Abstract: A rotor and a method of constructing a rotor are disclosed. The rotor includes a hub that is capable of being supported by a shaft that extends along an axis, a plurality of laminations, and a plurality of wire windings supported by the plurality of laminations. The hub includes an inner structure configured to support the hub relative to the shaft, an outer structure that supports the laminations, and an intermediate structure that is coupled to the inner and outer structures and supports the inner and outer structures relative to one another.

Abstract: The present invention provides for a fitted wedge wherein a formed outer frame is loosely fitted into a desired gap. The formed outer frame contains a lateral gap such that the formed outer frame is substantially or completely divided into two halves. A thin, stiff sheet coated with a resin saturated felt is then inserted between the two halves of the outer frame. The two halves are pushed apart, snuggly fitting the formed outer frame into place. The resin in the felt is then cured, forming a single, snuggly fit wedge.

Abstract: The machine comprises a rotor with a winding for cooling, which is in particular superconducting, in a winding support. A device with a composite body made of fiber-reinforced plastic is provided, for retention of the winding support within a rotor outer housing, on a torque transmitting side. The composite body is in one piece and comprises lateral pieces and a center piece, whereby the lateral pieces extend outwards in a funnel shape and the center piece is in the form of a hollow cylinder. The lateral pieces should at least partly comprises a corrugated form in the circumferential direction and are connected with a positive or friction fit by press-ring bodies with flange-like fixing pieces made from metal.

Abstract: A joined assembly and kit for a rotor of a dynamoelectric machine are provided. The joined assembly is part of a conductive path generally extending from a radially inward section of the rotor to a radially outward section of the rotor. The conductive path includes a flexible connecting member from the radially inward section of the rotor to the joined assembly. The joined assembly includes a stacked winding energizable in response to excitation current carried by the conductive path to a top of the stacked winding located at the radially outward section of the rotor. The joined assembly further includes a connector with a first leg providing an electrically insulated mechanical point of contact relative to a bottom of the stacked winding.

Abstract: A rotary electric machine assembly includes a stator and a shaft including a hollow core. Mounted onto the shaft is an inner-flanged band with an inner hub, a first flange and a first containment band. An outer-flanged band includes an outer hub that nests over the inner hub and defines a coolant passage therebetween. The outer-flanged band includes a second flange and a second containment band. A rotor core is disposed within a space between the first and second flanges. Coolant flowing through the coolant passage absorbs heat from the rotor core. The rotor core includes windings having end portions. The first and second containment flanges radially support the end portions of the windings.

Abstract: A method of manufacturing a winding of a rotary electric machine includes steps of pressing a portion of a conductor segment in a predetermined direction to reduce its dimension in the direction, inserting the conductor segment into a slot of a stator core, bending the conductor segments and joining ends of the conductor segments. In the pressing step, the conductor segment is pressed with a punch in a condition that it is held in a die that has curved inside corner portions to restrict deformation of corners of the pressed portion.

Abstract: The rotor body of an electrical machine has end windings supported by a plurality of circumferentially spaced rakes having tines between which the end windings pass in an arcuate pattern from and for return to an axial orientation within the rotor body. The rakes are supported on axial beams secured to the rotor body. An end disk is secured at the opposite ends of the beams and to a shield overlying the end windings. The rakes, beams and end disks provide axial end winding restraint. The end disk is weighted at selected circumferential locations to resist tendencies of the end windings to distort, e.g., toward an elliptical or non-concentric configuration about the rotor axis.

Abstract: End windings of the field windings of a generator rotor body are flattened. A cap having a flat undersurface overlies the flattened end windings and an enclosure ring extends about the end windings and cap. Apertures are formed through the cap in communication with gaps between the coils of the end windings and passageways formed along the outer surface of the cap. The passageways and apertures form ventilation paths for a cooling medium flowing through the end windings outwardly into the air gap between the rotor body and stator.

