Abstract: A baffle structure that has a generally curved surface profile so that ventilation windage loss can be significantly reduced is provided. In an exemplary embodiment, the orientation and/or the height of the baffle can be adjusted to adjust flow gaps defined between it and the adjacent lamination/stator flange surfaces and/or between it and a facing adjacent space block, so that ventilation flow can be controlled to satisfy varying cooling requirements.

Abstract: A ventilation pathway for a cooling gas to flow extends on a radial axis in a generator stator core. The ventilation pathway comprises at least two magnetic laminations and a plurality of space blocks extending radially in the generator stator core. The space blocks are fastened and disposed between the magnetic laminations. At least one of the space blocks includes a wavy longitudinal profile that includes an alternating pattern of peaks and valleys with respect to the radial axis of the generator stator core. Alternatively, at least one of the space blocks has a plurality of protrusions defining a pattern of peaks and valleys extending from a sidewall of the space block. Several different shapes of vortex generators are punched in the lamination are located within the ventilation pathway.

Abstract: The brush seal includes a plurality of bristles located in grooves along opposite sides of a single carrier. The grooves extend at a predetermined cant angle relative to radii of a sealing surface about which the brush seal extends. The grooves are formed between ribs which terminate in tips deformed to overlie the bristles in the groove and thereby retain the bristles on the carrier. An epoxy overlies the carrier surfaces and grooves to facilitate their retention. The brush seal may be fabricated by rolling knurled rollers with oblique cutting ribs along opposite surfaces of the carrier to form the grooves. The bristles are then wrapped about the carrier and in the grooves. Subsequently, the tips of the ribs defining the grooves are deformed to overlie and retain the bristles in the grooves.

Abstract: A baffle structure that has a generally curved surface profile so that ventilation windage loss can be significantly reduced is provided. In an exemplary embodiment, the orientation and/or the height of the baffle can be adjusted to adjust flow gaps defined between it and the adjacent lamination/stator flange surfaces and/or between it and a facing adjacent space block, so that ventilation flow can be controlled to satisfy varying cooling requirements.

Abstract: A flexible magnetic brush seal is employed as a low flow fluid film seal and/or a diffusion and mass transfer prevention seal in a hydrogen generator to seal between a hydrogen atmosphere and a fluid on an opposite side of the seal. The brush seal is formed of a magnetic rubber flexible material, enabling the seal to be flexed and altered in dimension to fit a number of different sealing environments of different dimensions. The magnetic properties of the brush seal enable temporary securement of the brush seal to a brush seal holder prior to final securement.

Abstract: The series loop blocks of an armature end-winding structure are formed with grooves along a portion of their side surfaces to allow air flow to pass through the grooves to the series loop caps. Provision of the grooves on the side surfaces also facilitates machining of the ungrooved side surface portions of the series loop blocks for better fit and assembly between adjacent series loop caps.

Abstract: A seal is provided at the intersegments of hydrogen seal rings for preventing oil leakage through this potential gap between the seal ring segments. By minimizing leakage through the gaps between the open rings, hydrogen consumption in hydrogen-cooled generators due to leakage oil is reduced. In a preferred embodiment, the seal is provided by a brush seal secured to one of the seal ring segments and received in a slot defined in the other of the seal ring segments.

Abstract: A magnetic armature wedge is provided for replacing conventional dovetail wedges in high-powered large-size turbine generators. The magnetic armature wedges that are used for supporting the armature bars are made by molding resin, e.g., epoxy with ferromagnetic particles, wires, laminates and the like embedded therewithin. The magnetic particles, wires, laminates and the like increase the magnetic permeability of the wedges causing higher slot flux leakage and high generator subtransient reactants.

Abstract: In a rotating electric machine including a rotor and a stator surrounding said rotor in substantially concentric relation therewith to establish a gap therebetween, and wherein the stator is formed with a plurality of radially oriented slots, each slot receiving a stator bar held in place by a wedge, an arrangement to minimize rotor windage loss wherein each wedge substantially fills its respective slot such that an end surface of the wedge is substantially flush with adjacent surfaces of the stator.

