Abstract: An assembly comprises a resistor plate for a rotating rectifier assembly (RRA). A shaft bore is defined through the resistor plate for passage of a shaft of an electrical machine, and the resistor plate defines a main annular body around the shaft bore. A first protrusion extends radially outward from the main annular body, so that a first pin bore extends through the first protrusion. At least one contact band is seated in a the pin bore of the resistor plate for mounting a direct current (DC) pin to the resistor plate.

Abstract: An assembly comprises an AC (alternating current) housing connection block and a plurality of inserts seated in the AC housing connection block, wherein for each of the inserts, an interface between the insert and the housing is continuous. A method includes inserting a plurality of inserts into a mold; and molding an AC (alternating current) housing connection block.

Abstract: An end winding support of a rotor of an electric machine is provided. The end winding support includes a first part and a second part. The first part includes an elongate body about which a conductive winding is wound. The elongate body has a surface defining a first groove. The second part is attached to the first part. The second part includes a body which extends outwardly from the elongate body and which has a surface defining a second groove corresponding to the first groove.

Abstract: An assembly comprises a mounting ring for a rotating rectifier assembly (RRA) having a pin bore defined in the mounting ring oriented in an axial direction and at least one contact band seated in a the pin bore of the mounting ring for mounting a direct current (DC) pin to the mounting ring. A method comprises forming a mounting ring for a rotating rectifier assembly (RRA), including forming a pin bore in the mounting ring oriented in an axial direction, and installing at least one contact band into a the pin bore of the mounting ring.

Abstract: A diode pack housing for a rotating rectifier assembly can include a body having an interior surface defining an interior cavity open on a first end and configured to contain a diode pack and a plurality of bus bar channels defined axially on or in the inner surface in the interior cavity. The plurality of bus bar channels can be five or less bus bar channels.

Abstract: An end winding support of a rotor of an electric machine is provided. The end winding support includes a first part and a second part. The first part includes an elongate body about which a conductive winding is wound. The elongate body has a surface defining a first groove. The second part is attached to the first part. The second part includes a body which extends outwardly from the elongate body and which has a surface defining a second groove corresponding to the first groove.

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 having multiple poles is provided and includes at each pole an end winding support forming a channel, a bus bar disposed in the channel and edge-wound coils disposed to extend around the end-winding support and the bus bar. The edge-wound coils are stacked radially and include an inner diameter coil routed to an adjacent pole and brazed to an inner diameter coil of the adjacent pole and an outer diameter coil brazed to the bus bar.

Abstract: A terminal assembly includes a terminal block of a dielectric material defining a plurality of bores therethrough. A respective terminal contact of an electrically conductive material is seated in each of the respective bores. The terminal contact defines a longitudinal axis therethrough with a terminal bore defined through the terminal contact along the longitudinal axis. A divider wall separates the terminal bore into a solder cup for a lead wire on an interior side of the terminal bore, and a lug receptacle on an exterior side of the terminal bore.

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: An assembly comprises a mounting ring for a rotating rectifier assembly (RRA) having a pin bore defined in the mounting ring oriented in an axial direction and at least one contact band seated in a the pin bore of the mounting ring for mounting a direct current (DC) pin to the mounting ring. A method comprises forming a mounting ring for a rotating rectifier assembly (RRA), including forming a pin bore in the mounting ring oriented in an axial direction, and installing at least one contact band into a the pin bore of the mounting ring.

Abstract: An assembly comprises an AC (alternating current) housing connection block and a plurality of inserts seated in the AC housing connection block, wherein for each of the inserts, an interface between the insert and the housing is continuous. A method includes inserting a plurality of inserts into a mold; and molding an AC (alternating current) housing connection block.

Abstract: An assembly comprises a resistor plate for a rotating rectifier assembly (RRA). A shaft bore is defined through the resistor plate for passage of a shaft of an electrical machine, and the resistor plate defines a main annular body around the shaft bore. A first protrusion extends radially outward from the main annular body, so that a first pin bore extends through the first protrusion. At least one contact band is seated in a the pin bore of the resistor plate for mounting a direct current (DC) pin to the resistor plate.

Abstract: An assembly comprises a resistor support housing for a rotating rectifier assembly (RRA). A shaft bore is defined through the resistor support housing for passage of a shaft of an electrical machine. The resistor support housing defines a main annular body around the shaft bore. An end housing is mounted to one axial end of the resistor support housing. The end housing defines a portion of the shaft bore therethrough.

Abstract: A rotor having multiple poles is provided and includes at each pole an end winding support forming a channel, a bus bar disposed in the channel and edge-wound coils disposed to extend around the end-winding support and the bus bar. The edge-wound coils are stacked radially and include an inner diameter coil routed to an adjacent pole and brazed to an inner diameter coil of the adjacent pole and an outer diameter coil brazed to the bus bar.

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 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: 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 diode pack housing for a rotating rectifier assembly can include a body having an interior surface defining an interior cavity open on a first end and configured to contain a diode pack and a plurality of bus bar channels defined axially on or in the inner surface in the interior cavity. The plurality of bus bar channels can be five or less bus bar channels.

Abstract: A terminal assembly includes a terminal block of a dielectric material defining a plurality of bores therethrough. A respective terminal contact of an electrically conductive material is seated in each of the respective bores. The terminal contact defines a longitudinal axis therethrough with a terminal bore defined through the terminal contact along the longitudinal axis. A divider wall separates the terminal bore into a solder cup for a lead wire on an interior side of the terminal bore, and a lug receptacle on an exterior side of the terminal bore.