Abstract: Methods and apparatus are provided for automatically adapting a stator winding station to wind stator cores of different lengths, without changing the lengths of the winding needles installed in the winding machine, and with minimum operator intervention. The method includes the step of translating the stator core, depending upon its length, to maintain the midpoint of the stator core at a fixed distance from a suitable reference frame, for example, the winding machine. Apparatus comprising first and second precision movement locators are described, wherein the first locator carries a stator housing, and the second locator carries lead termination equipment. The apparatus is adjusted automatically to position the stator core in a predetermined relation to the stator winding station, based on the length of the stator core to be wound.

Abstract: A machine for winding two-pole stators includes a revolving table around which are located at least three working stations: a station to feed the machine with unwound stators from a conveyor placed alongside the machine and for returning the wound stators to the conveyor; a winding station where one or more winding needles with alternating translatory and angular motion wind the stator; and a terminating station with means to anchor the coil leads to the stator. The revolving table carries a plurality of circumferentially spaced stator housings, each stator housing having stator-containing means. The stator housings and table are equipped with mechanical, reciprocally meshing means, those on the table being located between the winding station and the load/unload station for rotating the stator housings about the horizontal axis tangentially to the table between a position in which the axis of the stator-containing means is vertical and a position in which that axis is horizontal.

Abstract: Multiple electric motor parts are processed simultaneously by apparatus which removes the parts from a conveyor (on which the parts are side by side in a substantially horizontal plane), repositions the parts so that they are vertically above one another, processes the parts while they are thus repositioned, and then returns the parts to the conveyor in their original side by side relationship in a horizontal plane.

Abstract: Apparatus for holding a stator (e.g., during stator processing steps such as the winding of coils on the stator) includes a first jaw member removably insertable in a housing and a second jaw member movably mounted on the first jaw member for releasably gripping a stator between the first and second jaw members. When stators of different sizes are to be held, the first and second jaw members can be readily removed, as a unit, from the housing and replaced by a differently configured first and second jaw member unit.

Abstract: Methods and apparatus for changing the collet assembly or armature-holding assembly of an armature winding machine are provided. The apparatus permits the collet assembly and selected sleeves of the armature-holding assembly to rotate about a longitudinal axis, while preventing undesirable translation along the axis. The apparatus permits translation of at least one other sleeve. The collet assembly may be removed from the armature-holding assembly to accommodate armature shafts of various diameters. Alternatively, the entire armature-holding assembly may be removed and replaced as a single unit, to accommodate commutators of various diameters. The change-over process can be automated.

Abstract: Methods and apparatus for marking and identifying a commutator hook of an electric motor are povided. A preselected commutator hook is marked by deforming the hook while the armature is in a winding machine, with a known angular position. The marked hook is identified by apparatus which determines whether or not the hook has been deformed while in the winding machine, and thereby recognizing the hook.

Abstract: Methods and apparatus are provided for connecting a lead wire extending from a coil portion wound on a pole of a stator core to one or more terminals mounted on the stator core, wherein the method includes the steps of: grasping a lead wire; disposing the lead wire adjacent at least a first terminal; partially and then fully engaging the lead wire with the terminal; repeating the steps of disposing and engaging the lead wire with later terminals, if any; and then cutting the lead wire. Apparatus is provided for performing the method steps for complex lead wire connection patterns.

Abstract: A pallet system for supporting a workpiece (such as an electric motor stator or rotor) during processing of the workpiece includes a pallet member on which a workpiece holder can be removably placed. The workpiece holder may have multiple workpiece-engaging sites, each of which is adapted to hold a differently configured workpiece, and multiple pallet-engaging sites, each of which is associated with a respective one of the workpiece-engaging sites and any one of which can be used to engage the pallet so that the workpiece holder can hold a workpiece of the appropriate configuration at the associated workpiece-engaging site. Methods and apparatus for storing and manipulating the workpiece holders are also shown and described.

Abstract: Methods and apparatus for fusing armature wires to a commutator, and fusing stator lead wires and stator hooks, are provided. An electrode assembly having a screw mechanism converts the rotational motion of a motor into a translational motion of the fusing electrode. A microprocessor-based control circuit receives electrode force and displacement data from a load cell and an encoder, respectively, to control the fusing operation. The fusing operation is performed according to a predetermined force or displacement function that is stored in the control circuit.

Abstract: A pallet having adjustable support members and an apparatus for automatically adjusting the distance between two support members for carrying workpieces of different dimensions. The support members are mounted on guides that are fitted to pallets that travel on conveyor transport systems for automatic production/assembly lines. In one embodiment the support members have a frictional locking mechanism which can be locked in place on the pallet and can be unlocked for movement along the guide. A positioning unit engages the pallet so that the locking mechanism is unlocked and the support members are engaged and translated to the desired locations under the control of a threaded bar. The locking mechanism has a first condition which causes the guide to contact the support members to secure frictionally the support members to the pallet and a second condition which permits the support members to be moved. A positioning unit engages the pallet to translate the support members to the desired locations.

