Sundstrand Corporation

Other

Sunstrand Corporation

John B Huss

Richard J Hoppe

Thomas Albert Sutrina

Lawrence E Crowe

Eric D Lakin

Mahesh J Shah

Alexander Krinickas, Jr

Jayant G Vaidya

Barry J Parker

Merle L Bennett

Bert J Fennel

Leo A Lynch

Electromotive apparatus comprising at least one winding (30) including a plurality of generally triangular coil turns (34). A plurality of generally triangular stator segments (55, 56, 57) are mounted within the coil turns (34). The winding is formed by a hollow conductor, and it is shaped for connection to a source of cooling fluid. A molded support (32) is fastened to the windings 30 and to the segments (55, 56, 57) for supporting the apparatus at its outer diameter.

Stator windings for axial gap generators

A dual permanent magnet generator (10) is provided with a differential gear arrangement (20) comprising two ring gears (21, 26), two planetary gears (30, 31) and a carrier (32) which is splined to an input shaft (12) in the generator (10) so as to rotate the carrier (32) at the same speed as the input shaft (12) while allowing the input shaft (12) to shift axially. One of the ring gears (21) has a threaded connection (18, 38) with the input shaft (12). Consequently, as either the ring gear (21) or the ring gear (26) is slowed down through the application of a resistive load on small generators (22, 23 and 27, 28) associated with the respective ring gears (21, 26), the threaded connection (18, 38) will cause the input shaft (12) to move axially in one of two directions and, via lefthand and righthand spline connections (15, 16) between the input shaft (12) and main rotors (13, 13'), cam the rotors (13, 13') to shift into and out of phase with respect to each other.

Dual permanent magnet generator planetary gear actuator and rotor phase

A permanent magnet generator having a plurality of permanent magnet generator units which produce a controlled output potential for driving variable electrical load (20) by vectorially adding an output potential of the permanent magnet generator units to produce the controlled output potential in accordance with the invention which includes a plurality of permanent magnet rotors (12 and 14) mounted on a drive shaft (16) with at least one of the rotors being rotatable with respect to the drive shaft to vary an angular position of the at least one of the rotors relative to the shaft to produce a variable magnitude permanent magnetic field; at least one stator (24) magnetically coupled to the variable permanent magnetic field for producing the controlled output potential; and a torsion spring (30), coupled to the drive shaft and to the at least one rotor, for angularly positioning the rotors relative to each other so that the variable permanent magnetic field coupled to the at least one stator is zero in response to a stator fault.

Torque driven dual PMG actuator

A permanent magnet generator having a plurality of permanent magnet generator units which produce a controlled output potential by mutual magnetic flux linkage between the permanent magnet generator units to produce the controlled output potential in accordance with the invention includes a plurality of permanent magnet rotors (20 and 22) mounted on a drive shaft (26) with at least one of the rotors being rotatable with respect to the drive shaft to vary an angular position of the at least one of the rotors relative to the shaft to produce a mutual variable magnitude magnetic axial field extending parallel to the drive shaft; at least one stator (26, 28, 72) disposed at a position axially offset from the plurality of rotors which is magnetically coupled to the variable magnitude permanent magnet axially field; and a mechanism (46, 48) responsive to a stator fault for angularly positioning the rotors relative to each other so that the permanent magnetic field coupled to the at least one stator is zero.

Axial gap dual permanent magnet generator

An electrical power generating system (10) for generating alternating current in accordance with the invention includes a main generator (14) for generating the alternating current having a stator (22) and a rotor (24) and an excitor (12) for generating excitation current of the main generator having a stator (16) and a rotor (18) With the rotors being coaxial and driven by an input shaft (36); a cylindrical non-electrically conductive containment sleeve (70) mounted in surface contact with the coaxial rotors so that the rotors fit within the sleeve to provide support for the rotors against centrifugal acceleration and for containing coolant liquid inside the cylinder and an outside surface facing an inner cylindrical surface of the stator; and a coolant circuit (50) for circulating the coolant liquid to cool windings (30) of the main generator rotor and windings (42) of the excitor rotor, the coolant circuit including a first portion (52) through which flows the coolant liquid received from a coolant input (50) through the windings of the main generator rotor and a second portion (56) through which liquid coolant flows into contact with the windings of the excitor rotor with the containment sleeve preventing coolant from flowing radially outward into an air gap between the rotors and stators of the main generator and the excitor.

