Hamilton Sundstrand Corporation

Duane C Johnson

Ted A Martin

Glenn C Lemmers, Jr

Derek R Hochstetler

Dhaval S Patel

Edward C Allen

Kyle S Sirbasku

Andrew R Wilkinson

Mary Christelle Ann Calacal

Craig J Wojcik

Yaser J Isa

Andrew P Grosskopf

Aaron M Finke

Doren Smith

Skyler Ripplinger

William B Beard

Diego Rocha

Jessica M Friedberg

Diego A Rocha

The present disclosure provides for terminal block cover assemblies for electric generators, and related methods of fabrication and use. More particularly, the present disclosure provides for terminal block cover assemblies for generators for aircraft or the like, with the terminal block cover assemblies having electrical arcing mitigation features and structures, and related methods of fabrication and use. The terminal block cover assemblies of the present disclosure can be utilized to reduce electrical arcing events in environments where de-icing fluid is used in the engine cowl.

Terminal block and cover for arcing mitigation

An assembly comprises a resistor support housing for a rotating rectifier assembly (RRA). A shaft bore is defined through the resistor support housing for passage of a shaft of an electrical machine. The resistor support housing defines a main annular body around the shaft bore. An end housing is mounted to one axial end of the resistor support housing. The end housing defines a portion of the shaft bore therethrough.

Resistor support assembly with spring seat

An assembly comprises a resistor plate for a rotating rectifier assembly (RRA). A shaft bore is defined through the resistor plate for passage of a shaft of an electrical machine, and the resistor plate defines a main annular body around the shaft bore. A first protrusion extends radially outward from the main annular body, so that a first pin bore extends through the first protrusion. At least one contact band is seated in a the pin bore of the resistor plate for mounting a direct current (DC) pin to the resistor plate.

Resistor plate assembly with contact bands

An assembly comprises an AC (alternating current) housing connection block and a plurality of inserts seated in the AC housing connection block, wherein for each of the inserts, an interface between the insert and the housing is continuous. A method includes inserting a plurality of inserts into a mold; and molding an AC (alternating current) housing connection block.

Alternating current connection housing with integrated inserts

An assembly comprises a mounting ring for a rotating rectifier assembly (RRA) having a pin bore defined in the mounting ring oriented in an axial direction and at least one contact band seated in a the pin bore of the mounting ring for mounting a direct current (DC) pin to the mounting ring. A method comprises forming a mounting ring for a rotating rectifier assembly (RRA), including forming a pin bore in the mounting ring oriented in an axial direction, and installing at least one contact band into a the pin bore of the mounting ring.

Diode mounting ring with contact band inserts

An input shaft includes an annular main shaft extending along a longitudinal axis with an internal bore configured for fluid flow through the annular main shaft. A generator spline is included on an exterior surface of a first end of the main shaft. A gearbox spline is included on an exterior surface of a second end of the main shaft opposite the first end. At least one orifice is defined through the main shaft from the internal bore to the exterior surface of the second end of the main shaft for flow of fluid from the internal bore to the exterior surface for cooling and lubrication.

Input shafts for generators

A terminal assembly includes a terminal block of a dielectric material defining a plurality of bores therethrough. A respective terminal contact of an electrically conductive material is seated in each of the respective bores. The terminal contact defines a longitudinal axis therethrough with a terminal bore defined through the terminal contact along the longitudinal axis. A divider wall separates the terminal bore into a solder cup for a lead wire on an interior side of the terminal bore, and a lug receptacle on an exterior side of the terminal bore.

Terminal block assemblies

A resistor pack assembly including an anti-rotation housing. The anti-rotation housing includes a first surface, a second surface opposite the first surface, one or more anti-rotation lugs extending away from the first surface, and an internal cavity extending from the second surface into the anti-rotation housing towards the first surface. The resistor pack assembly also including a positive rail located at least partially within the internal cavity, a negative rail having an inner circular face and an outer circular face located radially outward from the inner circular face, and an insulator ring is interposed between the second surface of the anti-rotation housing and the outer circular face of the negative rail.

Connection assembly cover with integrated anti-rotation

A rectifier assembly includes a terminal arranged along an assembly axis, a mounting ring axially offset from the terminal and seating a diode, a bus bar received within the mounting ring and electrically connecting the diode to the terminal through the bus bar, and a mounting ring. The mounting ring insulator receives the bus bar, is axially offset from the mounting ring, and contains an insert. The insert fixes the bus bar to the mounting ring insulator and compressively fixing the diode within the mounting ring. Generators and methods of making rectifier assemblies for generators are also described.

Rotating rectifier assemblies, generators having rotating rectifier assemblies, and methods of making rotating rectifier assemblies

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.

Lamination for main generator rotor in an integrated drive generator

A generator driven 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 having a unique gear tooth profile with roll angles A, B, C, and D. An integrated drive generator and a method are also disclosed.

Generator driven gear for integrated drive generator

A port plate for use in an integrated drive generator has a body defining a semi-cylindrical charge port communicating with two circumferentially smaller charge port portions. A diametrically opposed working pressure port has three smaller working pressure ports. A center plane is defined extending through a center axis of a bore within the body and equidistance between circumferential ends of the charge port and the working fluid port. A first angle is defined between the plane and a circumferential end of the smaller charge port. The first angle is between 15 and 25 degrees. An integrated drive generator and a method are also disclosed.

Port plate for integrated drive generator

A pump sleeve for an inversion pump in an integrated drive generator has a pump sleeve body extending between a first end and a second end, the first end being at a location adjacent an enlarged endplate. The body extends to the second end with a generally cylindrical body portion having a bore of an inner diameter from the first end to the second end, and between the first and second ends for a distance. A ratio of the first distance to the inner diameter being is 1.8 and 2.0. In addition, an integrated drive generator is disclosed as is a method of replacing an accessory drive gear in an integrated drive generator.

Growing community of inventors

Beloit, WI, United States of America

Duane C Johnson