Abstract: A method and assembly of a dry cavity oil cooled electric machine includes a housing, a shaft configured to operably couple with a source of rotational force and rotate about a rotational axis, and an exciter rotor and a permanent magnet generator rotor carried by the shaft, wherein the exciter rotor and the permanent magnet generator rotor rotate relative to the housing, which provides such a construction of dry cavity generators that have high efficiency and high power density.

Abstract: An electric machine assembly having a main machine stator core having at least one stator post, a set of stator windings wound about the at least one stator post and having a first end and an opposing second end, a coolant inlet housing defining an inlet passage, a coolant outlet housing defining an outlet passage, proximate to the coolant inlet housing, and wherein the coolant inlet passage and the coolant outlet passage define a coolant circuit configured to receive a supply of coolant to remove heat generated in the set of stator windings.

Abstract: A method for manufacturing a stator assembly for an electrical machine includes printing a stator core. The method also includes printing a first part of a stator winding. In addition, the method includes coupling the first part of the stator winding to the stator core. The method also includes printing a second part of the stator winding onto the first part of the stator winding to form the stator assembly. In particular, coupling the first part of the stator winding to the stator core precedes printing the second part of the stator winding onto the first part of the stator winding.

Abstract: A method for manufacturing an electrical machine includes printing a stator core; printing a first part of a stator winding; coupling the first part of the stator winding to the stator core; printing a second part of the stator winding onto the first part of the stator winding to form a stator assembly; printing a first part of a rotor shaft; printing a rotor core onto the first part of the rotor shaft; printing a second part of the rotor shaft onto the rotor core; printing a first part of a rotor winding; coupling the first part of the rotor winding to the rotor core; and printing a second part of the rotor winding onto the first part of the rotor winding to form a rotor assembly.

Abstract: A method for manufacturing a rotor assembly for an electrical machine includes printing a first part of a rotor shaft. The method also includes printing a rotor core onto the first part of the rotor shaft. In addition, the method includes printing a second part of the rotor shaft onto the rotor core; printing a first part of the rotor winding. The method also includes coupling the first part of the rotor winding to the rotor core. After coupling the first part of the rotor winding to the rotor core, the method includes printing a second part of the rotor winding onto the first part of the rotor winding to form the rotor assembly.

Abstract: A method for integrally manufacturing a stator core and a housing for an electrical machine includes printing, by a three-dimensional (3D) printing process, the stator core. In addition, the method includes printing, by the 3D printing process, the housing. In particular, printing the housing occurs contemporaneously with printing the stator core. The method also includes printing, by the 3D printing process, at least one end cap and coupling the at least one end cap to the housing to enclose a cavity defined by the housing.

Abstract: A method for manufacturing a housing for an electrical machine includes printing, by a three-dimensional (3D) printing process, the housing. In addition, the method includes printing, by the 3D printing process, a cooling jacket that is integral with the housing. The method also includes printing, by the 3D printing process, at least one end cap configured to enclose a cavity defined by the housing. In addition, the method includes coupling the at least one end cap to the housing.

Abstract: A wet cavity electric machine includes a stator core having two stator poles formed by a post and a wire wound about the post to form a stator winding, with the stator winding having end turns, and a rotor having two rotor poles and configured to rotate relative to the stator and a channel for liquid coolant to flow through the rotor, and at least one fluid port in fluid communication with the channel and the stator winding end turns wherein the end turns will be exposed to liquid coolant passing through the channel.

Abstract: A method and power converter unit for operating a generator includes a rotatable shaft operably coupled with a source of rotational force, a rotor mounted to the rotatable shaft and having at least one rotor pole defining a rotatable direct axis, a stator encircling the rotor and having a set of stator windings, and a power output electrically coupled with the set of stator windings and operable in a power generating mode and a power absorption mode

Abstract: A generator includes a stator core having a set of stator poles formed by a post and a wire wound about the post to form a stator winding, with the stator winding having end turns, a rotor having a set of rotor poles and configured to rotate relative to the stator and a rotor channel for liquid coolant to flow through the rotor to a set of coolant apertures, and a set of rotor pole coolant channels aligned with and proximate to the set of rotor poles. The liquid coolant flow extracts heat from the generator.

Abstract: A rotor assembly for an electric machine includes a core having at least one post and a cap wherein electrical windings are wound about the rotor assembly to define a pole. The rotation of the rotor and rotor pole relative to a stator generates a current supplied from the electric machine to a power consuming device.

Abstract: A wet cavity electric machine includes a stator core having stator poles formed by a post and a wire wound about the post to form a stator winding, with the stator winding having end turns, a rotor having two rotor poles and configured to rotate relative to the stator and a channel for liquid coolant to flow through the rotor to at least one nozzle, and liquid coolant sprays from the at least one nozzle at least a portion of the stator windings.

Abstract: A method and power converter unit for operating a generator includes a rotatable shaft operably coupled with a source of rotational force, a rotor mounted to the rotatable shaft and having at least one rotor pole defining a rotatable direct axis, a stator encircling the rotor and having a set of stator windings, and a power output electrically coupled with the set of stator windings and operable in a power generating mode and a power absorption mode

Abstract: A slot liner for a rotor assembly in one embodiment includes a metallic support member and a coating. The coating is disposed on at least one side of the metallic support member, and includes a mixture of a filler and a polyimide resin. The filler is a high thermal conductivity electrical insulating (HTCEI) filler, and includes particles of at least one of boron nitride, aluminum nitride, or a diamond material.

Abstract: An electrical machine includes a rotor, a stator having a slot liner including an electrical insulator which extends beyond the stator ends, and a strengthening element provided at each of the slot liner ends, wherein the strengthening strip reduces the splitting of the corresponding slot liner end.

Abstract: A ram air turbine system includes a rotatable shaft, a housing having a body defining an interior, a generator located within the interior and having a stator and a rotor, and a turbine having a first set of blades operably coupled with the rotatable shaft and configured such that airstream passing through the first set of blades rotates the shaft.

Abstract: An assembly for a gas turbine engine includes a S/G having a rotatable shaft, a main machine, a PMG, and an exciter wherein at least one of the main machine, PMG, and exciter includes a rotor mounted to the shaft and having multiple rotor poles, a stator having multiple stator poles and at least one of the rotor poles and stator poles being formed by a core with a post and wire wound about the post to form a winding, with the winding having at least one end turn, and a layer to increase cooling capabilities of a portion of at least one of the stator and the rotor.

Abstract: A rotor assembly for an electric machine includes a core and a cap wherein electrical windings are wound about the rotor assembly to define a pole. The rotation of the rotor and rotor pole relative to a stator generates a current supplied from the electric machine to a power consuming device.

Abstract: A rotor assembly for an electric machine includes a core having at least one post and a cap wherein electrical windings are wound about the rotor assembly to define a pole. The rotation of the rotor and rotor pole relative to a stator generates a current supplied from the electric machine to a power consuming device.

Abstract: A rotor assembly (40) for an electric machine including a core (42) having at least one post (44) about which a winding may be wound, and a cap (52) coupled to the post (44) and having a portion overlying a winding (46), wherein the cap (52) comprises a plurality of laminations and the core (42) does not comprise a plurality of laminations.