Abstract: A stub shaft of a main rotor shaft of a generator has its flange or shoulder removed from its outer portion so in the event of a bending failure of the stub shaft the resulting axial load of the stub shaft is not transmitted to the main rotor shaft. Instead of a retention plug adjacent the distal end of the inside portion of the stub shaft, a knock out plug is lightly press-fit into the main rotor shaft. In the event of a failure, the outside portion of the stub shaft enters the main rotor shaft without applying an axial load onto the main rotor shaft, moves axially and displaces the knock-out plug without exiting the main rotor shaft.

Abstract: A high speed generator cooling system directs a cooling oil spray through a chamber inside a coil support wedge assembly, which may be disposed adjacent to the generator coils. Heat from the generator coils may be conducted through the walls of the coil support wedge assembly and into the chamber where it is removed by the cooling oil spray passing through the chamber. The cooling oil passes through a generator rotor shaft and into a cooling passage in least one of the rotor laminations.

Abstract: A permanent magnet rotor of a generator is used to excite a electromagnet stator to generate electric power for the generator and to control a disengagement mechanism whereby the generator can disengage from an accessory, such as a gear box drive shaft, when the generator is not working properly. The permanent magnet is affixed to an outer ball screw which normally rotates with an inner ball screw that is operatively engaged to the accessory. An increased load to the electromagnet stator slows or stops rotation of the permanent magnet rotor and outer ball screw, causing the inner ball screw to move axially from the outer ball screw and away from an accessory and toward a re-settable lock.

Abstract: A generator may incorporate a positively restrained balance ring. A generator may include a rotor core including a rotor, and a balance ring. The balance ring may include a weight. The balancer may include a plurality of balance holes in the ring, at least one of the plurality of balance holes to receive a weighted insert. A method of balancing a rotor of a generator may include mounting a balance ring adjacent to a rotor core, and adjusting weights to be located at one or more of a plurality of positions equally spaced around the balance ring to balance the rotor.

Abstract: A rotor for use in a high speed electrical machine includes a shaft, a plurality of poles, a plurality of coils, and a rotor crossover that is relatively flexible, and that does not crack under the centrifugal forces and the mechanical and thermal cycles encountered during machine operation, startup, and shutdown. The poles extend radially outwardly from the shaft and are spaced apart from each other to form an interpole region, and the coils are wrapped around the poles. The rotor crossover is coupled between selected ones of the coils, and includes a stranded wire conductor and an insulator.

Abstract: An outflow valve is disclosed for use in a pressure vessel. The outflow valve includes a dual wall valve housing having a central bore, a butterfly plate assembly and an angled drive shaft. The butterfly plate assembly is designed to fit and rotate within the central bore. The angled drive shaft has first and second ends rotateably coupled to the dual wall valve housing, and the angled drive shaft is attached to the butterfly plate. The drive shaft is designed to rotate the butterfly plate assembly between a closed position and an open position within the central bore.

Abstract: A permanent magnet rotor of a generator is used to excite a permanent magnet stator to generate electric power for the generator and to control a disengagement mechanism whereby the generator can disengage from an accessory, such as a gear box drive shaft, when the generator is not working properly. The permanent magnet is affixed to an outer ball screw which normally rotates with an inner ball screw that is operatively engaged to the accessory. An increased load to the permanent magnet stator slows or stops rotation of the permanent magnet rotor and outer ball screw, causing the inner ball screw to move axially from the outer ball screw and away from an accessory and toward a re-settable lock.

Abstract: A stub shaft of a main rotor shaft of a generator has its flange or shoulder removed from its outer portion so in the event of a bending failure of the stub shaft the resulting axial load of the stub shaft is not transmitted to the main rotor shaft. Instead of a retention plug adjacent the distal end of the inside portion of the stub shaft, a knock out plug is lightly press-fit into the main rotor shaft. In the event of a failure, the outside portion of the stub shaft enters the main rotor shaft without applying an axial load onto the main rotor shaft, moves axially and displaces the knock-out plug without exiting the main rotor shaft.

