Abstract: A port plate for use in an integrated drive generator has a body defining a semi-cylindrical charge port communicating with two circumferentially smaller charge port portions. A diametrically opposed working pressure port has three smaller working pressure ports. A center plane is defined extending through a center axis of a bore within the body and equidistance between circumferential ends of the charge port and the working fluid port. A first angle is defined between the plane and a circumferential end of the smaller charge port. The first angle is between 15 and 25 degrees. An integrated drive generator and a method are also disclosed.

Abstract: A terminal lead support for use in an integrated drive generator has a body defining an outer end extending to two outer angled surfaces. The outer angled surfaces each extend to curved end portions. The curved end portions connect the outer angled surfaces into inner angled surfaces. The inner angled surfaces each extend into cupped portions formed about a radius. There are six apertures formed within the body, with laterally outer apertures spaced from the outer surface by a greater amount than laterally intermediate apertures. The laterally intermediate apertures are spaced from the outer surface by a greater amount than laterally inner apertures. An integrated drive generator and a method of replacing a terminal lead support are also disclosed.

Abstract: A pump sleeve for an integrated drive generator has a pump sleeve body extending between a first end and a second end. The first end is at a location adjacent a radially enlarged end plate. The body extends to the second end with a generally cylindrical body portion having an inner bore diameter defining a first distance. The body extends between the first and second ends for a second distance. A ratio of the first distance to the second distance is between 0.15 and 0.30. An integrated drive generator and a method are also disclosed.

Abstract: A fixed block shaft has a body extending from a first end to a second end. A disc extends radially outwardly of a shaft portion. The shaft portion extends to the second end. The disc extends radially outwardly from the shaft adjacent the first end with a boss extending to the first end from the disc. The boss defines an inner peripheral surface and the inner peripheral surface has a bearing race. The bearing race extends from the first end to a bearing race end. An inner diameter of the bearing race defines a first distance. An inner diameter of the bearing race is defined as a first distance and the bearing race extends along a central axis for a second distance. A ratio of the first distance to the second distance is between 4.30 and 4.50. An integrated drive generator and a method are also disclosed.

Abstract: A variable wobbler plate has a stub shaft and a pivot shaft. The pivot shaft has a smaller diameter portion and a larger diameter portion. The smaller diameter portion has a generally cylindrical outer periphery with a flat over a limited circumferential extent and a diameter to opposed portions of the generally cylindrical portion defining a first distance. A second distance is defined from an end of the smaller diameter portion spaced furthest from the stub shaft to an end of the larger diameter portion spaced closest to the stub shaft and measured along a central axis of the pivot shaft and defines a second distance. A ratio of the first distance to the second distance is between 0.60 and 0.75. An integrated drive generator and a method are also disclosed.

Abstract: A cam liner for use in an integrated drive generator has a cam liner body extending between a first end spaced from the second end by a first distance. The body is generally cylindrical. An outer diameter of the cam liner defines a second distance. A ratio of the first distance to the second distance is between 0.90 and 1.00. An integrated drive generator and a method are also disclosed.

Abstract: A variable block shaft has a radially enlarged disc formed at a first end. A shaft portion extends from the disc to a second end. An inner bearing race surface is defined intermediate the first and second end and has an outer peripheral surface. An axial length of the inner bearing race surface is defined between inner facing surfaces of lands at each axial side. The axial distance is measured along the center axis of the body and an outer diameter to the inner bearing race surface being defined as a first distance. The axial length of the inner bearing race surface is defined as a second distance and a ratio of the first distance to the second distance being between 3.75 and 3.90. An integrated drive generator and a method are also disclosed.

Abstract: An inner bearing race has a body extending from a first end to a second end. An inner bearing race surface defined between a pair of lands extends radially outwardly of the inner bearing race surface, with one of the lands extending to the second end. The bearing race surface is defined by inner face surfaces of the lands. The inner bearing race surface extends for an axial distance between the inner facing surfaces along a central axis C of the body and defines a first distance. A second distance defines an outer diameter of the inner bearing race surface is defined as a second distance and a ratio of the first distance to the second distance being between 0.20 and 0.30. An integrated drive generator and a method are also disclosed.

Abstract: A terminal block for use in an integrated drive generator has a body having an outer support surface and extending to an inner surface. There are four connection channels for supporting electric connections for each of three phases of power and a neutral. There are fingers formed between adjacent ones of each of the four connection channels, with the fingers extending away from the support surface in a direction away from the inner surface. An integrated drive generator and a method are also disclosed.

