Abstract: A rotor assembly for an electric machine includes a first end and a second end, the second end distal from the first end in an axial direction, a first radial wall extending between the first end and the second end and defining an inner cavity, and a second radial wall extending between the first end and the second end, the second radial wall radially-overlying the first radial wall and defining an outer cavity between the first radial wall and the second radial wall.

Abstract: A rotor assembly for an electric machine is disclosed. The rotor core has a cylindrical body defining an outwardly facing peripheral surface comprising a slotted portion including a set of slots defined by a set of rotor teeth projecting outwardly from the peripheral surface. Each rotor tooth comprises a respective first distal tip and a respective first radial length extending radially from a center point of the rotor core to the first distal tip. The peripheral surface further comprises a non-slotted portion defining a respective second radial length, extending radially from the center point of the rotor core to the outwardly facing peripheral surface. The first radial length is less than the second radial length.

Abstract: A method of cooling rotor winding end turns extending from a rotor core includes coupling a collar to a rotatable shaft of the rotor core. The collar has a first wall confronting the rotor core, a second wall spaced from and opposing the first wall, a third wall between the first and second walls defining a set of apertures therethrough, a first cavity cooperatively defined by the first, second and third walls, having a first opening opposing the third wall, a fourth wall circumscribing the third wall, a second cavity cooperatively defined by the second, third and fourth walls, the second cavity defining a second opening opposing the second wall. The first and second cavities are in fluid communication, and the rotor winding end turns are receivable into the second cavity. The method includes directing a coolant into the first cavity, and delivering the coolant to the second cavity.

Abstract: A method of cooling a set of rotor winding end turns of a rotor assembly can include directing a fluid coolant flow to a coil support assembly, delivering the fluid coolant flow, by a first coolant distribution ring of the coil support assembly, radially outward toward rotor winding end turns; and delivering the fluid coolant flow, by a coil support disc of the coil support assembly, axially outward toward the rotor winding end turns. The method can further include expelling fluid coolant flow by a second coolant distribution ring radially outward toward a set of stator windings, and expelling, by the coil support disc, the fluid coolant flow axially outward toward the rotor core.

Abstract: A rotor assembly for an electric machine is disclosed. The rotor core has a cylindrical body defining an outwardly facing peripheral surface comprising a slotted portion including a set of slots defined by a set of rotor teeth projecting outwardly from the peripheral surface. Each rotor tooth comprises a respective first distal tip and a respective first radial length extending radially from a center point of the rotor core to the first distal tip. The peripheral surface further comprises a non-slotted portion defining a respective second radial length, extending radially from the center point of the rotor core to the outwardly facing peripheral surface. The first radial length is less than the second radial length.

Abstract: A rotor assembly includes a rotor core having a rotatable shaft and defining at least one rotor post, a winding wound around the post that defines an end turn, and a coil support assembly including a coil support disc rotatably coupled to the rotatable shaft and comprising a radially inner portion and a radially outer portion coupled via a set of spokes. The radially outer portion overlies an end turn and defines a set of channels therethrough sized and disposed to receive a flow of fluid from the set of rotor windings.

Abstract: A rotor assembly comprises a rotor core comprising a first end and an opposing second end, and an outwardly facing peripheral surface having a set of rotor teeth projecting outwardly therefrom to define a set of rotor slots therebetween. Each rotor tooth can comprise a first rotor tooth wall, an opposing second rotor tooth wall, and a distal tip between the first rotor tooth wall and second rotor tooth wall. Each respective rotor slot can be defined by a respective first rotor tooth wall of a first rotor tooth, and a respective second rotor tooth wall of a second rotor tooth, and includes a first rotor core conduit extending axially along a length of the first rotor tooth. The first rotor core conduit can comprise a first rotor core conduit inlet at the rotor core first end and a first rotor core conduit inlet at the rotor core second end, the rotor core conduit defining a first taper that is narrower at first rotor core conduit inlet than the first rotor core conduit outlet.

Abstract: A method and apparatus for a rotor assembly. The rotor assembly includes a rotor core having a rotatable shaft and defining at least one rotor post, a winding wound around the post that defines an end turn, and at least one coolant conduit defined in part by an end support and in a thermally conductive relationship with a portion of the winding.

