Sundstrand Corporation

Hamilton Sundstrand Corporation

Tyrone A Johnsen

Walter J Iseman

Timothy Scott Konicek

Bernard A Raad

Mohammad Shahamat

Harry Raymond Carter, Jr

Todd Alan Spierling

The present invention is a rectifier assembly, which has a first support and a second support. The supports have either a ring or plate shape. Each support has an inner peripheral surface with inwardly facing diode mounting surfaces. A diode is mounted to each of the inwardly facing diode mounting surfaces. Phase connectors connect one diode from the first support with one diode from the second support. The supports are received within an electrically insulated housing. The diodes are connected to the supports such that when assembled, each diode is perpendicular to a central axis that extends along a length the electrically insulated housing. During operation of the rectifier assembly, both supports rotate about the axis.

Rotating rectifier assembly with inner mounted diodes

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.

Cooling of high speed electromagnetic rotor with fixed terminals

A high-power electrodynamic machine has a relatively elongated rotor. In a preferred generator embodiment, a rotor having a winding formed integral therewith is integral to a hollow shaft mounted within a stator having a plurality of windings. The shaft has an axial end region with an inlet for a cooling fluid. The rotor winding is disposed in apposition to one of the stator windings. The rotor comprises a plurality of laminations. At least one pair of adjacent laminations has periodic slots. The slotted laminations are sandwiched between laminations without slots such that the slots in the adjacent laminations form a continuous, zigzag, generally radial outward passageway for the cooling fluid. The outlet of the passageway is arranged to discharge the fluid onto the winding to provide relatively even cooling along the entire length of the rotor without significantly reducing structural integrity.

Cooling of a rotor for a rotary electric machine

A high-power electrodynamic machine operates at a relatively high rotational speed and has dual rotors. In a preferred generator embodiment, one relatively massive first rotor having a magnetic device integral therewith is dedicated to the main generator. The exciter generator, which is relatively less massive, is isolated on a second rotor, which has a magnetic device integral to it. Only three bearings are required. The distance between the two bearings for the first rotor is relatively short, and the first rotor is relatively stiff, both of which facilitate operation of the first rotor below the critical speed. The junction of the first and second rotors further includes support of a junction end of the second rotor. The second rotor is driven by a prime mover via the first rotor. Means for providing electrical connections between the magnetic devices of the first and second rotors is also provided.

High-speed, high-power rotary electrodynamic machine with dual rotors

The need for specialized tooling which was previously required to accurately place the first layer of turns in a precision winding of a rotor having an even number of layers of turns is eliminated by providing self-fixturing wire-guiding features in corners of slots in the rotor which receive the winding, thereby facilitating the manufacture or repair of precision-wound rotors. In some exemplary embodiments, the self-fixturing wire-guiding features are provided by configuring the corners of the slots to include a chamfer or shoulder. In other exemplary embodiments, a specially shaped slot liner inserted into the slots includes a corner spacer which provides the self-fixturing wire-guiding feature.

Precision-wound rotor for a dynamoelectric machine

An adaptable rotating rectifier and suppression resistor assembly is designed to fit and mate with state-of-the-art, two-pole generators with maximum flexibility to accept a variety of known possible diode configurations and a relatively large suppression resistor in a cost effective manner. A tubular housing of the assembly has an axially extending internal cavity with a plurality of bus bars arranged in fixed, spaced relation in a radially outer portion of the internal cavity so as to extend axially along the internal cavity. A plurality of diodes of any one of at least three significantly different configuration diodes and a suppression resistor are arranged in line along the axis of the internal cavity with radially outwardly extending spring contact plates electrically connecting the diodes and suppression resistor with the bus bars. A desired preload force is provided on these components between an end cap at one end of the housing and a retainer at the other. The end cap is rotationally indexed and constrained with respect to the housing by connections of terminals in the end cap with bus bars.

Adaptable rotating rectifier and suppression resistor assembly for

A compact rotor for a dynamoelectric machine in the form of a brushless alternator is provided through the use of a compact rotating rectifier of unitary construction and a suppression resistor which are mounted within the rotor. The rectifier is of an elemental construction in which all elements of the rectifier perform dual functions as essential structure and as elements of an electrical circuit. The rotor, rectifier, and resistor are highly integrated and configured in a complementary manner such that virtually all non-essential structure related to the rectifier and resistor are eliminated, and such that electrical connections between the components of the rotor are significantly simplified. The rotor also includes features for directing a flow of coolant about the rectifier and the resistor.

Rotor for a dynamoelectric machine having a one-piece rotation rectifier

A thermally compensated assembly for a generator for controlling the stress on a stator within a housing subject to temperature changes. The thermally compensated assembly includes a stator, a housing enclosing the stator, first and second thermal compensation members provided on each end of the stator and means for securing the first and second thermal compensation members with respect to the housing. The thermal compensation members are provided with angled portions disposed with respect to each other. The angle of the angled portions may be chosen equal or slightly different than a predetermined angle to provide a constant or variable axial load on said stator when said thermally compensated assembly is subject to changes in temperature.