Abstract: A high speed aircraft generator utilizes a resistor bobbin to constrain field leads from radial displacement during operation of the generator. The resistor bobbin is provided with passages through which the field leads are passed. The passages are parallel to an axis of the generator. The resistor bobbin thus serves two purposes in the generator; its normal function of supporting a resistor coil and a second function of constraining field leads. The field leads have a round cross-sectional configuration. The field leads are attached to flat conductors of a field coil with a unique brazing clip.

Abstract: A generator may incorporate a positively restrained balance ring. A generator may include a rotor core including a rotor, and a balance ring. The balance ring may include a weight. The balancer may include a plurality of balance holes in the ring, at least one of the plurality of balance holes to receive a weighted insert. A method of balancing a rotor of a generator may include mounting a balance ring adjacent to a rotor core, and adjusting weights to be located at one or more of a plurality of positions equally spaced around the balance ring to balance the rotor.

Abstract: A high speed generator cooling system directs a cooling oil spray through a chamber inside a coil support wedge assembly, which may be disposed adjacent to the generator coils. Heat from the generator coils may be conducted through the walls of the coil support wedge assembly and into the chamber where it is removed by the cooling oil spray passing through the chamber. The cooling oil passes through a generator rotor shaft and into a cooling passage in least one of the rotor laminations.

Abstract: A rotor balancing system is provided that includes a rotor core, a plurality of core channels, a support wedge, a wedge channel, and balance masses. The rotor core includes an annular section, a first pole, and a second pole. The first and second poles each extend radially outwardly from the annular section and form an interpole region therebetween. The plurality of core channels are formed in the rotor core annular section and extend axially through the rotor core annular section. The support wedge is disposed in the interpole region. The wedge channel is formed in the support wedge and extends therethrough. One or more balance masses are selectively disposed in one or more of the core channels and the wedge channel, and each balance mass is disposed at a predetermined axial location to thereby correct rotor imbalance.

Abstract: A coil retention system for a rotor of a high speed electrical generator, such as an aircraft generator, that uses compliant material to fill variable dimension voids and/or gaps in the coils wound around the rotor of an electrical machine. During processing of the rotor and coil retention system, the compliant material hardens and is able to withstand the centrifugal loads imposed by, and environmental conditions within, the high speed generator.

Abstract: The coil end-turn segments of a generator exciter rotor are retained using an end-turn retention assembly that includes an inner band and an outer band. The inner band is located around at least a portion of each of the end-turn segments and has two ends. The outer peripheral surface of the inner band is tapered such that the thickness of the inner band varies between its ends. The outer band is located around the inner band and also has two ends. The inner peripheral surface of the outer band is tapered in a fashion that is reverse to that of the inner band outer surface, and such that the outer band thickness varies between its ends. By forming oppositely configured tapers in the inner and outer bands, the outer bands will remain in place and not migrate axially away from the lamination core during exciter rotor rotation.

Abstract: A coil support wedge for a high speed generator is integrally constructed and includes a plurality of flow passageways. Because it is integrally formed, the support wedge is substantially fluid tight. Thus, it is less susceptible to cooling fluid leakage from the flow passageways, which increases the overall reliability of the generator into which the wedge is installed.

Abstract: A coil support wedge for a high speed generator is integrally constructed and includes a plurality of flow passageways. Because it is integrally formed, the support wedge is substantially fluid tight. Thus, it is less susceptible to cooling fluid leakage from the flow passageways, which increases the overall reliability of the generator into which the wedge is installed.

Abstract: A coil retention system for a rotor of a high speed electrical generator, such as an aircraft generator, that uses compliant material to fill variable dimension voids and/or gaps in the coils wound around the rotor of an electrical machine. During processing of the rotor and coil retention system, the compliant material hardens and is able to withstand the centrifugal loads imposed by, and environmental conditions within, the high speed generator.