Mechanical strength of connection of wound rotor generator/motor

A refurbished rotor of a wound rotor motor/generator having diamond-shaped rotor windings removed from a rotor core thereof, the refurbished rotor comprising:

• a plurality of windings assembled to the rotor core, each of the plurality of windings manufactured from two separate bars, in particular, a top coil and a bottom coil, the top coil positioned in a rotor core slot at a position radially outward of a position of the bottom coil within another rotor core slot, wherein each top coil and each bottom coil has a flat rectangular cross-section,
• wherein, on a connection end of the rotor where rotor leads are attached, the top coil of each of the plurality of windings has a flat end positioned alongside and in alignment with a flat end of the bottom coil of an adjacent one of the plurality of windings, and a joint is formed therebetween for establishing electrical continuity, and
• wherein, for each of the plurality of windings, the top coil and the bottom coil have respective flat ends joined to each other on a non-connection end of the rotor opposite the connection end by a joint for establishing electrical continuity,
• the refurbished rotor further comprising
• extended spacer blocks positioned between adjacent pairs of bottom coils at the connection end, each of the extended spacer blocks having a tapered shape and having a portion extending radially inwardly of the bottom coils;
• and
• glass fiber insulating rope situated axially between the radially inwardly extending portions of the extended spacer blocks and a first cross connection assembly, the glass fiber insulating rope being oversized and compressed into an available space between the radially inwardly extending portions of the extended spacer blocks and the first cross connection assembly.