Abstract: Each of the rotor magnetic poles is composed of a winding around a laminated core and each of both ends of each wound wire is connected to a commutator leg part coupled with a tip of a corresponding commutator segment of the commutator unit. Each of the commutator leg parts comprises a base portion extending outward in a direction substantially normal to the radial direction from the tip of the corresponding commutator segment tip and coupled to the commutator segment tip and a tip portion narrowed stepwise to let the ends of a wound wire be connected. A disk-shaped varistor having a hole at the center is mounted over the base portion of the commutator leg part, and each electrode of the varistor is soldered onto the corresponding base portion. Further, the commutator leg parts are punched and cut out of a reel-wound flat parent metal sheet and fixed to the commutator segment tips.

Abstract: An improved generator rotor (30) and a method of repairing an existing generator rotor (12) are disclosed. Methods consistent with the present invention provide techniques for repairing existing stress-damaged rotors (12) to remove stress-induced cracks (29), without requiring new retaining rings (16), to significantly extend the useful life of a generator without the cost and complexity of conventional repair techniques. Improved generator rotors (30) consistent with the present invention provide a tooth-top design that is more resistant to stress-induced cracking than conventional designs, resulting in new generators with longer useful lives.

Abstract: A corona suppression apparatus for a dynamoelectric machine having a stator coil (12) covered with a corona suppression covering (16), the apparatus including a member (10) conducting to ground (20) abutting a top layer (28) of the corona suppression covering proximate an overlap region (18) of the corona suppression covering. The member may be positioned in a gap (30) between the stator coil corona suppression covering and a stator core clamping finger (24) extending from the stator core proximate the stator coil. The member may also be configured to exert a compressive force on the overlap region by being compression biased between the corona suppression covering and the stator core clamping finger.

Abstract: The present invention increases the life of a pole crossover while minimizing the need for timely inspections and costly replacements. The present invention splits the pole crossover band 4 at one or more locations along its circumference and then joins the multiple arcs with a flexible member 10, such as an omega shaped bow. As deflection related stresses 8 increase, the circumference of the pole crossover band, the flexible member 10 allows for a natural expansion point in the otherwise rigid material. This relieves stresses that would otherwise be transferred to the connection point 6 between the pole crossover and the generator windings that can cause cracking and eventually generator failure.

Abstract: A compact and light electric blower which is improved in wiring cooling capability without reducing the airflow efficiency. The electric blower includes a spool attached to end surfaces of a field core fixed to a motor frame of which outer periphery portion is in an approximately cylindrical shape, and field wiring each wound across the field core and the spool, wherein a gap capable of passing air is formed between the coil end between slots of the field wiring and the field core, and each spool is provided with a wall surface which narrows the airflow section formed between the field core and the motor frame while forming a periphery portion of the field wiring.

Abstract: Apparatus for fastening a winding assembly disposed at least partially in an air gap between a stator yoke and a rotor of an electric machine, includes a main body made of electrically insulating non-magnetic material. The main body includes a cylindrical base and a plurality of axial webs projecting radially outwards from the base in a direction of the stator yoke for at least partial engagement in complementary recesses in the stator yoke.

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 superconducting rotor assembly includes an axial shaft and a winding support structure. A torque tube is connected to this winding support structure. An interconnection assembly mechanically couples the torque tube to the axial shaft. This interconnection assembly is configured to convert a torsional torque load experienced by the torque tube to a tangential torque load which is provided to the axial shaft.

Abstract: A machine comprises: a rotor comprising (a) axially extending coils, each coil extending into an endwinding region, (b) a plurality of cavities between the coils in the endwinding region, and (c) a plurality of spacers situated between the coils. Ventilation grooves having an inlet and an outlet are defined in the rotor with at least some of the coils including at least one of the ventilation grooves. The ventilation grooves provide at least one path for gas flow from at least one first cavity to at least one of (i) a second cavity or (ii) a different portion of the first cavity.

