Abstract: A method of installing a diffuser in an air cycle machine includes placing a first housing on a shaft, placing a seal plate on the shaft, and placing a diffuser on the shaft. Next, the diffuser and the seal plate are aligned with an alignment tool. The alignment tool has a first annular surface to align with a radially outer surface of the seal plate and a second annular surface to align with an annular flange on the diffuser. Finally, the diffuser is fastened to the seal plate and the alignment tool is removed from the diffuser and the seal plate.

Abstract: A vane for a variable diffuser includes a body with an inlet end and an outlet end, a leading surface extending from the inlet end to the outlet end, a trailing surface opposite the leading surface and extending from the inlet end to the outlet end, a first surface extending from the inlet end to the outlet end, and a second surface opposite the first surface and extending from the inlet end to the outlet end. The vane further includes a first cavity on the first surface of the vane adjacent the inlet end, a second cavity on the first surface of the vane adjacent the outlet end, a third cavity on the second surface of the vane adjacent the inlet end, and a fourth cavity on the second surface of the vane adjacent the outlet end.

Abstract: A method of installing a diffuser in an air cycle machine includes placing a first housing on a shaft, placing a seal plate on the shaft, and placing a diffuser on the shaft. Next, the diffuser and the seal plate are aligned with an alignment tool. The alignment tool has a first annular surface to align with a radially outer surface of the seal plate and a second annular surface to align with an annular flange on the diffuser. Finally, the diffuser is fastened to the seal plate and the alignment tool is removed from the diffuser and the seal plate.

Abstract: A method of installing a diffuser in an air cycle machine includes placing a first housing on a shaft, placing a seal plate on the shaft, and placing a diffuser on the shaft. Next, the diffuser and the seal plate are aligned with an alignment tool. The alignment tool has a first annular surface to align with a radially outer surface of the seal plate and a second annular surface to align with an annular flange on the diffuser. Finally, the diffuser is fastened to the seal plate and the alignment tool is removed from the diffuser and the seal plate.

Abstract: A motor housing includes a central body having a central cavity region configured to receive an electric motor. Also included is a first end portion having a first inner surface that defines a first internal cavity region configured to receive a first end winding of a stator of the electric motor, wherein the first internal cavity region comprises a first radius defined by a distance from a main axis of the motor housing to the first inner surface. Further included is a second end portion having a second inner surface that defines a second internal cavity region configured to receive a second end winding of the stator, wherein a ratio of the first radius to a first end portion wall thickness ranges from 19.89 to 27.85.

Abstract: A method of installing a diffuser in an air cycle machine includes placing a first housing on a shaft, placing a seal plate on the shaft, and placing a diffuser on the shaft. Next, the diffuser and the seal plate are aligned with an alignment tool. The alignment tool has a first annular surface to align with a radially outer surface of the seal plate and a second annular surface to align with an annular flange on the diffuser. Finally, the diffuser is fastened to the seal plate and the alignment tool is removed from the diffuser and the seal plate.

Abstract: A vane for a variable diffuser includes a body with an inlet end and an outlet end, a leading surface extending from the inlet end to the outlet end, a trailing surface opposite the leading surface and extending from the inlet end to the outlet end, a first surface extending from the inlet end to the outlet end, and a second surface opposite the first surface and extending from the inlet end to the outlet end. The vane further includes a first cavity on the first surface of the vane adjacent the inlet end, a second cavity on the first surface of the vane adjacent the outlet end, a third cavity on the second surface of the vane adjacent the inlet end, and a fourth cavity on the second surface of the vane adjacent the outlet end.

Abstract: A motor housing includes a central body having a central cavity region configured to receive an electric motor. Also included is a first end portion having a first inner surface that defines a first internal cavity region configured to receive a first end winding of a stator of the electric motor, wherein the first internal cavity region comprises a first radius defined by a distance from a main axis of the motor housing to the first inner surface. Further included is a second end portion having a second inner surface that defines a second internal cavity region configured to receive a second end winding of the stator, wherein a ratio of the first radius to a first end portion wall thickness ranges from 19.89 to 27.85.

Abstract: A journal bearing designed for use with a rotatable shaft of an air cycle machine is disclosed. The bearing includes a journal bearing housing, air bearings for facilitating rotation of the shaft, and a journal bearing shell positioned in the housing. The shell includes a single piece body structure having a first half integral with a second half. The first half includes a first outside end and the second half includes a second outside end. The first half is sufficiently spaced from the second half for supporting and aligning the air bearing for supporting the rotatable shaft. The first and second integral halves define a continuously formed inner diameter adapted to receive the air bearings between the rotatable shaft and the inner diameter for facilitating rotation of the shaft relative to the body structure.