Abstract: A rotor and a method of constructing a rotor are disclosed. The rotor includes a hub that is capable of being supported by a shaft that extends along an axis, a plurality of laminations, and a plurality of wire windings supported by the plurality of laminations. The hub includes an inner structure configured to support the hub relative to the shaft, an outer structure that supports the laminations, and an intermediate structure that is coupled to the inner and outer structures and supports the inner and outer structures relative to one another.

Abstract: A rotor for a high speed generator is constructed of a plurality of laminations and interlamination disks, which are disposed between each of the laminations. A coil support assembly is disposed within each of the rotor interpole regions and is secured to the interlamination disks.

Abstract: A rotor with wedges and a method of retaining wedges in a rotor are disclosed. The rotor includes a shaft, first and second poles extending radially from the shaft, and first and second coils of windings respectively wrapped around the first and second poles. Each coil includes a respective outer face including two end portions and two side portions, and a respective inward-facing edge including two end sections and two side sections. The rotor further includes a first outer wedge positioned between neighboring side portions of the first and second coils, and a first inner wedge positioned between neighboring side sections of the first and second coils. The first inner wedge is coupled to the first outer wedge so that the first outer wedge is at least partly retained from moving radially outward away from the shaft.

Abstract: A terminal block assembly for electrical generators, such as high speed AC generators used in aircraft, is made from components that are readily assembled and disassembled for ease of installation, maintenance, and repair. The terminal block assembly is formed of a terminal block and one or more terminal assemblies. The terminal block has a main body with at least an upper surface and a lower surface. A first cavity is formed in the main body lower surface, and an opening that extends through the main body between the upper surface and the first cavity. A threaded fastener is inserted into the opening and into the first cavity, and a bolt is coupled to the fastener to secure the fastener in the opening. Each terminal assembly is coupled to the terminal block and includes one or more electrically conductive terminal plates, feed-throughs, and slugs for connection to stator output leads, that are electrically and mechanically coupled together using electrically conductive fasteners.

Abstract: A system and method for electrically coupling windings of a main generator rotor to a plurality of DC sources on an exciter that each have respective first-voltage and second-voltage terminals is disclosed. The system includes first and second conductive plates supported by the rotor that respectively define first and second apertures that surround a rotor shaft. The first plate includes a first rotor winding terminal by which the plate is electrically coupled to the windings, and a first plurality of terminals configured to be respectively coupled to the first-voltage terminals of the DC sources. The second plate is electrically insulated from the first plate, includes a second rotor winding terminal by which the second plate is electrically coupled to the windings, and includes a second plurality of terminals configured to be respectively coupled to the second-voltage terminals of the DC sources.

Abstract: A new improved system and method for end turn retention for wires on a generator rotor for use in high speed applications such as in aircraft applications. The rotor includes a shaft, spokes, supports, and wire winding coils, and at least one cap device. The spokes extend radially outwardly from the shaft, and each support is positioned on an associated spoke. Each coil wraps around an associated support and spoke. Each cap device is coupled to an end of its associated spoke to prevent the windings from moving radially outwardly while the rotor spins. Each support is coupled to an associated cap device, and includes at its radially inward edge a flange protruding away from the respective spoke. Because of the flange and the cap device, slack of the wire coil between the flange and the associated cap is taken up.

Abstract: A rotor with wedges and a method of retaining wedges in a rotor are disclosed. The rotor includes a shaft, first and second poles extending radially from the shaft, and first and second coils of windings respectively wrapped around the first and second poles. Each coil includes a respective outer face including two end portions and two side portions, and a respective inward-facing edge including two end sections and two side sections. The rotor further includes a first outer wedge positioned between neighboring side portions of the first and second coils, and a first inner wedge positioned between neighboring side sections of the first and second coils. The first inner wedge is coupled to the first outer wedge so that the first outer wedge is at least partly retained from moving radially outward away from the shaft.

