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

• US 6,897,584 B2
• Filed: 04/25/2002
• Issued: 05/24/2005
• Est. Priority Date: 04/25/2002
• Status: Expired due to Fees

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Doherty, Kieran P J, Jim, Lengel, McDowall, Gregor, Scherzinger, William M., Tornquist, Gerald E., Kane, David B.
• Primary Examiner(s): Schuberg, Darren
• Assistant Examiner(s): Comas, Yahveh
• Application Number:
  US10/132,439
• Publication Number:
  US 20030203673A1
• Time in Patent Office: 1,125 Days
• Field of Search: 310/71, 310/89, 310/87, 439/702, 439/722, 439/564, 439/596, 411/389, 411/427
• US Class Current: 310/71
• CPC Class Codes: H02K 5/225 Terminal boxes or connection arrangements specially adapted for submersible motors H02K5/132

Abstract

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.

Claims

1. A terminal assembly for electrically connecting generator stator output leads to external systems and equipment, comprising:

an electrically conductive terminal plate adapted for mounting to an external portion of a generator housing, the terminal plate having an opening formed therein;

an electrically conductive feed-through adapted to pass through an opening formed in the generator housing, the feed-through having a first end end and a second end, the feed-through first and second ends having a first and second opening, respectively, formed therein and a first and second annular bore extending from the respective first and second openings a distance into the feed-through to form a first and a second inner circumferential surface, respectively, the first and second inner circumferential surfaces each having threads formed on at least a portion thereof;

a first electrically conductive fastener having threads on at least a portion thereof, the first fastener extending through the terminal plate opening and into the first annular bore, the threads on the first fastener engaging the threads on the first inner circumferential surface to thereby couple the feed-through first end to the terminal plate;

a slug adapted to join to at least one of the stator output leads, the slug having an opening formed therein; and

a second electrically conductive fastener having threads on at least a portion thereof the second fastener extending through the slug opening and into the second annular bore, the threads on the second fastener engaging the threads on the second inner circumferential surface to thereby couple the slug to the feed-through second end.

2. The terminal assembly of claim 1, further comprising:

a first insulator surrounding at least a portion of the conductive feed-through for electrically insulating the feed-through from the generator housing.

3. The terminal assembly of claim 2, further comprising:

a first seal surrounding the first insulator for providing a substantially leak-tight seal between the first insulator and the generator housing.

4. The terminal assembly of claim 3, further comprising:

a second seal positioned between the first insulator and the conductive feed-through for providing a substantially leak-tight seal therebetween.

5. The terminal assembly of claim 1, wherein the slug has a substantially I-shaped cross section.

6. The terminal assembly of claim 1, further comprising:

an insulator assembly surrounding at least a portion of the conductive feed-through for electrically insulating the feed-through from the generator housing; and

a spring clip having a first portion thereof positioned in a groove formed in the generator housing and a second portion thereof in contact with the insulator assembly.

7. The terminal assembly of claim 1, wherein the slug is joined to the stator output lead by a brazing process.

8. A terminal block assembly adapted for mounting to an external portion of a generator housing and for electrically connecting generator stator output leads to external systems and equipment comprising:

a main body having at least an upper surface and a lower surface;

a first cavity formed in the main body lower surface;

an opening extending through the main body between the upper surface and the first cavity;

a threaded fastener having a first end and a second end, the fastener second end extending through the opening and into the first cavity;

a first bolt coupled to the fastener second end to secure the fastener in the opening;

an electrically conductive terminal plate mounted to the main body upper surface, the terminal plate having an opening formed therein;

an electrically conductive feed-through adapted to pass through an opening formed in the generator housing, the feed-through having a first end and a second end, the feed-through first and second ends having a first and second opening, respectively, formed therein and a first and second annular bore extending from the respective first and second openings a distance into the feed-through to form a first and a a second inner circumferential surface, respectively, the first and second inner circumferential surfaces each having threads formed on at least a portion thereof;

a first electrically conductive fastener having threads on at least a portion thereof, the first fastener extending through the terminal plate opening and into the first annular bore, the threads on the first fastener engaging the threads on the first inner circumferential surface to thereby couple the feed-through first end to the terminal plate;

a slug adapted to join to at least one of the stator output lead, the slug having an opening formed therein; and

a second electrically conductive fastener having threads on at least a portion thereof, the second fastener extending through the slug opening and into the second annular bore, the threads on the second fastener engaging the threads on the second inner circumferential surface to thereby couple the slug to the feed-through second end.

9. The terminal assembly of claim 8, further comprising:

a first insulator surrounding at least a portion of the conductive feed-through for electrically insulating the feed-through from the generator housing.

10. The terminal assembly of claim 9, further comprising:

a first seal surrounding the first insulator for providing a substantially leak-tight seal between the first insulator and the generator housing.

11. The terminal assembly of claim 10, further comprising:

a second seal positioned between the first insulator and the conductive feed-through for providing a substantially leak-tight seal therebetween.

12. The terminal assembly of claim 8, wherein the slug has a substantially I-shaped cross section.

13. The terminal assembly of claim 8, further comprising.

an insulator assembly surrounding at least a portion of the conductive feed-through for electrically insulating the feed-through from the generator housing;

and

a spring clip having a first portion thereof positioned in a groove formed in the generator housing and a second portion thereof in contact with the insulator assembly.

14. The terminal block of claim 8, further comprising:

a second cavity formed in the main body upper surface, the second cavity having an inner perimeter formed into a predetermined shape; and

a mating section formed on an intermediate portion of the threaded fastener, the mating section having an outer perimeter formed substantially similar to the predetermined shape,

wherein the mating section is at least partially inserted into, and mates with, the second cavity.

15. A generator, comprising:

a housing;

a stator mounted within the housing;

a rotor rotationally mounted within the stator; and

a terminal block assembly mounted to an external surface of the housing, the terminal block assembly including;

a main body having at least an upper surface and a lower surface;

a first cavity formed in the main body lower surface,

an opening extending through the main body between the upper surface and the first cavity,

a threaded fastener having a first end and a second end, the fastener second end extending through the opening and into the first cavity,

a first bolt coupled to the fastener second end to secure the fastener in the opening,

an electrically conductive terminal plate mounted to the main body upper surface, the terminal plate having an opening formed therein;

an electrically conductive feed-through adapted to pass through an opening formed in the generator housing, the feed-through having a first end and a second end, the feed-through first and second ends having a first and second opening, respectively, formed therein sod a first and second annular bore extending from the respective first and second openings a distance into the feed-through to form a first and a second inner circumferential surface, respectively, the first and second inner circumferential surfaces each having threads formed on at least a portion thereof;

a first electrically conductive fastener having threads on at least a portion thereof, the first fastener extending through the terminal plate opening and into the first annular bore, the threads on the first fastener engaging the threads on the first inner circumferential surface to thereby couple the feed-through first end to the terminal plate;

a slug adapted to join to at least one of the stator output leads, the slug having an opening formed therein; and

a second electrically conductive fastener having threads on at least a portion thereof, the second fastener extending through the slug opening and into the second annular bore, the threads on the second fastener engaging the threads on the second inner circumferential surface to thereby couple the slug to the feed-through second end.