Abstract: A starter/generator system that includes a first and second electric machine. The first electric machine has a first rotor and a first stator where the first rotor is adapted to receive kinetic energy and the first stator includes a first set of windings. The second electric machine has a second rotor rotatable and a second stator. The second stator is fixed relative to the first stator and the second stator includes a second set of windings.

Abstract: A rotating rectifier associated with an electric machine is provided. In one example aspect, a rotating rectifier includes a diode. The diode can be one diode of a stage of diodes. The rotating rectifier can also include a connection lead, such an exciter connection lead. The connection lead has a diode contact segment in contact with the diode and a first spring segment and a second spring segment positioned on opposite sides of the diode contact segment. The first spring segment and the second spring segment can be positioned adjacent to the diode contact segment. The first spring segment and the second spring segment each have one or more spring laps. The spring laps can be non-planar spring laps, such as undulating spring laps.

Abstract: A method and apparatus for a rotor assembly. The rotor assembly includes a rotor core having a rotatable shaft and defining at least one rotor post, a winding wound around the post that defines an end turn, and at least one coolant conduit defined in part by an end support and in a thermally conductive relationship with a portion of the winding.

Abstract: A starter/generator system that includes a first and second electric machine. The first electric machine has a first rotor and a first stator where the first rotor is adapted to receive kinetic energy and the first stator includes a first set of windings. The second electric machine has a second rotor rotatable and a second stator. The second stator is fixed relative to the first stator and the second stator includes a second set of windings.

Abstract: A rotor assembly includes a rotor core having winding slots, and one or more coils, which have slot-inserted segments included in the winding slots, and first and second end-turn segments external to the winding slots and located around opposite axial ends of the rotor core, respectively. The rotor assembly further includes a first containment band located around at least a portion of the first end-turn segments and configured to prevent the first end-turn segments from moving away from the rotor core radially, a second containment band located around at least a portion of the second end-turn segments and configured to prevent the second end-turn segments from moving away from the rotor core radially, and one or more sticks mounted in one or more of the winding slots, respectively. The first and second containment bands are retained via the sticks against moving away axially.

Abstract: A rotor for an electric machine includes a core having circumferentially-spaced, axially-extending posts, and defining an axial passage, a winding carried by each of the posts and comprising an electrically-conductive wire repeatedly wound around the post such that a portion of the winding extends axially beyond the post to define an overhang with upper and lower surfaces connected by an end, and a hollow shaft defining a rotor inner surface and a rotor outer surface.

Abstract: A method and apparatus for a rotor assembly. The rotor assembly includes a rotor core having a rotatable shaft and defining at least one rotor post, a winding wound around the post that defines an end turn, and at least one coolant conduit defined in part by an end support and in a thermally conductive relationship with a portion of the winding.

Abstract: A method and apparatus for cooling a rotor assembly includes a rotor core having a rotatable shaft and defining at least one rotor post, a winding wound around the post, and at least one coolant conduit supported by the rotor core and in a thermally conductive relationship with a portion of the winding.

Abstract: A rotor for an electric machine includes a core having circumferentially-spaced, axially-extending posts, and defining an axial passage, a winding carried by each of the posts and comprising an electrically-conductive wire repeatedly wound around the post such that a portion of the winding extends axially beyond the post to define an overhang with upper and lower surfaces connected by an end, and a hollow shaft defining a rotor inner surface and a rotor outer surface.

Abstract: An electrical machine and method of forming includes electroforming a first set of metal laminates having a first predetermined geometry. The method also includes arranging an insulating layer between each in the first set of metal laminates in a stack to define a layered component having the first predetermined geometry.

Abstract: A method and apparatus for a rotor assembly. The rotor assembly includes a rotor core having a rotatable shaft and defining at least one rotor post, a winding wound around the post that defines an end turn, and at least one coolant conduit defined in part by an end support and in a thermally conductive relationship with a portion of the winding.

Abstract: A rotor assembly includes a rotor core having winding slots, and one or more coils, which have slot-inserted segments included in the winding slots, and first and second end-turn segments external to the winding slots and located around opposite axial ends of the rotor core, respectively. The rotor assembly further includes a first containment band located around at least a portion of the first end-turn segments and configured to prevent the first end-turn segments from moving away from the rotor core radially, a second containment band located around at least a portion of the second end-turn segments and configured to prevent the second end-turn segments from moving away from the rotor core radially, and one or more sticks mounted in one or more of the winding slots, respectively. The first and second containment bands are retained via the sticks against moving away axially.