Abstract: A retaining system for field winding end turns of a rotor, such as for a dynamoelectric machine. The rotor has an outer peripheral surface, radial end surfaces, axially-extending slots in the peripheral surface, and field windings in the slots. The field windings axially project from the end surfaces of the rotor and are connected outside of the slots by field winding end turns. The end turns are surrounded by the retaining system, which includes a shield member surrounding the end turns and a retainer member surrounding to the shield member. The shield member has flanges received in the slots along with the field windings. Fastening features engage the flanges to inhibit axial movement of the retaining system.

Abstract: A new improved system and method for end turn retention for wires on a generator rotor for use in high speed applications such as in aircraft applications. The rotor includes a shaft, spokes, supports, and wire winding coils, and at least one cap device. The spokes extend radially outwardly from the shaft, and each support is positioned on an associated spoke. Each coil wraps around an associated support and spoke. Each cap device is coupled to an end of its associated spoke to prevent the windings from moving radially outwardly while the rotor spins. Each support is coupled to an associated cap device, and includes at its radially inward edge a flange protruding away from the respective spoke. Because of the flange and the cap device, slack of the wire coil between the flange and the associated cap is taken up.

Abstract: A winding module for an electric machine is provided wherein the winding module comprises a flat field winding that is angled at an end turn and wherein a vertex of the flat field winding is aligned with an axis of rotation. The vertex provides a predetermined axial offset so as to compensate for a radial expansion of the flat field winding when it is disposed to a centrifugal force.

Abstract: The invention relates to a device (12) for tensioning a winding (9) of a stator (1), in particular a generator stator (1) of a power plant. The winding (9) includes a winding head (10). Several winding supports (13) are arranged at the front side (4) of the core (2). Each winding support (13) abuts against the front side (4) of the core (2) and via a pressure spring element (19) against the funnel-shaped outer side (14) of the winding head (10). The winding supports (13) are fixed at the winding head (10) in the circumferential direction and in the surface line direction of the winding head (10). The winding supports (13) are movable perpendicularly with respect to the outer side (14).

Abstract: The object of the invention is to provide improved protection for the insulation of the rotor end windings of electrical machines that is suitable in particular for electrical limit-rating machines. This is achieved by the rotor end bell (2) consisting of steel and the retaining ring liner sheet (10), spatially separating the end winding insulation (9) from the rotor end bell (2), consisting of titanium or a titanium alloy. Moreover, a lubricant (11) with a temperature stability of >300° C. is applied between the retaining ring liner sheet (10) and the rotor end bell (2).

Abstract: An interconnecting assembly for a rotor assembly of a dynamoelectric machine is provided. The interconnecting assembly may be part of a conductive path generally extending from a radially inward section of the rotor assembly to a winding located at a radially outward section of the rotor assembly. The interconnecting assembly may be made up of a flexible member (44) comprising a bend (50). The interconnecting assembly may be further made up of a connector (70) connected to the flexible member to pass axial and radial forces that develop during operation of the machine. The positioning of the connector relative to the flexible member may be arranged so that an effect of an axial force on a radius of curvature of the bend and an effect of a radial force on that radius of curvature are opposed to one another. This leads to lower peaks of mechanical stress at the flexible member (44) (e.g.

Abstract: A commutator-integrated armature of a rotary electric machine is comprised of a rotary shaft, an armature core composed of a plurality of laminated sheets, an armature coil composed of a plurality of conductor segments. The conductor segments have in-slot portions respectively inserted into a plurality of slots of the armature core and end portions forming a flat commutator. The armature core has an anchoring portion for anchoring a part of each of the in-slot portions to the armature core more strongly than the rest thereof. The surface of the flat commutator is maintained flat even if the conductor segments repeat thermal expansion and contraction.