Abstract: A seal is provided at the intersegments of hydrogen seal rings for preventing oil leakage through this potential gap between the seal ring segments. By minimizing leakage through the gaps between the open rings, hydrogen consumption in hydrogen-cooled generators due to leakage oil is reduced. In a preferred embodiment, the seal is provided by a brush seal secured to one of the seal ring segments and received in a slot defined in the other of the seal ring segments.

Abstract: A magnetic armature wedge is provided for replacing conventional dovetail wedges in high-powered large-size turbine generators. The magnetic armature wedges that are used for supporting the armature bars are made by molding resin, e.g., epoxy with ferromagnetic particles, wires, laminates and the like embedded therewithin. The magnetic particles, wires, laminates and the like increase the magnetic permeability of the wedges causing higher slot flux leakage and high generator subtransient reactants.

Abstract: A ventilation pathway for a cooling gas to flow extends on a radial axis in a generator stator core. The ventilation pathway comprises at least two magnetic laminations and a plurality of space blocks extending radially in the generator stator core. The space blocks are fastened and disposed between the magnetic laminations. At least one of the space blocks includes a wavy longitudinal profile that includes an alternating pattern of peaks and valleys with respect to the radial axis of the generator stator core. Alternatively, at least one of the space blocks has a plurality of protrusions defining a pattern of peaks and valleys extending from a sidewall of the space block. Several different shapes of vortex generators are punched in the lamination are located within the ventilation pathway.

Abstract: A brush seal includes a brush seal body formed of heat-resistant magnetic silicone rubber material in the form of a channel. Bristles are disposed in the channel of the brush seal body at a cant angle and project from the edges of the body terminating in bristle tips. The brush seal is formed linearly and, in use, flexed to form an annular seal between adjacent annular sealing components, with the seal carried by one component and the bristle tips engaging the opposite component. The magnetic material of the seal body enables temporary securement of the seal to one of the components, while the seal is adjusted and finally secured in place.

Abstract: Welded stator winding splice joints are provided that utilize gas tungsten arc welding to offer high performance and reliability. The application of welded stator winding joints can significantly raise operation reliability of rotary electric machines such as turbine generator and induction motors, simplify the manufacturing process, and reduce the cost and product cycle time.

Abstract: A rotor assembly including a rotor body and a stator, the rotor body having field coils seated within radial slots formed in the rotor body with end turns of the coils extending beyond opposite ends of the rotor body, and annular retaining rings fixed to the opposite ends of the rotor body and adapted to constrain the end turns against centrifugal forces, and wherein the stator includes a core with stator bars secured therein, the core having core-end tapers at opposite ends thereof that define, in combination with the retaining rings, annular ventilation air exit gaps; each the retaining ring comprising axially inboard and outboard ends, and wherein a radially outer surface at the axially inboard end has an aerodynamically smooth spline shape defined by compound radii that merges into a rounded nose portion, the core-end tapers of the stator core tapering in an axial and radially outward direction in a manner approximating a smooth curve.

Abstract: A retaining ring for a rotor assembly, the retaining ring adapted to constrain field winding end turns arranged in a rotor body, the retaining ring comprising axially inboard and outboard ends and radially inner and outer surfaces, the radially outer surface at the axially inboard end having an aerodynamically smooth spline shape defined by compound radii that merge into a rounded nose portion.

Abstract: In this invention is described a linear feedback shift register that is enhanced with XOR circuits and free running oscillators to maximize the random nature of the sequence of digital bit created at the output of the generator in response to a clock signal. XOR circuits are included in the feedback path of a LFSR to randomize digital signals being fed back from the output to the input. Additional XOR circuits are interposed between stages of the LFSR and each connected to a high frequency oscillator to randomize the digital signals flowing between stages of the LFSR. The frequency of the oscillators are set so as not to be duplicated, and not to be a factor or multiple of another oscillator connected to the enhanced LFSR. The frequency of the oscillators are higher than the frequency of the clock used to step the LFSR. The output of the LFSR is a highly randomized sequence of digital bits that can be used in integrated circuits for such purposes as Smart Cards.