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.

Abstract: A rotor pack for a generator has an exciter rotor rotating with a shaft. A rectifier assembly is in electric communication with the exciter rotor to receive AC current and rectify the AC current into a DC voltage. Positive and negative busses extend from the rectifier assembly to a negative rail and a positive rail on a connection assembly. The negative rail is in contact with the shaft to provide a ground connection. The negative and positive rails are formed of a metal. The negative and positive rails are connected to a main field winding. A high speed generator is also disclosed.

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 rectifier assembly according to an example of the present disclosure includes, among other things, a first housing and a second housing extending along an assembly axis, the first housing surrounding a pair of electrical rings. At least one spring strip includes a first spring strip portion transverse to a second spring strip portion, the second spring strip portion to bias diodes against an inner periphery of the pair of electrical rings. The second housing includes at least one connection terminal for receiving a wire from an exciter rotor, the at least one connection terminal including a screw threaded area which receives a bolt holding the first spring strip portion. A generator and a method of assembling a rectifier assembly are also disclosed.

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: 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 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: An electrical machine includes a rotor including windings circumferentially spaced apart by rotor wedges. The electrical machine includes a rotor end plate mounted to the rotor. The rotor end plate includes an annular end plate body with an interior surface and axially opposed exterior surface. The interior surface includes a cavity for engaging the rotor. The interior surface has a base that is bounded by an inner rim and an outer rim radially opposite the inner rim. The interior surface is free of anti-rotation projections extending axially therefrom. The outer rim is free of anti-rotation features extending radially inward therefrom.

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 pack for a generator has an exciter rotor rotating with a shaft. A rectifier assembly is in electric communication with the exciter rotor to receive AC current and rectify the AC current into a DC voltage. Positive and negative busses extend from the rectifier assembly to a negative rail and a positive rail on a connection assembly. The negative rail is in contact with the shaft to provide a ground connection. The negative and positive rails are formed of a metal. The negative and positive rails are connected to a main field winding. A high speed generator is also disclosed.

Abstract: A rotating resistor assembly for use in a rotating shaft of an electrical machine can include a first housing configured to contact the rotating shaft and be grounded to the rotating shaft. The first housing can include a first bus bar connection aperture configured to receive a first bus bar. The assembly can include a second housing configured to connect to the first housing. The second housing can be configured to be insulated from the rotating shaft and to be insulated from direct electrical connection with the first housing. The second housing can include a second bus bar connection aperture configured to receive a second bus bar. The assembly can include a suppression resistor disposed between the first housing and the second housing and in electrical communication with the first housing and the second housing to provide an electrical pathway between first housing and the second housing.

Abstract: A rotating resistor assembly for use in a rotating shaft of an electrical machine can include a first housing configured to contact the rotating shaft and be grounded to the rotating shaft. The first housing can include a first bus bar connection aperture configured to receive a first bus bar. The assembly can include a second housing configured to connect to the first housing. The second housing can be configured to be insulated from the rotating shaft and to be insulated from direct electrical connection with the first housing. The second housing can include a second bus bar connection aperture configured to receive a second bus bar. The assembly can include a suppression resistor disposed between the first housing and the second housing and in electrical communication with the first housing and the second housing to provide an electrical pathway between first housing and the second housing.

Abstract: A variable frequency generator (VFG) rotor can include a plurality of windings configured to form a plurality of magnetic poles, each winding comprising a first winding end and a second winding end, and a first winding support structure comprising a plurality of first winding support segments configured to retain a first portion of each winding, each winding support segment being configured to move radially relative to an axis of rotation of the rotor. The first winding end of each winding extends from each winding support segment. The rotor can include at least one flexible bus bar jumper connected to two first winding ends of adjacent windings and configured to flex with radial movement of the winding support segments of respective windings attached to the flexible bus bar jumper.

Abstract: A variable frequency generator (VFG) rotor can include a plurality of windings configured to form a plurality of magnetic poles, each winding comprising a first winding end and a second winding end, and a first winding support structure comprising a plurality of first winding support segments configured to retain a first portion of each winding, each winding support segment being configured to move radially relative to an axis of rotation of the rotor. The first winding end of each winding extends from each winding support segment. The rotor can include at least one flexible bus bar jumper connected to two first winding ends of adjacent windings and configured to flex with radial movement of the winding support segments of respective windings attached to the flexible bus bar jumper.

Abstract: An electrical machine includes a rotor including windings circumferentially spaced apart by rotor wedges. The electrical machine includes a rotor end plate mounted to the rotor. The rotor end plate includes an annular end plate body with an interior surface and axially opposed exterior surface. The interior surface includes a cavity for engaging the rotor. The interior surface has a base that is bounded by an inner rim and an outer rim radially opposite the inner rim. The interior surface is free of anti-rotation projections extending axially therefrom. The outer rim is free of anti-rotation features extending radially inward therefrom.

Abstract: A resistor pack assembly comprising: a positive rail having a circular face; a negative rail having an inner circular face and an outer circular face located radially outward from inner circular face; an insulator ring having a first circular face and a second circular face opposite first circular face, the second circular face contacts the outer circular face of the negative rail; a first DC bus bar electrically connected to the insulator ring; a second DC bus bar electrically connected to negative rail; and a cylindrical suppression resistor having a first flat surface and a second flat surface opposite the first flat surface, the cylindrical suppression resistor is located radially inward of the insulator and axially between the positive rail and negative rail, wherein the first flat surface contacts the circular face of the positive rail and the second flat surface contacts the inner circular face of the negative rail.

Abstract: A rectifier assembly according to an example of the present disclosure includes, among other things, a first housing and a second housing extending along an assembly axis, the first housing surrounding a pair of electrical rings. At least one spring strip includes a first spring strip portion transverse to a second spring strip portion, the second spring strip portion to bias diodes against an inner periphery of the pair of electrical rings. The second housing includes at least one connection terminal for receiving a wire from an exciter rotor, the at least one connection terminal including a screw threaded area which receives a bolt holding the first spring strip portion. A generator and a method of assembling a rectifier assembly are also disclosed.

Abstract: A disclosed terminal block assembly for a generator includes a terminal block with a base with first and second transverse terminal surfaces adjoining one another. One of the terminal surfaces includes an increased width greater than a length of a cable terminal lug for providing a lightning strike and creepage barrier. The terminal surfaces include spaced apart protrusions extending from the first and second surfaces to provide spaced apart terminal areas overlapping the first and second surfaces. First and second terminal studs are disposed within each corresponding first and second terminal areas and are electrically connected by a bus bar.

Abstract: A roller bearing outer race of a hydraulic unit having a body having a first part and a second part. The first part comprising a central section having an exterior curved portion, an exterior angled portion, and a circular inner portion, wherein a central aperture defining a first axis passes through the circular inner portion of the central section, a first arm extending from a first side of the central section, and a second arm extending from a second side of the central section. A race within the circular inner portion of the central section, the race defined by a first race wall and a second race wall and wherein a thickness of the first arm and the second arm is about 0.450 inches (1.143 cm) and a radial distance of an exterior surface of the exterior curved portion from the first axis is about 0.657 inches (1.669 cm).