Abstract: A rotor winding series connector 40a is for a dynamoelectric machine, such as an exciter 25 of a generator apparatus 20 including a rotor 32 and a stator 34 surrounding the rotor. The rotor 32 may include rotor windings defining at least one pair of first and second rotor winding ends 38a, 39a arranged in spaced relation. The rotor winding series connector 40a may include a C-shaped connector body 42a including a medial connector portion 44a and respective first and second end connector portions 46a, 47a extending outwardly therefrom. The rotor winding series connector 40a may further include first and second connector brackets 48a, 49a carried by the respective first and second end connector portions 46a, 47a for receiving the respective first and second rotor winding ends 38a, 39a therein.

Abstract: A rotor for a synchronous machine comprising: a superconducting field winding assembly having a coil winding and at least one winding support extending between opposite sides of the winding, and a rotor core formed of a plurality of rotor core sections, each of said core sections having a tension bar slot to receive said at least one tension bar.

Abstract: A rotor for a synchronous machine is disclosed having: a rotor core having a rotor axis; at least one super-conducting coil winding arranged around the rotor core; at least one pair of coil support beams attached to the coil winding and secured to the rotor core, wherein said coil support beams are separated from the rotor core, and a cold coil support cylinder fitted over an outside surface of said beams.

Abstract: A generator gas shield includes an annular ring body having an outer radially extending flange terminating at a first free end of a first diameter; a curved inlet portion; a substantially axial portion surrounding a center opening, and a curved outlet portion terminating at a second free end of a second diameter smaller than the first diameter.

Abstract: A rotor for a synchronous machine is disclosed including a rotor core; a super-conducting coil winding extending around the rotor core, the coil winding having a coil end section adjacent an end of the rotor core, and a coil support bracing the end section and being thermally isolated from the rotor core.

Abstract: Arrangement of internally cooled electrical conductors, in particular for a generator rotor. A number of internally cooled conductors in each case having a longitudinal conductor and a transverse conductor connected to it, the longitudinal conductors and the transverse conductors being respectively arranged at least approximately parallel and a small distance apart. Advantageous cooling in terms of fluid mechanics is achieved by a cooling duct of a longitudinal conductor of one conductor being connected to a cooling duct of a transverse conductor of an adjacent conductor.

Abstract: A rotor for a synchronous machine is disclosed comprising: a rotor; a super-conducting coil winding extending around at least a portion of the rotor, the coil winding having a pair of side sections on opposite sides of the rotor; at least one tension rod extending between the pair of side sections of the coil winding and through conduits in the rotor; and a coil housing at each of opposite ends of the tension rod, wherein the coil housing wraps around the coil winding and is attached to the tension rod.

Abstract: A new improved system and method for end turn retention for wires on a generator rotor for use in high speed applications such as in aircraft applications. The rotor includes a shaft, spokes, supports, and wire winding coils, and at least one cap device. The spokes extend radially outwardly from the shaft, and each support is positioned on an associated spoke. Each coil wraps around an associated support and spoke. Each cap device is coupled to an end of its associated spoke to prevent the windings from moving radially outwardly while the rotor spins. Each support is coupled to an associated cap device, and includes at its radially inward edge a flange protruding away from the respective spoke. Because of the flange and the cap device, slack of the wire coil between the flange and the associated cap is taken up.

Abstract: In a rotary electric machine, a collar for restricting expansion of coil ends includes a boss fitted on an armature rotation shaft, a flange radially extending from the boss and a pressing portion for pressing coil ends toward an armature core. The thickness of the boss is greater than that of the flange, so that the force F1 that is caused by deflection of the flange when coil ends expand due to a temperature increase is smaller than the force F2 that is required to remove the boss from the rotation shaft. The force F1 is applied to the boss in a direction that the collar separates from the armature core. Because the pressing portion presses against the coil ends toward the armature core through an insulation ring, the coil ends are restricted from expanding by a centrifugal force when the armature rotates.

