Abstract: A disconnect shaft for use in an integrated drive generator longitudinally extending between a first end and a second end having a plurality of gear teeth extending longitudinally from a first face disposed at the first end. A cam ledge is at an intermediate location between the first end and the second end. An annular cavity is defined between an inner surface of an inner bore of the disconnect shaft and an outer surface of a radially inner portion of the disconnect shaft. A 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 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 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 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: An accessory drive gear for use in the integrated drive generator includes a gear body extending between a first end and a second end and having a plurality of gear teeth at a radially outer surface adjacent the first end, and the gear teeth having a gear tooth profile, with roll angles A, B, C, and D, and the roll angle at A being between 17.0 and 18.5°, the roll angle at B being between 20.0 and 21.5°, the roll angle at C being between 29.5 and 31.0°, and the roll angle at D being between 32.5 and 34.0°. In addition, an integrated drive generator is disclosed as is a method of replacing an accessory drive gear in an integrated drive generator.

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 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 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: 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 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.

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: 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 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 governor and inversion pump drive gear for an integrated drive generator has a gear body extending from a first end to a second end. There is an enlarged disc between the first and second ends. A boss extends from the enlarged disc toward the second end and has an internal bore with spline teeth. The enlarged disc has input gear teeth at an outer periphery. A shaft portion extends from the disc to the first end. A flange is formed at a location intermediate the first end and the enlarged disc. The inner gear teeth and the drive gear teeth have unique tooth profiles. An integrated dive generator and a method are also disclosed.

Abstract: A terminal block cover for use in an integrated drive generator has a body having a closed outer face and extending to an open inner face, and having an open side and a closed side. There are four connection channels for receiving electric connections for each of three phases of power and a neutral, and they extend from the closed side to the open side. There are spacing channels formed between adjacent ones of each of the four connection channels, with the spacing channels being formed by two spaced ribs with an interior space. An integrated drive generator and a method are also disclosed.

Abstract: A cylinder block for use in an integrated drive generator has a shaft portion with a relatively small outer diameter and a cylindrical body portion having a larger outer diameter than the shaft portion, and said cylindrical body portion formed with a plurality of piston chambers, said cylindrical body portion extending from a first end to a second end, said second end being provided with cylindrical ports leading into said piston chambers and said cylindrical ports having a third end and a fourth end wherein a ratio of a first distance from said first end to said fourth end to a second distance from said first end to said second end being between 0.91 and 0.93. A generator and a method are also described.

Abstract: A seal plate body has a first the zone including three bolt hole ears and an oil passage ear. A second zone includes four bolt hole ears. A third zone includes six bolt ears and one alignment pin ear. A fourth zone has three bolt hole ears. A fifth zone includes five bolt hole ears and one oil passage ear. A sixth zone includes three bolt hole ears and one alignment pin ear. Each of the bolt hole ears includes a bolt hole, and each of the oil passage ears includes an oil passage hole. An integrated drive generator and a method are also disclosed.

Abstract: Generator housings for generators of aircraft are provided. The generator housings include a mounting pad at a first end, the generator housing extending to a second end, and a base arranged to connect to an electronics module. The generator housing defines a generator cavity and a flow path to supply a working fluid through the generator housing, the flow path extending between an inlet formed in the mounting pad and at least one outlet formed in the mounting pad. One or more electronics flow ports enable fluid connection between the flow path within the generator housing and the electronic module when connected and one or more inductor ports enable fluid connection between the flow path within the generator housing and one or more inductors when mounted to the generator housing.