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: 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: An electrical machine includes a rotor including windings circumferentially spaced apart by rotor wedges. The electrical machine includes a rotor end plate mounted to the rotor. The rotor end plate includes an annular end plate body with an interior surface and axially opposed exterior surface. The interior surface includes a cavity for engaging the rotor. The interior surface has a base that is bounded by an inner rim and an outer rim radially opposite the inner rim. The interior surface is free of anti-rotation projections extending axially therefrom. The outer rim is free of anti-rotation features extending radially inward therefrom.

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 pack for a generator has an exciter rotor rotating with a shaft. A rectifier assembly is in electric communication with the exciter rotor to receive AC current and rectify the AC current into a DC voltage. Positive and negative busses extend from the rectifier assembly to a negative rail and a positive rail on a connection assembly. The negative rail is in contact with the shaft to provide a ground connection. The negative and positive rails are formed of a metal. The negative and positive rails are connected to a main field winding. A high speed generator is also disclosed.

Abstract: A rotating resistor assembly for use in a rotating shaft of an electrical machine can include a first housing configured to contact the rotating shaft and be grounded to the rotating shaft. The first housing can include a first bus bar connection aperture configured to receive a first bus bar. The assembly can include a second housing configured to connect to the first housing. The second housing can be configured to be insulated from the rotating shaft and to be insulated from direct electrical connection with the first housing. The second housing can include a second bus bar connection aperture configured to receive a second bus bar. The assembly can include a suppression resistor disposed between the first housing and the second housing and in electrical communication with the first housing and the second housing to provide an electrical pathway between first housing and the second housing.

Abstract: A multiphase switched flux electric machine including a rotary drive shaft, a ferromagnetic salient pole rotor assembly operably coupled to the rotary drive shaft having a plurality of rotor teeth defining a circumferential outer periphery of the rotor assembly, and a stator assembly. The stator assembly includes a ferromagnetic stator core, a plurality of permanent magnets positioned substantially equidistant about an inner circumference of the stator core, a plurality ferromagnetic stator teeth mounted to the permanent magnets on the stator core with distal ends forming an inner periphery of the stator assembly, the inner periphery proximate the outer axial periphery of the rotor assembly separated by an air gap; and a plurality of stator coils with an axial active portions disposed within selected teeth of the plurality of ferromagnetic stator teeth.

Abstract: A method of manufacturing a rotor of an electric motor or an electric generator includes positioning a plurality of amortisseur bars and using additive manufacturing to place electrically conductive material. More specifically, positioning the amortisseur bars may include circumferentially positioning the bars around a rotor stack and using additive manufacturing to place electrically conductive material may include forming a non-solid pattern of electrically conductive material, such as a pattern of electrically conductive traces, across opposite axial ends of the rotor stack to electrically interconnect an amortisseur circuit.

Abstract: A core for an electric machine includes a core body with a tooth arranged along a rotation axis, a winding with a flat wire coil fixed to the core body and seated on the tooth of the core body, and a flat wire jumper. The flat wire jumper is supported by the core body and is connected to the flat wire coil to place the flat wire coil in electrical communication with flat wire coils of the winding. Methods of making cores with flat wire jumpers and generators having cores with flat wire jumpers are also described.

Abstract: A rotor for an electrical machine includes a rotor core having a plurality of circumferentially spaced apart rotor poles. Windings are seated in gaps between circumferentially adjacent pairs of the rotor poles. A wedge secures the windings in each gap. The wedge includes a first member made of a first material and at least one second member made of a second material. The second material has a higher electrical conductivity than the first material. The wedge is configured to supply Q-axis damping. A pair of end plates is connected electrically to the at least one second member at opposing longitudinal ends thereof thereby completing a Q-axis winding circuit for each wedge.

Abstract: A wedge for securing windings in a slot in the rotor poles of a rotor core of an electrical machine includes an elongate wedge body extending in an axial direction along a longitudinal axis. The wedge body includes layers perpendicular to the axial direction. The layers vary in electrical conductivity from layer to layer to inhibit eddy currents within the wedge body.