Abstract: An apparatus for automatically adjusting the distance between two support members for carrying workpieces of different dimensions. The support members are mounted on guides that are fitted to pallets that travel on conveyor transport systems for automatic production/assembly lines. The support members have locking devices that frictionally secure the support members in place on the pallet and can be unlocked for movement along the guide. A positioning unit engages the pallet so that the locking devices is unlocked, and the support members are translated, under the control of the drive, to the desired relative position. A device for bringing a pallet and the positioning unit together to make the adjustment are provided. The positioning unit may have two movable carriages and a device for unlocking one or both support members from the guide, and drive for moving one or both of the carriages to slide one or both of the support members along the guides into their desired positions.

Abstract: Methods and apparatus for winding stators (e.g., electric motor stators) so that the ends of each coil can be terminated at respective opposite ends of the stator. The coil wire is anchored adjacent a first end of the stator. Then the coil supply means is alternately reciprocated longitudinally along and rotationally about the longitudinal axis of the stator to wind the wire on the stator. When the desired number of windings has been applied, the wire supply means is stopped adjacent the second end of the stator and the wire is anchored adjacent that end of the stator. The wire is then cut between the second anchoring point and the wire supply means, and the wire supply means is returned to the starting position to prepare for winding the next stator.

Abstract: The axial end portions of the insulating members which are used to line the longitudinal channels formed between circumferentially adjacent, radially inwardly projecting poles in a stator (e.g., an electric motor stator) are protected from damage by the wire being wound by providing terminal boards at each axial end of the stator having portions which overhang the axial ends of the insulating members. Temporary wire grippers may also or alternatively be mounted on the axial ends of the stator (e.g., on the above-mentioned terminal boards) for temporarily holding the leads of the stator coils prior to permanent termination of those leads on permanent terminals on the terminal boards.

Abstract: A needle of a stator winding machine is positioned such that its central longitudinal axis is eccentric relative to a central longitudinal axis of the stator. More particularly, the central longitudinal axis of the needle is spaced a predetermined distance from the central longitudinal axis of the stator along a line which is coincident with an axis about which slots in which a wire is being wound are symmetrical. The predetermined distance is selected such that the point of the needle extends at least to an end of a frontal tooth adapted to retain the wire in one of the slots.

Abstract: A production line capable of producing more than one variation of a particular type of electric motor component (e.g., more than one variation of armature or more than one variation of stator) is provided. The line includes at each workstation either a machine adjustable to the different variations to be produced, or more than one machine. Workpieces are carried down the line on coded pallets from which it can be determined automatically which variation it is, so that the workstation can be adjusted to perform the correct operation, or so that the pallet can be directed to the correct machine.

Abstract: A machine for winding two-pole electric motor stators has a housing for holding the stator during winding. Winding forms are pressed against both ends of the stator and clamped to the housing. The clamping structure is partly operated by the structure which presses the winding forms against the stator so that the clamping structure automatically compensates for differences in stator dimension parallel to the axis along which the winding forms are pressed against the stator.

Abstract: A machine for winding two-pole stators includes a revolving table around which are located at least three working stations: a station to feed the machine with unwound stators from a conveyor placed alongside the machine and for returning the wound stators to the conveyor; a winding station where one or more winding needles with alternating translatory and angular motion wind the stator; and a terminating station with means to anchor the coil leads to the stator. The revolving table carries a plurality of circumferentially spaced stator housings, each stator housing having stator-containing means. The stator housings and table are equipped with mechanical, reciprocally meshing means, those on the table being located between the winding station and the load/unload station for rotating the stator housings about the horizontal axis tangentially to the table between a position in which the axis of the stator-containing means is vertical and a position in which that axis is horizontal.

Abstract: A pallet system for supporting a workpiece (such as an electric motor stator or rotor) during processing of the workpiece includes a pallet member on which a workpiece holder can be removably placed. The workpiece holder may have multiple workpiece-engaging sites, each of which is adapted to hold a differently configured workpiece, and multiple pallet-engaging sites, each of which is associated with a respective one of the workpiece-engaging sites and any one of which can be used to engage the pallet so that the workpiece holder can hold a workpiece of the appropriate configuration at the associated workpiece-engaging site. Methods and apparatus for storing and manipulating the workpiece holders.

Abstract: The density, regularity, and efficiency of the coils wound on a stator (e.g., an electric motor stator) are improved by providing winding needle trajectories which tend to urge the wire to fill empty areas which may otherwise develop in the coils at the ends of the stator. The phase relationship between the oscillation and reciprocation components of needle motion is selected to optimize coil formation. In particular, each oscillation stroke is typically somewhat delayed (as compared to the prior apparatus) relative to the reversal of reciprocation direction. The reciprocation stroke length is also typically increased. Needle actuation apparatus in which adjustment of these parameters is facilitated is also disclosed.

Abstract: A machine for driving and variable length cutting of the paper used in the armature of an electric motor rotor. The machine comprises a feed distance covered by the paper between shaping rollers, over which a pressure wheel is located which pushes the paper against a ledge and then slips. A paper cutting blade is inserted between the wheel and the ledge. Transfer devices located between the blade and the ledge transfer the cut paper to a bending fixture, which gives the paper the shape of the rotor slot. The paper is pushed into the rotor slot by inserting devices. The rotor is moved from the conveyor on which it is supplied to a suitable position to receive the paper. Locking elements connected to the ledge vary the length of the cut paper with respect to the height of the rotor slots where the paper is inserted.