Exciter rotor flow through cooling

An improved connection arrangement is provided for forming the electrical connection between a rotor winding and a rotatable diode pack, mounted on the rotor, in which rotor winding terminals are compressably sandwiched between the diode pack and the rotor or a diode pack mounting arrangement, such as an end winding support, attached thereto. By sandwiching the winding terminal in this manner, mechanical stresses and strain hardening of the connection may be avoided to increase reliability. Further mechanical support for the electrical connection is also provided while avoiding the use of parts which significantly contribute to the overall length of the electrical machine.

Connection for rotating diode package

Prior power converters have utilized discrete components mounted on circuit boards of differing designs. Failure of one or more of the components requires testing each component to determine which is faulty. The faulty component must then be replaced. This results in significant down time for the inverter and can require stocking a large number of specialized boards. In order to overcome these problems, an inverter is assembled using modular circuit boards. Each circuit board includes components mounted on a multilayer substrate and a heat exchanger which cools high power components. When a malfunction of a component occurs, the entire board containing the failed component may be readily replaced so that inverter down time is minimized. The use of modular circuit boards also reduces stocking requirements and inventory costs.

Modular circuit board

A stator drain supports stator windings and rotor bearings and permits fluid coolant for the rotor bearings to be drained outward past the stator windings from the bearings. The drain is formed of a non-metallic material and has an inner surface for supporting a bearing liner of the rotor bearings, a plurality of spaced openings for receiving stator windings and drain slots extending through the annular member at locations corresponding to spaces between the stator windings for draining the fluid coolant. The stator drain is useful in a dual permanent magnet generator, for example.

Stator drain and electrical apparatus employing the same

The disclosed rotating rectifier assembly (12) has a reduced axial length thereby achieving the goal of reducing the overall axial length of a brushless generator (10) which includes a rectifier assembly disposed along its axis (26) for developing DC output power from three phase AC power supplied by a three phase rotor armature (14) also contained within the generator (10). A typical rotating rectifier assembly is comprised of plates and diodes arranged in a stack clamped axially along the axis of rotation with a diode sandwiched between each adjacent pair of plates. The reduction of the axial length of the rectifier (12) is achieved by positioning a stack (67) of diodes (19) and plates (52 through 64) perpendicular to the axis of rotation (26) while providing the necessary electrical conductors to define a rectifier circuit.

Reduced length rotating rectifier assembly

Prior power converters have utilized discrete components mounted on circuit boards of different design. Failure of one or more of the components requires the components to be separately tested to determine which is faulty. The faulty component or the board containing same must then be replaced. This results in significant down time for the inverter and can require stocking of a large number of specialized boards. In order to overcome these problems, an inverter is assembled using a series of circuit boards of standardized type. Each circuit board includes separate layers which interconnect components mounted thereon together with a heat exchanger which cools high power components. When a malfunction of a component occurs, the entire board may be replaced so that inverter down time is minimized. Also, the use of standardized boards reduces stocking requirements and inventory costs.

Power converter circuit board

A power converter comprises a plurality of modular circuit boards assembled in a stacked relationship. The circuit boards include heat exchangers which are interconnected and cooling fluid is provided thereto to remove heat generated by high power devices.

Stacked power converter

An improved actuator for angularly adjusting first and second rotors of an alternating current generator reduces friction and minimizes the power necessary for affecting the angular adjustment. The rotors are driven by a common shaft through left and right hand helical ball splines. Axial movement of the shaft relative to the rotors is effected for simultaneously rotating each of the rotors a like amount in opposite directions during a relative angular adjustment.

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Rockford, IL, United States of America

John B Huss