Abstract: A new improved system and method for end turn retention for wires on a generator rotor for use in high speed applications such as in aircraft applications. The rotor includes a shaft, spokes, supports, and wire winding coils, and at least one cap device. The spokes extend radially outwardly from the shaft, and each support is positioned on an associated spoke. Each coil wraps around an associated support and spoke. Each cap device is coupled to an end of its associated spoke to prevent the windings from moving radially outwardly while the rotor spins. Each support is coupled to an associated cap device, and includes at its radially inward edge a flange protruding away from the respective spoke. Because of the flange and the cap device, slack of the wire coil between the flange and the associated cap is taken up.

Abstract: A rotor and a method of constructing a rotor are disclosed. The rotor includes a hub that is capable of being supported by a shaft that extends along an axis, a plurality of laminations, and a plurality of wire windings supported by the plurality of laminations. The hub includes an inner structure configured to support the hub relative to the shaft, an outer structure that supports the laminations, and an intermediate structure that is coupled to the inner and outer structures and supports the inner and outer structures relative to one another.

Abstract: A high speed generator with a hydraulic rotor mounting system that dampens rotor vibrations at the rotor's critical speeds. Oil is supplied to a gap formed between the outer race of the rotor bearing assembly and the bearing liner. The oil provides soft bearing support for, and viscous damping of, the rotor.

Abstract: A new improved system and method for end turn retention for wires on a generator rotor for use in high speed applications such as in aircraft applications. The rotor includes a shaft, spokes, supports, and wire winding coils, and at least one cap device. The spokes extend radially outwardly from the shaft, and each support is positioned on an associated spoke. Each coil wraps around an associated support and spoke. Each cap device is coupled to an end of its associated spoke to prevent the windings from moving radially outwardly while the rotor spins. Each support is coupled to an associated cap device, and includes at its radially inward edge a flange protruding away from the respective spoke. Because of the flange and the cap device, slack of the wire coil between the flange and the associated cap is taken up.

Abstract: A terminal block assembly for electrical generators, such as high speed AC generators used in aircraft, is made from components that are readily assembled and disassembled for ease of installation, maintenance, and repair. The terminal block assembly is formed of a terminal block and one or more terminal assemblies. The terminal block has a main body with at least an upper surface and a lower surface. A first cavity is formed in the main body lower surface, and an opening that extends through the main body between the upper surface and the first cavity. A threaded fastener is inserted into the opening and into the first cavity, and a bolt is coupled to the fastener to secure the fastener in the opening. Each terminal assembly is coupled to the terminal block and includes one or more electrically conductive terminal plates, feed-throughs, and slugs for connection to stator output leads, that are electrically and mechanically coupled together using electrically conductive fasteners.

Abstract: A high speed generator with a hydraulic rotor mounting system that dampens rotor vibrations at the rotor's critical speeds. Oil is supplied to a gap formed between the outer race of the rotor bearing assembly and the bearing liner. The oil provides soft bearing support for, and viscous damping of, the rotor.

Abstract: A self piloting balance arbor for use in the dynamic balancing of gas turbine engine components having shafts extending therefrom. The arbor includes a cylindrical sleeve for receiving the shaft, and an annular flange at one end. A conical compliant member extends axially and radially inward from the flange to an end portion having two flat surfaces perpendicular to each other. Upon the application of a load to the arbor the two flat surfaces come into contact with the component, thereby correctly positioning the arbor relative to the component.

Abstract: The present invention provides a compliant nut that can provide a more consistent compressive force to engine components by using a compliant section to absorb axial deflections. The present invention also provides a self centering feature that positions the nut upon compression, reduces thread stresses and prevents nut and shaft runnout. The invention consists of an annular member having threads on the inner diameter for mating with a threaded shaft and having a conical portion extending axially and radially inward from the annular member for abutting engine components and the engine shaft. The nut includes a plurality of exciter teeth circumferentially disposed and extending radially from the annular member used to provide shaft speed signal for engine controls and a plurality of axial spline members extending axially from the annular member on the opposite face from conical section for mating with torque applying tools and locking mechanisms.