The present disclosure relates to a generator, and more particularly to a main rotor thereof.
Aircraft powered by gas turbine engines often include a mechanically driven accessory gearbox which connects to accessory systems such as an electrical starter-generator or electric generator. Integrated Drive Generator (IDG), Variable Frequency Generator (VFG) and Variable Frequency Starter Generator (VFSG), and other such systems incorporate a main rotor having a main field winding wound around a rotor core. On some generators, the wires in the main field winding may move during operation.
An end turn support for a generator according to an exemplary aspect of the present disclosure includes a wire support. The wire support extends along an axis in a radial direction from an axis of rotation. The wire support defines an arcuate wire receipt surface.
A rotor for a generator according to an exemplary aspect of the present disclosure includes a main field winding. A shaft which defines an axis of rotation and an end turn support mounted to the main field rotor core to support the main field winding. The end turn support includes a wire support which extends along an axis in a radial direction from the axis of rotation, the wire support defines an arcuate wire receipt surface to receive at least one wire of the main field winding.
A generator according to an exemplary aspect of the present disclosure includes a shaft which defines an axis of rotation. A first end turn support mounted to the main field rotor core, the first end turn support includes at least one first wire support which extends along an axis in a radial direction from the axis of rotation, each of the at least one first wire supports defines a first arcuate wire receipt surface. A second end turn support mounted to the main field rotor core, the second end turn support includes at least one second wire support which extend along an axis in a radial direction from the axis of rotation, each of the at least one second wire supports defines a second arcuate wire receipt surface. A main field winding which includes at least one wire which is wound around the first arcuate wire receipt surface and the second arcuate wire receipt surface.
A method of forming a rotor for a generator according to an exemplary aspect of the present disclosure includes mounting an end turn support to a main field rotor core, which defines an axis of rotation. Winding a main field winding at least partially around a wire support of the end turn support such that at least one wire of the main field winding is supported on an arcuate wire receipt surface of said end turn support.
Various features will become apparent to those skilled in the art from the following detailed description of the disclosed non-limiting embodiment. The drawings that accompany the detailed description can be briefly described as follows:
The dynamoelectric portion 22 in the disclosed, non-limiting embodiment is a 3-phase machine that includes three machines 30, 32 and 34 mounted along a rotor shaft 36 along an axis of rotation A. Stator assemblies 30B, 32B, 34B of the three machines are installed in the housing assembly 28 and the three rotor assemblies 30A, 32A, 34A are installed on the rotor shaft 36. The housing assembly 28 may be closed with a drive end (DE) cover assembly 28A through which the rotor shaft 36 extends and a non-drive end (NDE) cover assembly 28B.
The first machine 30 includes a permanent magnet generator (PMG) with a PMG rotor assembly 30A and a stator assembly 30B. The PMG stator assembly 30B supplies power for generator excitation, as well as power for other components of the electrical system. The second machine 32 includes a Main Exciter (ME) with a ME rotor assembly 32A and a stator assembly 32B. The ME receives field excitation from the PMG through a GPCU (Generator Power Control Unit). The output of the ME rotor assembly 32A is supplied to a rotor mounted diode pack 38. The diode pack 38 may be divided into six diodes to provide a 3-phase full wave bridge rectification. The DC output of the diode pack 38 supplies the third machine 34.
Referring to
Referring to
The wire supports 44 extend along an axis B in a radial direction from the axis of rotation A. Each wire support 44 defines a length dimension SL referenced to an end turn support length ESL which extends in a radial direction from the axis of rotation A (
An end cap 46 defines an end section of each wire support 44. The end cap 46 extends in an axial direction along the axis of rotation A so as to be relatively wider than the wire support 44 (also illustrated in
Referring to
Each wire support 44 includes a multiple of scallops 48 to receive a respective wire of the main field winding 42. The multiple of scallops 48 defines a length dimension CLw, which in one non-limiting dimensional embodiment is approximately 0.92 inches (23.4 mm). In one non-limiting embodiment, fourteen scallops 48 are provided (
The primary area of wire 42W movement was determined by Applicant to be at the end turns of the main field winding 42 as radial loads are significantly increased due, in part, to the relatively large diameter and high speed operation. Conventional end turn supports are flat where the wires rest upon the end turns. Because the end turn supports are flat, the wires may be pulled across relatively tightly and strung like a bow to minimize movement, however, the wires may then not be supported in the middle of the flat end turn support.
Referring to
In one non-limiting embodiment, a six wire non-nested stack dimension CHw located upon the arcuate wire receipt surface 50 is approximately 0.396 inches (10.1 mm) with an end cap extension dimension ECX which extends from the top of the six wire non-nested stack toward the top of the end cap 46. In one non-limiting dimensional embodiment, dimension ECX is approximately 0.07 inches (1.8 mm). A particular ratio of dimension CH to dimension ECH is between 5.5:1-6:1. That is, dimension ECH is 5.5 to 6 times dimension EC. Such a ratio facilitates effective supports the higher radial loads of the larger diameter end turn support 40.
The foregoing description is exemplary rather than defined by the limitations within. Various non-limiting embodiments are disclosed herein, however, one of ordinary skill in the art would recognize that various modifications and variations in light of the above teachings will fall within the scope of the appended claims. It is therefore to be understood that within the scope of the appended claims, the disclosure may be practiced other than as specifically described. For that reason the appended claims should be studied to determine true scope and content.
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