Abstract: A shaft assembly includes a shaft with magnets surrounding the shaft, and thermal conducting disks coupled to the shaft, and coupled to two ends of the magnets.

Abstract: A cooling system for an electrical motor or generator includes a first cooling loop, a second cooling loop, and a heat exchange system. The first cooling loop may extract heat from an iron stack and winding of the electrical motor or generator. The second cooling loop may extract heat from end turns of the stator winding, the rotor, and the bearings independently from and simultaneously to the first cooling loop. At least the first cooling loop may pass through the heat exchange system. A liquid coolant may circulate in the first cooling loop and a compressed gas, such as compressed air or compressed refrigerant in vapor form, may circulate in the second cooling loop. The cooling system and method for an electrical motor or generator may be suitable for, but not limited to, applications in the aircraft and aerospace industries, such as driving a cabin air compressor of an aircraft.

Abstract: A method for manufacturing a rotor assembly. The method includes providing a stub shaft having a first part and a second part, providing a magnet between the first part and the second part, and compressing the magnet between the first part and the second part using a connecting device. The method also includes drilling a hole through the first part and the magnet, cooling an inner shaft, and inserting the inner shaft into the hole.

Abstract: A cooling system for an electrical motor or generator includes a first cooling loop, a second cooling loop, and a heat exchange system. The first cooling loop may extract heat from an iron stack and winding of the electrical motor or generator. The second cooling loop may extract heat from end turns of the stator winding, the rotor, and the bearings independently from and simultaneously to the first cooling loop. At least the first cooling loop may pass through the heat exchange system. A liquid coolant may circulate in the first cooling loop and a compressed gas, such as compressed air or compressed refrigerant in vapor form, may circulate in the second cooling loop. The cooling system and method for an electrical motor or generator may be suitable for, but not limited to, applications in the aircraft and aerospace industries, such as driving a cabin air compressor of an aircraft.

Abstract: The present invention provides an apparatus and methods for providing constant voltage from a permanent magnet generator at varying prime mover speeds or under varying loads. A constant voltage permanent magnet generator includes a housing, a magnetized rotor, a prime mover operationally coupled with the rotor, a stator, a main winding coupled to the stator, and an excitation winding also coupled to the stator. A controllable three-phase inverter may be coupled to the excitation winding and a control system operationally coupled to the main winding for measuring the voltage of the main winding. The control system is further operationally coupled between the power source and the controllable three phase inverter to provide a supplemental current to the excitation winding such that a combined current through the main winding and the excitation winding produces a constant voltage from the generator.

Abstract: The present invention provides an apparatus and methods for providing constant voltage from a permanent magnet generator at varying prime mover speeds or under varying loads. A constant voltage permanent magnet generator includes a housing, a magnetized rotor, a prime mover operationally coupled with the rotor, a stator, a main winding coupled to the stator, and an excitation winding also coupled to the stator. A controllable three-phase inverter may be coupled to the excitation winding and a control system operationally coupled to the main winding for measuring the voltage of the main winding. The control system is further operationally coupled between the power source and the controllable three phase inverter to provide a supplemental current to the excitation winding such that a combined current through the main winding and the excitation winding produces a constant voltage from the generator.

Abstract: A method for manufacturing a rotor assembly. The method includes providing a stub shaft having a first part and a second part, providing a magnet between the first part and the second part, and compressing the magnet between the first part and the second part using a connecting device. The method also includes drilling a hole through the first part and the magnet, cooling an inner shaft, and inserting the inner shaft into the hole.

Abstract: An aluminum alloy and a method of making the aluminum alloy comprised of pure aluminum and a casting aluminum. The pure aluminum and casting aluminum are alloyed in appropriate proportions such that the aluminum alloy includes a desired electrical conductivity in the range of about twenty-seven percent (27%) to about fifty-four percent (54%) International Annealed Copper Standard (IACS). Embodiments of the aluminum alloy include a combination of A100 aluminum, and A356 aluminum, A357 aluminum, A360 aluminum, and/or A380 aluminum. The aluminum alloy is made for use in applications where an electrical conductivity less than copper is desired (e.g., wiring cables, cast rotors for induction motors, wound rotors for induction motors, and the like).

Abstract: A flux collector for an electrical machine includes a continuous strand of ferromagnetic material; and an electrical insulator covering the strand. The strand forms a tight cylindrical coil including a plurality of turns that are stacked axially. The insulator provides turn-to-turn insulation. The insulated wire is covered with a binder and cured. The strand can be a high permeability wire made of soft iron, silicon steel or cobalt steel. In the alternative, the strand can be a strip of METGLAS® amorphous alloy.

Abstract: An ac motor controller is operated by a modified time-switching scheme where the switches of the inverter are "on" for electrical-phase-and-rotation intervals of 180.degree. as opposed to the conventional 120.degree.. The motor is provided with three-phase drive windings, a power inverter for power supplied from a dc power source consisting of six switches, and a motor controller which controls the current controlled switches in voltage-fed mode. During full power, each switch is gated continuously for three successive intervals of 60.degree. and modulated for only one of said intervals. Thus, during each 60.degree. interval, the two switches with like signs are "on" continuously and the switch with the opposite sign is modulated.