Abstract: A rotating resistor assembly for use in a rotating shaft of an electrical machine can include a first housing configured to contact the rotating shaft and be grounded to the rotating shaft. The first housing can include a first bus bar connection aperture configured to receive a first bus bar. The assembly can include a second housing configured to connect to the first housing. The second housing can be configured to be insulated from the rotating shaft and to be insulated from direct electrical connection with the first housing. The second housing can include a second bus bar connection aperture configured to receive a second bus bar. The assembly can include a suppression resistor disposed between the first housing and the second housing and in electrical communication with the first housing and the second housing to provide an electrical pathway between first housing and the second housing.

Abstract: A rotor of a generator includes a plurality of permanent magnets and at least one magnetic band. The plurality of permanent magnets is arranged about an axis such that magnetic poles of the plurality of permanent magnets are radially oriented in regard to the rotor. The at least one magnetic band is disposed on a surface of the rotor such that magnetic poles of the magnetic band are between 1 degree and 90 degrees from being axially oriented in regard to the rotor.

Abstract: A method of manufacturing a rotor of an electric motor or an electric generator includes positioning a plurality of amortisseur bars and using additive manufacturing to place electrically conductive material. More specifically, positioning the amortisseur bars may include circumferentially positioning the bars around a rotor stack and using additive manufacturing to place electrically conductive material may include forming a non-solid pattern of electrically conductive material, such as a pattern of electrically conductive traces, across opposite axial ends of the rotor stack to electrically interconnect an amortisseur circuit.

Abstract: A method of manufacturing a rotor of an electric motor or an electric generator includes positioning a plurality of amortisseur bars and using additive manufacturing to place electrically conductive material. More specifically, positioning the amortisseur bars may include circumferentially positioning the bars around a rotor stack and using additive manufacturing to place electrically conductive material may include forming a non-solid pattern of electrically conductive material, such as a pattern of electrically conductive traces, across opposite axial ends of the rotor stack to electrically interconnect an amortisseur circuit.

Abstract: A lamination for an electrical machine lamination stack includes a body defining a plurality of winding slots on an inner diameter thereof and at least one inner diameter cleat aperture defined by the body configured to receive a cleat in an unlocked position and to interfere with the cleat when the cleat is transitioned to a locked position within the inner diameter cleat aperture such that a plurality of laminations can be stacked and locked together by the cleat.

Abstract: An electrical machine includes a rotor including windings circumferentially spaced apart by rotor wedges. The electrical machine includes a rotor end plate mounted to the rotor. The rotor end plate includes an annular end plate body with an interior surface and axially opposed exterior surface. The interior surface includes a cavity for engaging the rotor. The interior surface has a base that is bounded by an inner rim and an outer rim radially opposite the inner rim. The interior surface is free of anti-rotation projections extending axially therefrom. The outer rim is free of anti-rotation features extending radially inward therefrom.

Abstract: A resistor pack assembly comprising: a positive rail having a circular face; a negative rail having an inner circular face and an outer circular face located radially outward from inner circular face; an insulator ring having a first circular face and a second circular face opposite first circular face, the second circular face contacts the outer circular face of the negative rail; a first DC bus bar electrically connected to the insulator ring; a second DC bus bar electrically connected to negative rail; and a cylindrical suppression resistor having a first flat surface and a second flat surface opposite the first flat surface, the cylindrical suppression resistor is located radially inward of the insulator and axially between the positive rail and negative rail, wherein the first flat surface contacts the circular face of the positive rail and the second flat surface contacts the inner circular face of the negative rail.

Abstract: A rotor of a generator includes a plurality of permanent magnets and at least one magnetic band. The plurality of permanent magnets is arranged about an axis such that magnetic poles of the plurality of permanent magnets are radially oriented in regard to the rotor. The at least one magnetic band is disposed on a surface of the rotor such that magnetic poles of the magnetic band are between 1 degree and 90 degrees from being axially oriented in regard to the rotor.

Abstract: A wedge for securing windings in a slot in the rotor poles of a rotor core of an electrical machine includes an elongate wedge body extending in an axial direction along a longitudinal axis. The wedge body includes layers perpendicular to the axial direction. The layers vary in electrical conductivity from layer to layer to inhibit eddy currents within the wedge body.