Honeywell International Inc.

Kieran P J Doherty

Gerald Eugene Tornquist

Raymond Walter Borden

James D Lengel

Gregor J S McDowall

Ming Xu

WuenFar L Chen

William M Scherzinger

Gregor L McDowall

Mingzhou Xu

David E Stout

Jim Lengel

Wayne T Pearson

Simon L Waddell

David B Kane

Edward W Down

Lengel Jim

An improved apparatus and method of having a pair of end caps on a rotor assembly of a multi-pole high-speed generator is provided for use with a turbine engine. The rotor assembly provides improved balancing and/or cooling during generator operation. The rotor assembly includes a plurality of poles and at least one support wedge positioned between each of the poles. The rotor assembly is mounted on a shaft. An annular flange of the end caps restrains the support wedges in the rotor assembly for improved balancing and maintaining concentricity. The end caps may also include a manifold for circulating a cooling medium through the shaft to and from the support wedges to cool the generator.

Method of assembling a balanced high speed generator rotor

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.

Rotor assembly method

A rotor with wedges and a method of retaining wedges in a rotor are disclosed. The rotor includes a shaft, first and second poles extending radially from the shaft, and first and second coils of windings respectively wrapped around the first and second poles. Each coil includes a respective outer face including two end portions and two side portions, and a respective inward-facing edge including two end sections and two side sections. The rotor further includes a first outer wedge positioned between neighboring side portions of the first and second coils, and a first inner wedge positioned between neighboring side sections of the first and second coils. The first inner wedge is coupled to the first outer wedge so that the first outer wedge is at least partly retained from moving radially outward away from the shaft.

System and method for retaining wedges in a rotor

A terminal block assembly for electrical generators, such as high speed AC generators used in aircraft, is made from components that are readily assembled and disassembled for ease of installation, maintenance, and repair. The terminal block assembly is formed of a terminal block and one or more terminal assemblies. The terminal block has a main body with at least an upper surface and a lower surface. A first cavity is formed in the main body lower surface, and an opening that extends through the main body between the upper surface and the first cavity. A threaded fastener is inserted into the opening and into the first cavity, and a bolt is coupled to the fastener to secure the fastener in the opening. Each terminal assembly is coupled to the terminal block and includes one or more electrically conductive terminal plates, feed-throughs, and slugs for connection to stator output leads, that are electrically and mechanically coupled together using electrically conductive fasteners.

High power terminal block assembly for generators and method of assembling and installing the same

A high speed generator has its main rotor located within the main generator shaft assembly. The main rotor is mounted on a substantially hollow rotor shaft, which is also mounted within the main generator shaft assembly. The main stator surrounds at least a portion of the main generator shaft assembly. Main rotor cooling supply orifices extend through the rotor shaft. Main stator cooling supply orifices, which are in fluid communication with the main rotor cooling supply orifices, extend through the main generator shaft assembly. Cooling fluid is directed into the main generator shaft assembly, and flows through the main rotor cooling supply orifices and the main stator cooling supply orifices. The main rotor and main stator cooling supply orifices are configured to supply the main rotor and main stator with a cooling fluid spray. This configuration reduces the rotational fluid mass associated with flood-cooled rotors, which increases structural integrity, lowers material stresses, improves rotor dynamics.

High speed generator with the main rotor housed inside the shaft

A system and method for electrically coupling windings of a main generator rotor to a plurality of DC sources on an exciter that each have respective first-voltage and second-voltage terminals is disclosed. The system includes first and second conductive plates supported by the rotor that respectively define first and second apertures that surround a rotor shaft. The first plate includes a first rotor winding terminal by which the plate is electrically coupled to the windings, and a first plurality of terminals configured to be respectively coupled to the first-voltage terminals of the DC sources. The second plate is electrically insulated from the first plate, includes a second rotor winding terminal by which the second plate is electrically coupled to the windings, and includes a second plurality of terminals configured to be respectively coupled to the second-voltage terminals of the DC sources.

System and method for coupling rectifiers of an exciter to the rotor of a main generator

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.

System and method for end turn retention on a high speed generator rotor

A coil support wedge for a high speed generator is integrally constructed and includes a plurality of flow passageways. Because it is integrally formed, the support wedge is substantially fluid tight. Thus, it is less susceptible to cooling fluid leakage from the flow passageways, which increases the overall reliability of the generator into which the wedge is installed.

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Oro Valley, AZ, United States of America

Kieran P J Doherty