Thermally compensated assembly for a generator

A core is retained within a housing, and a cooling fluid is supplied axially along an axis of the core between the housing and the core in order to cool the core. The core may have core laminations provided with cooling fins, and the core laminations may be rotated with respect to adjacent core laminations so that the cooling fins provide a cascaded cooling passage for the flow of the cooling fluid. A containment/growth sleeve may be inserted within, or around, the housing having a thermal growth rate which is intermediate the thermal growth rate of the housing and the thermal growth rate of the core in order to minimize deflection of the housing with respect to the core. Fluid conduits are provided in the housing which cooperate with the cascaded cooling passages.

Apparatus for containment and cooling of a core within a housing

A two-pole generator rotor assembly including a one-piece shaft, a prewound field coil assembly and a one-piece shaft. The one piece shaft includes a pair of axially spaced shaft end portions and a substantially cylindrical portion integrally formed with the spaced shaft end portions and interposed therebetween. The substantially cylindrical central portion includes a through slot for accommodating the prewound field coil assembly, with the through slot including a pair of opposed wall portions adapted to engage an outer peripheral portion of the prewound field coil assembly and provide means for retention of the prewound field coil.

One-piece rotor shaft for two-pole rotor

An improved rotor for a dynamoelectric machine which includes a rotor core of magnetizable material having a longitudinal axis and axially spaced core ends, winding end supports of electrically insulating material at the core ends, and a winding having a plurality of layers of continuously connected turns of wire and first and second exciter lead portions at electrically opposite ends of the winding. The first exciter lead portion includes a crossover section oriented generally transverse to the longitudinal axis and located at one of the core ends. The winding is oriented generally parallel to the longitudinal axis and extends around the core, over the crossover section of the first exciter lead portion of the winding, and over both winding end supports, forming a plurality of end turns at the core ends and thereby maintaining the core and the winding end supports fixed relative to each other and constraining the crossover section of the first exciter lead portion between the end turns and the winding end support. A slot and a recessed area are incorporated into the winding end support, with the slot allowing the crossover section of the first exciter lead portion of the winding to be conveniently routed between the end turns and the winding end support, and the recessed area providing constraint for the end turns, thereby preventing deformation of the end turns due to centrifugal forces incident with rotation of the rotor.

Main field winding and connections for a dynamoelectric machine

A machine assembly (10) of a first metallic part (22) having a first coefficient of thermal expansion which is mounted within a second metallic part (12) having a second coefficient of thermal expansion greater than the first coefficient of thermal expansion by an interference fit between surfaces of the parts with the first part having an outer cylindrical surface (44) and a second part having an inner cylindrical surface (24) prior to mounting with the interference fit between the surfaces in accordance with the invention includes at least three projections (26) projecting radially from one of the cylindrical surfaces at at least three equally spaced apart locations on a periphery of the cylindrical surface from which the projections project which extend axially along the one cylindrical surface with the projections forming the interference fit between the surfaces at points of contact with another of the surfaces; and wherein, the machine assembly has an operating temperature range extending from a lower temperature (-65.degree. F.) to an upper temperature (450.degree. F.) with the interference fit holding the surfaces at the upper temperature with a minimum of inward radial deflection of the inner surface between the projections and the interference fit holding the surfaces at the lower temperature with the inner surface deflecting radial inward between the projections in response to stress produced by a difference in the coefficients of thermal expansion.

Dynamoelectric machines with stator positioning

A starting system for an aircraft propulsion engine. An electrical motor (62 or 122) is mounted within a case (14) in which first and second hydraulic units (102, 104) are operated as part of a constant speed drive transmission. The electric motor accelerates a motor-generator set (24) to a velocity near the synchronous speed. The motor-generator set is coupled to the drive shaft (20) by operation of the hydraulic units as a variable torque link. The electric motor functions both as a heat source of hydraulic fluid contained within the hydraulic pump and motor case during extreme low temperature conditions at which point the starting torque of the motor is initially insufficient to cause rotation of the output shaft and to further accelerate the motor-generator set up to a rotational velocity at which the motor-generator set may be operated synchronously at which the motor-generator set is coupled to the drive shaft (120) by operation of the hydraulic units as a variable torque link to rotate the engine. When the temperaature of the hydraulic fluid within the case is below the stall temperature so that the electric motor has insufficient starting torque to initiate rotation, the heat generated by the windings heats the hydraulic oil to lower its viscosity to a point at which rotation may be initiated to permit the motor-generator set to be rapidly accelerated to operate as a synchronous motor during starting.

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Rockford, IL, United States of America

Tyrone A Johnsen