of the converging-diverging section is defined where the converging-diverging section is narrowest.

Abstract: An assembly comprises a resistor support housing for a rotating rectifier assembly (RRA). A shaft bore is defined through the resistor support housing for passage of a shaft of an electrical machine. The resistor support housing defines a main annular body around the shaft bore. An end housing is mounted to one axial end of the resistor support housing. The end housing defines a portion of the shaft bore therethrough.

Abstract: A permanent magnet generator (PMG) system can include a stator configured to output a voltage, and a rotor assembly configured to be magnetically coupled to the stator and to rotate relative to the stator to induce the voltage. The rotor assembly can be configured to passively attenuate the voltage output from the stator in response to acceleration of the rotor assembly at or above an impulse acceleration threshold.

Abstract: An assembly comprises a resistor plate for a rotating rectifier assembly (RRA). A shaft bore is defined through the resistor plate for passage of a shaft of an electrical machine, and the resistor plate defines a main annular body around the shaft bore. A first protrusion extends radially outward from the main annular body, so that a first pin bore extends through the first protrusion. At least one contact band is seated in a the pin bore of the resistor plate for mounting a direct current (DC) pin to the resistor plate.

Abstract: An assembly comprises an AC (alternating current) housing connection block and a plurality of inserts seated in the AC housing connection block, wherein for each of the inserts, an interface between the insert and the housing is continuous. A method includes inserting a plurality of inserts into a mold; and molding an AC (alternating current) housing connection block.

Abstract: A permanent magnet generator (PMG) system can include a stator configured to output a voltage, and a rotor assembly configured to be magnetically coupled to the stator and to rotate relative to the stator to induce the voltage. The rotor assembly can be configured to passively attenuate the voltage output from the stator in response to acceleration of the rotor assembly at or above an impulse acceleration threshold.

Abstract: An assembly comprises a mounting ring for a rotating rectifier assembly (RRA) having a pin bore defined in the mounting ring oriented in an axial direction and at least one contact band seated in a the pin bore of the mounting ring for mounting a direct current (DC) pin to the mounting ring. A method comprises forming a mounting ring for a rotating rectifier assembly (RRA), including forming a pin bore in the mounting ring oriented in an axial direction, and installing at least one contact band into a the pin bore of the mounting ring.

Abstract: A diode pack housing for a rotating rectifier assembly can include a body having an interior surface defining an interior cavity open on a first end and configured to contain a diode pack and a plurality of bus bar channels defined axially on or in the inner surface in the interior cavity. The plurality of bus bar channels can be five or less bus bar channels.

Abstract: A main field connection to connect to a main field winding has a semi-cylindrical portion with an axially thicker outer surface, an axially thinner inner surface, with an aperture. An extending portion extends from the semi-cylindrical portion to a remote extending end. The remote extending end extends for a first axial distance. The axially thicker portion of the semi-cylindrical portion extends for a second axial distance. A ratio of the first axial distance to the second axial distance is between 0.65 and 1.4. A rotating assembly, a generator and a method are also disclosed.

Abstract: A rotor having multiple poles is provided and includes at each pole an end winding support forming a channel, a bus bar disposed in the channel and edge-wound coils disposed to extend around the end-winding support and the bus bar. The edge-wound coils are stacked radially and include an inner diameter coil routed to an adjacent pole and brazed to an inner diameter coil of the adjacent pole and an outer diameter coil brazed to the bus bar.

Abstract: A resistor pack assembly including an anti-rotation housing. The anti-rotation housing includes a first surface, a second surface opposite the first surface, one or more anti-rotation lugs extending away from the first surface, and an internal cavity extending from the second surface into the anti-rotation housing towards the first surface. The resistor pack assembly also including a positive rail located at least partially within the internal cavity, a negative rail having an inner circular face and an outer circular face located radially outward from the inner circular face, and an insulator ring is interposed between the second surface of the anti-rotation housing and the outer circular face of the negative rail.

Abstract: An assembly comprises a resistor plate for a rotating rectifier assembly (RRA). A shaft bore is defined through the resistor plate for passage of a shaft of an electrical machine, and the resistor plate defines a main annular body around the shaft bore. A first protrusion extends radially outward from the main annular body, so that a first pin bore extends through the first protrusion. At least one contact band is seated in a the pin bore of the resistor plate for mounting a direct current (DC) pin to the resistor plate.

Abstract: An assembly comprises an AC (alternating current) housing connection block and a plurality of inserts seated in the AC housing connection block, wherein for each of the inserts, an interface between the insert and the housing is continuous. A method includes inserting a plurality of inserts into a mold; and molding an AC (alternating current) housing connection block.

Abstract: An assembly comprises a mounting ring for a rotating rectifier assembly (RRA) having a pin bore defined in the mounting ring oriented in an axial direction and at least one contact band seated in a the pin bore of the mounting ring for mounting a direct current (DC) pin to the mounting ring. A method comprises forming a mounting ring for a rotating rectifier assembly (RRA), including forming a pin bore in the mounting ring oriented in an axial direction, and installing at least one contact band into a the pin bore of the mounting ring.

Abstract: An assembly comprises a resistor support housing for a rotating rectifier assembly (RRA). A shaft bore is defined through the resistor support housing for passage of a shaft of an electrical machine. The resistor support housing defines a main annular body around the shaft bore. An end housing is mounted to one axial end of the resistor support housing. The end housing defines a portion of the shaft bore therethrough.

Abstract: A main field connection to connect to a main field winding has a semi-cylindrical portion with an axially thicker outer surface, an axially thinner inner surface, with an aperture. An extending portion extends from the semi-cylindrical portion to a remote extending end. The remote extending end extends for a first axial distance. The axially thicker portion of the semi-cylindrical portion extends for a second axial distance. A ratio of the first axial distance to the second axial distance is between 0.65 and 1.4. A rotating assembly, a generator and a method are also disclosed.

Abstract: A rotor having multiple poles is provided and includes at each pole an end winding support forming a channel, a bus bar disposed in the channel and edge-wound coils disposed to extend around the end-winding support and the bus bar. The edge-wound coils are stacked radially and include an inner diameter coil routed to an adjacent pole and brazed to an inner diameter coil of the adjacent pole and an outer diameter coil brazed to the bus bar.

Abstract: A rectifier assembly includes a terminal arranged along an assembly axis, a mounting ring axially offset from the terminal and seating a diode, a bus bar received within the mounting ring and electrically connecting the diode to the terminal through the bus bar, and a mounting ring. The mounting ring insulator receives the bus bar, is axially offset from the mounting ring, and contains an insert. The insert fixes the bus bar to the mounting ring insulator and compressively fixing the diode within the mounting ring. Generators and methods of making rectifier assemblies for generators are also described.

Abstract: A main field connection to connect to a main field winding has a semi-cylindrical portion with an axially thicker outer surface, an axially thinner inner surface, with an aperture. An extending portion extends from the semi-cylindrical portion to a remote extending end. The remote extending end extends for a first axial distance. The axially thicker portion of the semi-cylindrical portion extends for a second axial distance. A ratio of the first axial distance to the second axial distance is between 0.65 and 1.4. A rotating assembly, a generator and a method are also disclosed.