Hamilton Sundstrand Corporation

Brady A Manogue

Eric A Brust

Andrew P Grosskopf

Ted A Martin

Eric Alan Larson

Glenn C Lemmers, Jr

Edward C Allen

Dhaval S Patel

David S Behling

Jake A Rohrig

Alan D Hanson

Eric Andrew Nager

Christine Lynn Ooyen

William D Sherman

Glenn W Hufstedler

Kevin J Koester

Shaun Maconaghy

A generator including a stator winding, a rotor positioned radially inside the stator winding, including multiple coil assemblies each using a flat wire, a primary termination plate residing radially inside the rotor configured to connect a wire of a coil assembly to an adjacent wound coil and a secondary termination plate residing radially inside the rotor configured to connect a wound coil to an adjacent wound coil and connect the wound coil to a terminus connection.

Generator rotor flat wire winding

A supply end plate apparatus includes a supply end plate with an aperture therethrough configured to be mounted at a first axial end of the rotor core for supplying fluid to the rotor core. The supply end plate defines a plurality of end plate passages therein extending outward from an inward portion of the supply end plate toward an outward portion of the supply end plate. Each of the plurality of end plate passages includes: a radial section extending in a radial direction from an inlet in the inward portion of the supply end plate toward the outward portion; a transition section extending obliquely from the radial section; and a circumferential section extending circumferentially from the transition section to an outlet of the supply end plate.

Electric machine rotor end plates

A rotary electric machine includes a stator with a stator winding, a rotor with a field winding supported for rotation about a rotation axis relative to the stator, and an excitation winding. The excitation winding is fixed relative to the rotor and is electrically connected to the field winding. The rotor defines a coolant channel having an inlet and an outlet. Liquid coolant enters the inlet and flows outwardly through a portion of the excitation winding to conduct heat away from the excitation winding. Generators, aircraft electrical systems, and methods of cooling rotary electric machines are also described.

Rotary electric machines and methods of cooling rotary electric machines

An electric machine rotor assembly includes a rotor core defining a rotor axis. Windings are seated in the rotor core. A plurality of wedges circumferentially spaced apart around the rotor core relative to the rotor axis. Each rotor core extends axially and separates between two respective portions of the windings. A supply end plate is mounted at a first axial end of the rotor core. A return end plate is mounted at a second axial end of the rotor core opposite the first axial end. A flow path for coolant fluid extends through the supply end plate into the wedges, through the wedges and into the return end plate, and through the return end plate.

Rotor assembly and method of cooling

A rotor drive generator drive gear for an integrated drive generator can include an annular body having an outer diameter and an inner diameter defining an inner diameter channel through the body in a direction of an axis of rotation of the annular body. The annular body can define a gear defined on the outer diameter of the annular body and a bearing race defined on the outer diameter of the annular body. The bearing race can include a bearing race channel and one or more race relief channels defined from the bearing race channel at least partially inwardly toward the inner diameter channel. One or more lubrication conduits are defined through the body to fluidly connect the inner diameter opening and the bearing race such that lubricant can travel from the inner diameter channel to the bearing race for providing lubrication to a bearing assembly disposed in the bearing race.

Generator drive gear

A wedge for use in a generator rotor includes a wedge body extending for an axial length and having a generally triangular cross-section, a first side of the wedge body extending for the axial length of the wedge body, a second side of the wedge body extending for the axial length of the wedge body and having a generally flat surface, a third side of the wedge body extending for the axial length of the wedge body and having a generally flat surface, a first arm extending circumferentially away from the wedge body at an interface between the first side and the second side and extending axially along the wedge body, and a second arm extending circumferentially away from the wedge body at an interface between the first side and the third side and extending axially along the wedge body.

Rotor wedge with arms

A drive gear has a gear hub with a ledge. A plurality of gear teeth are formed at an outer periphery of the ledge, and centered about a central axis. A mount structure extends axially away from the ledge. A first distance is defined between axial ends of the gear teeth. A second distance is defined between ends of the gear hub. A ratio of the first distance to the second distance is between 0.52 and 0.54. An oil pump, a rotating portion for an electrical generator, and a generator are also disclosed. An oil pump, a rotating portion for an electrical generator, and a generator are also disclosed.

Electric generator oil pump drive gear

A driven gear includes a radially outwardly extending flange. The radially outwardly extending flange extends along an axial distance defined along a center axis of the flange. The flange merges into a generally conical portion which, in turn, extends radially inwardly to a hub. The hub extends to a remote end. A first distance defined between the remote end of the hub and an end of the flange faces the remote end. A second distance is defined between ends of the flange, with gear teeth formed at an outer periphery. A ratio of the first distance to the second distance is between 2.54 and 2.82. An oil pump, a rotating portion for an electrical generator, and a generator are also disclosed.

Electric generator oil pump driven gear

A generator includes a main cavity and a shaft located in the main cavity. The shaft is configured to be connected to an auxiliary power unit (APU) and rotated by the APU. The generator is configured to generate power based on the rotation of the shaft. A fluid system is configured to receive a fluid from the APU, flow the fluid through the main cavity and return the fluid to the APU through a fluid scavenge channel. A filter is configured to filter the fluid from the main cavity to the fluid scavenge channel and a sensor is configured to detect a characteristic of the fluid at the filter.

Auxiliary power unit generator

A stator core for a generator includes a multiple of core laminations along an axis, each of the multiple of core laminations define at least one leg which extends in a radial direction from the axis.

Laminated stator assembly

A pump gear includes a pump gear body having involute teeth that each have an involute surface that extends between a tooth tip and a tooth base. The involute surface includes at least reference points A-D, with reference point A near the base, reference point D near the tip, reference point B between reference points A and D, and reference point C between reference points B and D. The reference points A-D have associated respective roll angles, &#x3b5;, between a corresponding first line that is perpendicular to the involute surface at the given reference point A-D, and a second line that is tangent at a reference point that lies on a terminal end of the involute surface at the tooth base to a reference base circle having a center origin at the center axis.

Growing community of inventors

Beloit, WI, United States of America

Brady A Manogue