Abstract: A gas cooled dynamoelectric machine is provided that is comprised of a rotor, a rotor winding comprising axially extending coils and concentric endwindings, and a plurality of spaceblocks located between adjacent endwindings thereby to define a plurality of cavities, each bounded by adjacent spaceblocks and adjacent endwindings. To enhance the heat transfer rate from the copper end turns of the field endwinding region, at least one spaceblock has a trailing edge or downstream wall contoured to reduce generated wake. In a preferred embodiment, the trailing edge has an aerodynamic contour to reduce the extent and strength of the generated wake.

Abstract: An improved generator rotor (30) and a method of repairing an existing generator rotor (12) are disclosed. Methods consistent with the present invention provide techniques for repairing existing stress-damaged rotors (12) to remove stress-induced cracks (29), without requiring new retaining rings (16), to significantly extend the useful life of a generator without the cost and complexity of conventional repair techniques. Improved generator rotors (30) consistent with the present invention provide a tooth-top design that is more resistant to stress-induced cracking than conventional designs, resulting in new generators with longer useful lives.

Abstract: The An aspect of the invention relates to a machine comprising a rotor that is mounted so it can rotate about a rotational axis, and a superconductive winding located in a winding support. Further, Connection connection devices are provided to retain the winding support inside a rotor external housing. To compensate changes caused by the expansion of the winding support, a connection device should have at least one connection element that extends axially. One with one end of the element is connected to the winding support in a fixed manner, and the opposite free end is connected to a centering retaining element of the rotor eternal housing in a non-positive radial fit, so that it can be displaced axially.

Abstract: In a turbo generator with a rotor with direct gas cooling, which rotor is provided with a rotor winding arranged around a central rotor body, said rotor winding being on the front sides covered by one each annular cap plate, and in which rotor cold cooling gas for cooling the rotor flows into ring gap segments between the cap plate and the rotor body, whereby the ring gap segments are bordered, when seen in circumferential direction, on the sides in each case by the section of an end spacer plate provided between the cap plate and the rotor winding, whereby this section is projecting into the ring gap, improved cooling is achieved in that separations of the cooling gas stream on flowing into the ring gap segments are avoided by designing the sections of the end spacer plates, whereby these sections adjoin the ring gap, in a manner that is advantageous with respect to the flow.

Abstract: A gas cooled dynamoelectric machine is provided that is comprised of a rotor, a rotor winding comprising axially extending coils and concentric endwindings, and a plurality of spaceblocks located between adjacent endwindings thereby to define a plurality of cavities, each bounded by adjacent spaceblocks and adjacent endwindings. To enhance the heat transfer rate from the copper end turns of the field endwinding region, the downstream wall of at least one spaceblock is contoured to lower a suction pressure developed at the trailing edge of the spaceblock. In a preferred embodiment, the downstream wall of the spaceblock has a re-entrant contour to enhance the rotating cavity cooling flow.

Abstract: A star connected wound rotor has a shaft 12, a rotor core 14 fitted to the shaft, a commutator 16 fitted to the shaft adjacent one end of the rotor core and a star connector 18 fitted to the shaft adjacent the other end of the rotor core and a plurality of coils wound about the rotor core and connected to the commutator and the star connector, thereby forming a star connected rotor winding 20.

Abstract: A rotor is disclosed for a synchronous machine comprising: a rotor core; a super-conducting coil winding extending around at least a portion of the rotor core, said coil winding having a side section adjacent a side of the rotor core; at least one tension rod extending through a conduit in said rotor core; at least one tension bolt extending between an end of the tension rod and abutting the side section of the coil winding; and a channel housing attached to the tension bolt and the coil winding.

Abstract: A rotor having a superconducting coil winding is disclosed having a rotor core having at least one conduit extending through the core; at least one tension rod extending between the pair of side sections of the coil winding and through said at least one conduit of the rotor; and an insulator in the conduit thermally separating the tension rod from the rotor.

