Rotor winding having a braze joint spaced apart from stress concentration

A rotor for use in a generator, comprising:

• a rotor body having a shaft;
• a plurality of slots formed in the rotor body;
• a plurality of axial sections located within each slot;
• a plurality of end arc sections, wherein each end arc section is oriented transverse to an associated axial section;
• a leg section integrally formed with each end arc section wherein each leg section extends from each end arc section to form an associated corner section between each leg section and each end arc section wherein each leg section is affixed to an associated axial section at a joint that is spaced apart in an axial direction from an associated corner section such that the joint is not subjected to stress concentration which occurs at the associated corner section.

A method for forming a winding for a rotor, comprising:

• providing a plurality of axial sections;
• providing a plurality of end arc sections, wherein each end arc section is oriented transverse to an associated axial section;
• providing an integrated leg section which extends from each end arc section to form an associated corner section between each leg section and each end arc section;
• affixing each leg portion to an associated axial section at a joint;
• locating the joint at a position which is spaced apart in an axial direction from an associated corner section such that the joint is not subjected to stress concentration which occurs at the associated corner section.