Abstract: A sun gear for an integrated drive generator (IDG) includes a sun gear body having an outer diametric edge and an inner diametric wall. The outer diametric edge includes 33 gear teeth.

Abstract: An input drive shaft for use in an integrated drive generator has a body extending from an end to a clutch face. The clutch face includes a plurality of clutch teeth extending away from a nominal surface of the body. The clutch face defines an inner bore of a first diameter. The clutch face has an outer peripheral surface defining a second diameter and a ratio of the first diameter to the second diameter is between 1.50 and 1.65. An integrated drive generator and a method are also disclosed.

Abstract: A terminal lead assembly for use in an integrated drive generator has a body formed of a lead portion and a support portion. The lead portion is received within an aperture in the support portion. The support portion has an outer periphery defined within a plane extending perpendicularly to a central axis of the lead portion. The outer periphery includes two curved portions and straight side portions extending parallel to each other and connecting the curved portions. An integrated drive generator and a method are also disclosed.

Abstract: A governor drive gear for use in an integrated drive generator has a gear body extending between a first end and a second end and having a disc extending radially outwardly. A boss extends from the disc toward the second end. There are outer gear teeth outwardly of an outer diameter of the disc. The outer gear teeth have a unique gear tooth profile with roll angles A, B, C, and D. An integrated drive generator and a method are also disclosed.

Abstract: A lamination for use in an integrated drive generator is formed from a plurality of plates having a body including a pair of opposed cylindrical surfaces. Non-cylindrical ditches are defined circumferentially intermediate the pair of cylindrical surfaces. A plurality of passages are formed in an outer periphery of the cylindrical surfaces including relatively large holes extending through a slot to the outer periphery. Grooves are formed intermediate the relatively large holes.

Abstract: A stator sleeve for use in an integrated drive generator has a body extending between a first end and a second end and has a generally cylindrical inner peripheral surface. An outer peripheral surface has a plurality of circumferentially extending ribs define intermediate oil cooling channels. An integrated drive generator and a method are also disclosed.

Abstract: A generator driven gear for use in an integrated drive generator has a gear body extending between a first end and a second end and having a disc extending radially outwardly. A boss extends from the disc toward the second end. There are outer gear teeth outwardly of an outer diameter of the disc. The outer gear teeth having a unique gear tooth profile with roll angles A, B, C, and D. An integrated drive generator and a method are also disclosed.

Abstract: An output ring gear for use in an integrated drive generator has a gear body extending between a first end and a second end and having a disc extending radially outwardly. A boss extends from the disc toward the second end. There are outer gear teeth outwardly of an outer diameter of the disc. There are inner gear teeth inwardly of an inner surface of the disc. The outer and inner gear teeth have a unique gear tooth profile with roll angles A, B, C, and D. An integrated drive generator and a method are also disclosed.

Abstract: A wear ring for use in an integrated drive generator has a cylindrical body defining an axis and having a tab extending radially outwardly of an outer cylindrical surface of the cylindrical body. The tab has a radially outer point. A ratio of a first radius to the outer cylindrical surface from the axis to a second radius extending to the radially outer point from the axis is between 0.90 and 0.95. An integrated drive generator and a method are also disclosed.

Abstract: A rotor for a permanent magnet generator includes a rotor body extending between a first end and a second end, having a cylindrical bore and a plurality of flats on an outer peripheral surface. Permanent magnets are positioned at the flats. An outer ring surrounds the permanent magnets and defines an outer diameter. A ratio of the outer diameter to an axial length between the first and second ends is between 3.2 and 3.4. An integrated drive generator and a method are also disclosed.

Abstract: A disconnect plunger for use in an integrated drive generator includes a plunger body extending between a first end and a second end. A cam surface is formed on the second end, and has a cylindrical cam portion extending across the second end. The cylindrical cam portion has a location formed at a radius about a point spaced beyond the second end relative to the first end. A first distance is defined from a second end facing surface of a cylindrical guide portion positioned intermediate first and second end. A ratio of the first radius to the first distance is between 0.15 and 0.30. The point is spaced in a direction perpendicular to a center axis of the plunger body, and measured from the center axis by a second distance. A ratio of the second distance to the first radius is between 0.25 and 0.40. An integrated drive generator and a method of replacing a disconnect shaft are also disclosed.