Abstract: An improved apparatus and method of having a pair of end caps on a rotor assembly of a multi-pole high-speed generator is provided for use with a turbine engine. The rotor assembly provides improved balancing and/or cooling during generator operation. The rotor assembly includes a plurality of poles and at least one support wedge positioned between each of the poles. The rotor assembly is mounted on a shaft. An annular flange of the end caps restrains the support wedges in the rotor assembly for improved balancing and maintaining concentricity. The end caps may also include a manifold for circulating a cooling medium through the shaft to and from the support wedges to cool the generator.

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 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 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 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 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 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: An improved apparatus and method of having a pair of end caps on a rotor assembly of a multi-pole high-speed generator is provided for use with a turbine engine. The rotor assembly provides improved balancing and/or cooling during generator operation. The rotor assembly includes a plurality of poles and at least one support wedge positioned between each of the poles. The rotor assembly is mounted on a shaft. An annular flange of the end caps restrains the support wedges in the rotor assembly for improved balancing and maintaining concentricity. The end caps may also include a manifold for circulating a cooling medium through the shaft to and from the support wedges to cool the generator.

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: An improved apparatus and method of having a pair of end caps on a rotor assembly of a multi-pole high-speed generator is provided for use with a turbine engine. The rotor assembly provides improved balancing and/or cooling during generator operation. The rotor assembly includes a plurality of poles and at least one support wedge positioned between each of the poles. The rotor assembly is mounted on a shaft. An annular flange of the end caps restrains the support wedges in the rotor assembly for improved balancing and maintaining concentricity. The end caps may also include a manifold for circulating a cooling medium through the shaft to and from the support wedges to cool the generator.

Abstract: An improved apparatus and method of having a pair of end caps on a rotor assembly of a multi-pole high-speed generator is provided for use with a turbine engine. The rotor assembly provides improved balancing and/or cooling during generator operation. The rotor assembly includes a plurality of poles and at least one support wedge positioned between each of the poles. The rotor assembly is mounted on a shaft. An annular flange of the end caps restrains the support wedges in the rotor assembly for improved balancing and maintaining concentricity. The end caps may also include a manifold for circulating a cooling medium through the shaft to and from the support wedges to cool the generator.

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 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 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 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: Apparatus to lubricate generator bearings with an oil-air mist is disclosed. A screw pump, preferably an assembly of components comprising a ring, a teflon seal, a pump rotor and a hub is secured onto a rotor shaft of a generator for rotation therewith. The rotor shaft has at least one passageway extending radially from an axial bore therein through which oil is transferred. The screw pump has a first orifice coincident with the rotor shaft passageway, a second orifice, a passageway extending from the first orifice to the second orifice through which the oil is directed into a cavity in the generator housing where it mixes with air to form a mist to lubricate the bearing, a circumferential surface fitting within an opening in the generator housing, and a helical groove in the circumferential surface through which the oil-air mist is evacuated during rotation of the generator rotor shaft.

Abstract: A quick connect apparatus (10) for attaching a stub shaft (14) to a main rotor shaft (16) of a generator. A rotatable retaining device (12) is secured to the end of the main rotor shaft (16) and includes channels (22) which are engaged by pins (30) projecting radially inward from an inner diameter portion of the stub shaft (14). A polgon drive portion (34) extends from the stub shaft (14) and engages a similar shaped polygon opening (18) formed in the end of the main rotor shaft (16) when the stub shaft (14) is attached. A biasing spring (40) is provided between the back of the polygon opening (18) and a recess in the mating polygon drive portion (34) for biasing the stub shaft (14) axially away from the main shaft (16).