Abstract: The present disclosure provides for terminal block cover assemblies for electric generators, and related methods of fabrication and use. More particularly, the present disclosure provides for terminal block cover assemblies for generators for aircraft or the like, with the terminal block cover assemblies having electrical arcing mitigation features and structures, and related methods of fabrication and use. The terminal block cover assemblies of the present disclosure can be utilized to reduce electrical arcing events in environments where de-icing fluid is used in the engine cowl.

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: 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 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 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 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: 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 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: 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 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.