Abstract: A multi-pole electric machine rotor assembly includes a rotor forging including a rotor body having poles 13 with pole faces and a winding module including a plurality of field windings positioned adjacent the pole faces and winding insulators disposed between each successive pair of the field windings, respectively. A winding block, disposed in engagement with the winding module, is shaped to be shifted to a final position relative to the winding module when the rotor assembly rotates at about its rated speed to thereby compress the winding module. Either the winding block or the winding module can be displaced by centrifugal forces during rotation. In the final position, the winding block is locked by friction in a position to maintain compression in the winding module. The winding block serves to provide a pre-stress in the field windings to keep the field windings tight over the design range of spin speeds, thereby controlling winding position and reducing alternating radial movement.

Abstract: A method is disclosed for fitting a rotor enclosure over at least one assembly of field windings mounted on a rotor core, said method comprising the steps: applying a force to elastically reduce a circumference of the at least one assembly of field windings mounted on the rotor core, where the reduction in circumference is greater than a circumference reduction due to just eliminating clearances between adjacent end-turns of windings; generating a clearance between the field windings and the rotor enclosure due to the application of the force; axially sliding the rotor enclosure over the at least one assembly of field windings while the circumference is reduced, and releasing the force to allow the circumference of the at least one assembly of field windings to expand and cause the enclosure to tightly fit on the at least one assembly of field windings.

Abstract: A rotor for a rotating electrical machine includes pole faces arranged at locations on either side, respectively, of the rotor D-axis and fins arranged along the rotor Q-axis. The fins increase a section bending moment of inertia along the Q-axis, thereby reducing the need for deep slots in the pole faces extending along the D-axis, resulting in better symmetry of bending stiffness.

Abstract: A method is disclosed for fitting a rotor enclosure over at least one assembly of field windings mounted on a rotor core, said method comprising the steps: applying a force to elastically reduce a circumference of the at least one assembly of field windings mounted on the rotor core, where the reduction in circumference is greater than a circumference reduction due to just eliminating clearances between adjacent end-turns of windings; generating a clearance between the field windings and the rotor enclosure due to the application of the force; axially sliding the rotor enclosure over the at least one assembly of field windings while the circumference is reduced, and releasing the force to allow the circumference of the at least one assembly of field windings to expand and cause the enclosure to tightly fit on the at least one assembly of field windings.

Abstract: A winding assembly for a rotor is disclosed comprising a plurality of rotor field windings and a field support holding said plurality of windings in said winding assembly, wherein the winding assembly is mountable on said rotor.

Abstract: A winding module for an electric machine is provided wherein the winding module comprises a flat field winding that is angled at an end turn and wherein a vertex of the flat field winding is aligned with an axis of rotation. The vertex provides a predetermined axial offset so as to compensate for a radial expansion of the flat field winding when it is disposed to a centrifugal force.

Abstract: A generator rotor includes a rotor body having defined pole regions with pole faces and parallel sides adjacent the pole faces. A winding module is fitted over the parallel sides of the rotor body, and a pair of spindles are secured to respective ends of the rotor body. The spindles secure opposite sides of the winding module to the rotor body. The spindles preferably include a notch that is shaped to receive one side, respectively, of the winding module. With this construction, flat windings can be used for the winding module, eliminating the need for a curved module to fit over the spindle.

Abstract: A cooling gas ventilation circuit is provided for an end winding of a rotary machine having a rotor of the type having a plurality of radial slots and a plurality of coils respectively seated in the radial slots, the coils extending beyond a pole face of the rotor to form the end winding. The ventilation circuit is composed of first and second cooling gas passages, respectively defined in at least one turn of each coil of the end winding. Each first cooling gas passage extends from an inlet port in communication with a cavity on one longitudinal side of the turn to an exit port defined on the other longitudinal side of the turn. Each second cooling gas passage extends from an inlet port in communication with the cavity on the one longitudinal side of the turn to an outlet in the form of a radial chimney defined through a plurality of the turns of the coil within the respective radial slot.

Abstract: An end turn arrangement for turns in a rotor where individual windings are stacked in tapered radial slots in the rotor, with successive turns having a smaller width in a radial inward direction, the end turns of the individual turns of each stack being vertically aligned along a common edge. The end turns are separated by blocking separators, each including a first anchor component having a first planar exterior surface and a second planar interior engagement surface; and a second slide component having a first non-planar exterior surface and a second planar interior engagement surface; the anchor and slide components having mating guide elements permitting the anchor and slide components to move relative to each other along a straight assembly path.

Abstract: An end turn arrangement for turns in a rotor where individual windings are stacked in tapered radial slots in the rotor, with successive turns having a smaller width in a radial inward direction, the end turns of the individual turns of each stack being vertically aligned along a common edge. The end turns are separated by blocking separators, each including a first anchor component having a first planar exterior surface and a second planar interior engagement surface; and a second slide component having a first non-planar exterior surface and a second planar interior engagement surface; the anchor and slide components having mating guide elements permitting the anchor and slide components to move relative to each other along a straight assembly path.

Abstract: A creepage block for a turbine rotor slot in which coil windings are embedded, wherein the creepage block is sandwiched between the windings and a wedge block, and wherein aligned radial cooling passages are formed in axially spaced locations in the windings and the wedge block. The creepage block includes a pair of solid half blocks in substantially parallel relationship, the blocks held in laterally spaced relation by a plurality of discrete spacers which may be dowel pins.