Abstract: A rotor is disclosed for a synchronous machine comprising: a rotor core; a super-conducting coil winding extending around at least a portion of the rotor core, said coil winding having a side section adjacent a side of the rotor core; at least one tension rod extending through a conduit in said rotor core; at least one tension bolt extending between an end of the tension rod and abutting the side section of the coil winding; and a channel housing attached to the tension bolt and the coil winding.

Abstract: An axial zone block (20) and methods of using the same are provided. The axial zone block (20) preferably is adapted to be positioned to overlie a rotor shaft (18) of a generator rotor (10) and to underlie portions of a plurality of end windings (15) and portions of at least one coil pole cross-over connector (17) of the generator rotor (10) to assist in forming low pressure axial zones in the rotor (10).

Abstract: A high power density synchronous machine is disclosed comprising: a stator having conventional stator coils arranged in an annulus around a vacuum cylindrical cavity; a magnetically saturated cylindrical magnetic solid rotor core; a race-track super-conducting coil winding extending around the rotor core, and a coil supportextending through the core and attaching to opposite long sides of the coil winding.

Abstract: In a rotary electric machine, a collar for restricting expansion of coil ends includes a boss fitted on an armature rotation shaft, a flange radially extending from the boss and a pressing portion for pressing coil ends toward an armature core. The thickness of the boss is greater than that of the flange, so that the force F1 that is caused by deflection of the flange when coil ends expand due to a temperature increase is smaller than the force F2 that is required to remove the boss from the rotation shaft. The force F1 is applied to the boss in a direction that the collar separates from the armature core. Because the pressing portion presses against the coil ends toward the armature core through an insulation ring, the coil ends are restricted from expanding by a centrifugal force when the armature rotates.

Abstract: A rotor having a superconducting coil winding is disclosed having a rotor core having at least one conduit extending through the core; at least one tension rod extending between the pair of side sections of the coil winding and through said at least one conduit of the rotor; and an insulator in the conduit thermally separating the tension rod from the rotor.

Abstract: A retaining ring for a rotor assembly has inboard and outboard ends. Each of the inboard and outboard ends is formed with a locking key groove open in a radially inward direction, each groove having a base representing a maximum depth of the groove, and a pair of side walls, the base having at least one flat portion therealong. In one embodiment, the groove base is defined by a pair of quarter circles connected by respective flat portions, the slots themselves separated by a raised platform. In a second embodiment, the raised platform is eliminated in favor of a flat base extending between radiused curves at the corners of the groove. In the latter embodiment, a locking ring is employed that has corner radii less than the radii of the curves in the corners of the groove.

Abstract: A wound rotor 10 for an electric motor has a shaft 12, an insulating spacer 28 fitted to the shaft, a rotor core 18 and commutator 20 fitted to the spacer and windings 24 wound around poles of the rotor core and terminated on the commutator. A first end of the spacer 28 remote from the commutator 20 has an axially extending recess forming an annular space 30 with the shaft 12. A winding shield 32 having a tubular portion 34 and a radially extending portion 36 is fitted to the shaft 12 such that the tubular portion 34 is located within the annular space 30. The winding shield increases the electrical clearance distance and creepage distance between the windings and the shaft and/or bearing located on the shaft adjacent the shield.

Abstract: An axial zone block (20) and methods of using the same are provided. The axial zone block (20) preferably is adapted to be positioned to overlie a rotor shaft (18) of a generator rotor (10) and to underlie portions of a plurality of end windings (15) and portions of at least one coil pole cross-over connector (17) of the generator rotor (10) to assist in forming low pressure axial zones in the rotor (10).

Abstract: An electric rotating machine includes a stator, a rotor core which can rotate inside the stator with a clearance between the rotor core and the inner surface of the stator, a stator winding formed around the rotor core, and a rotor having feeding lead wires connected to the rotor winding by a joint conductor. The feeding lead wire includes a first part connected to the joint conductor, a second part thinner than the first part, and a third part which is formed between the first and second parts and has a thickness changing from the thickness of the first part to the thickness of the second part. The first part also has through-holes to pass a cooling medium.