A self-excited brushless machine with compensated field windings includes a rotor and a stator. The rotor Includes a field winding secured to the rotor, an auxiliary winding secured to the rotor, and an energy converter associated with the rotor and configured to convert current between the field winding and the auxiliary winding. The stator includes a multiphase winding. The self-excited brushless machine uses a first current to generate a first magnetomotive force on a stator of the machine, and uses a second current to generate a second magnetomotive force. A third current is induced on auxiliary windings of a rotor of the machine using the second magnetomotive force. A rotor field winding of the machine is excited with the induced currents of the auxiliary windings.

A self-excited brushless machine with compensated field windings includes a rotor and a stator. The rotor Includes a field winding secured to the rotor, an auxiliary winding secured to the rotor, and an energy converter associated with the rotor and configured to convert current between the field winding and the auxiliary winding. The stator includes a multiphase winding. The self-excited brushless machine uses a first current to generate a first magnetomotive force on a stator of the machine, and uses a second current to generate a second magnetomotive force. A third current is induced on auxiliary windings of a rotor of the machine using the second magnetomotive force. A rotor field winding of the machine is excited with the induced currents of the auxiliary windings.

A generator rotor assembly can include a diode holder configured to hold one or more diodes. The diode holder can be formed of a first material having a first coefficient of thermal expansion (CTE). The assembly can include a rotor housing configured to hold the diode holder within the rotor housing. The rotor housing can be formed of a second material having a second CTE. The second CTE is different than the first CTE. The assembly can include one or more CTE compensation spacers interfacing the diode holder to the rotor housing such that the diode holder and the rotor housing are connected via the one or more CTE compensation spacers. The one or more CTE compensation spacers can be configured to have a third CTE different than the first CTE and the second CTE to compensate for relative length change between the diode holder and the rotor housing to prevent and/or reduce temperature induced stress growth at the interface of the diode holder and the rotor housing.

A generator rotor assembly can include a diode holder configured to hold one or more diodes. The diode holder can be formed of a first material having a first coefficient of thermal expansion (CTE). The assembly can include a rotor housing configured to hold the diode holder within the rotor housing. The rotor housing can be formed of a second material having a second CTE. The second CTE is different than the first CTE. The assembly can include one or more CTE compensation spacers interfacing the diode holder to the rotor housing such that the diode holder and the rotor housing are connected via the one or more CTE compensation spacers. The one or more CTE compensation spacers can be configured to have a third CTE different than the first CTE and the second CTE to compensate for relative length change between the diode holder and the rotor housing to prevent and/or reduce temperature induced stress growth at the interface of the diode holder and the rotor housing.

A main field connection to connect to a main field winding has a semi-cylindrical portion with an axially thicker outer surface, an axially thinner inner surface, with an aperture. An extending portion extends from the semi-cylindrical portion to a remote extending end. The remote extending end extends for a first axial distance. The axially thicker portion of the semi-cylindrical portion extends for a second axial distance. A ratio of the first axial distance to the second axial distance is between 0.65 and 1.4. A rotating assembly, a generator and a method are also disclosed.

The present inventions include a rotating electromagnetic machine such as a motor or generator wherein changes of flux direction adjacent the air gap are avoided. The disclosed improvements apply to permanent magnet alternators, induction motors and generators, doubly fed induction generators, and the like. Adaptation of coils to and fixation within the required slot geometries are disclosed. Excitation systems co-located within the primary rotor core and primary stator core are also disclosed. The use of rubber vulcanized to the rotor in conjunction with a stainless steel rotor sleeve is also disclosed.

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.

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.

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.

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.