Abstract: The balance of rotors for dynamo-electric machines (e.g., electric motor armatures), which are wound with two diametrically opposite, simultaneously applied coils of wire, is improved by ensuring that wire is fed to both coils in substantially similar quantities. This can be accomplished by monitoring the lengths of the two wires as they are fed to the armature using wire sensors located adjacent to the flyer. Alternatively, wire sensors can be provided to monitor the rate at which wire is being fed towards respective flyers and to measure the rate of change of the lengths of those portions of the wires that are supported by the winding machine dancer arms. A control system processes the measurements from these sensors. A wire tensioner having a hysteresis clutch is also provided that allows the tension applied to a wire being wound to be adjusted rapidly. The wire tensioner also picks up slack that may develop in the wire.

Abstract: Armatures for dynamo-electric machines are balanced during manufacture by measuring the unbalance of the armature assembly prior to winding the coils on the armature. The numbers of turns of wire in at least some of the coils subsequently wound on the armature are then adjusted so that the unbalance of the resulting coils compensates for the unbalance of the armature prior to coil winding. Alternatively, one or more extra turns of wire that are short-circuited at the commutator may be added to help balance the armature. In addition, masses may be added to the armature to ensure that it is balanced dynamically as well as statically.

Abstract: Armatures for dynamo-electric machines are balanced during manufacture by measuring the unbalance of the armature assembly prior to winding the coils on the armature. The numbers of turns of wire in at least some of the coils subsequently wound on the armature are then adjusted so that the unbalance of the resulting coils compensates for the unbalance of the armature prior to coil winding. In addition, masses may be added to the armature to ensure that it is balanced dynamically as well as statically.

Abstract: A resin coating system having an endless conveyor for passing components to be coated with resin successively through a preheating station, a resin coating station, and a gelification station. Coated components are exchanged with uncoated components at a transfer station along the conveyor between the gelification station and the preheating station. If an uncoated component is not ready to be transferred into the coating system or later processing machines are not ready to receive a coated component, then exchange of coated and uncoated components does not take place at the transfer station, and the coated component reapproaches the preheating and coating stations. A system and method for allowing coating of uncoated components to be completed while coated components passing through the coating station are prevented from being recoated is also provided.

Abstract: A wire winding machine is provided that allows the connection of electric motor armature coil leads to slot-type commutators. The machine uses rotations of a flyer and rotations of the armature to perform much of the needed movement during the lead attachment process. The system uses a guide member to guide the wire into the commutator slots during rotation of the flyer. The guide member guides wire from the flyer toward the slots during both the initial insertion of the wire and the subsequent process of forming a loop in the wire.

Abstract: Methods and apparatus for marking and identifying a commutator hook of an electric motor are provided. 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: An improved armature testing apparatus and method are provided. The individual resistances of two commutator bar lead connections can be simultaneously measured in a single measurement step. Further, the resistances of two armature coil can be determined in the same step. The present invention makes it possible to measure individual commutator coil lead connections more quickly than was previously possible.

Abstract: Apparatus for applying powdered coating to a workpiece--particularly to electric motor armatures and stators--including features relating to handling and masking of workpieces before, during and after coating, is provided. A first feature of the invention is the inclusion of all coating steps--e.g., coating, cleaning and precuring--as modules in a single treatment station on the production line. The treatment station can also be enclosed in a single housing to contain excess powder from both the coating and cleaning processes, so that a single powder recovery system can be used to recover the excess powder from both processes. The invention also includes a handling system for removing the workpiece from the production line, inserting it into the treatment station and moving it past the various modules in the treatment station, withdrawing it from the treatment station, and returning it to the armature production line.

Abstract: Electric motor stators can have coils wound on their poles which coils have more turns than the poles could normally support by augmenting the pole with additional structures to support the added coil turns. The additional structures can be only temporarily associated with the stator, e.g., by adding them to the winding shrouds which are customarily applied to the stator during winding. Alternatively these additional structures can be permanent but non-magnetic portion of the stator, e.g., by adding them to the terminal board members of the stator.

Abstract: Methods and apparatus for identifying the occurrence of fusing electrical attachment during fusing operations are provided. After a conventional fusing operation is complete, an electrical signal is applied to the fusing electrode while the fusing electrode is returned to its home position. The electrical signal is monitored to determine whether a circuit path exists from the fusing electrode through the fused conductors to the ground electrode. The presence of a path would indicate that the fusing electrode has become attached to the fused conductors. An alternate embodiment is also described in which the force required to withdraw the fusing electrode is monitored while the electrode is returned to its home position. If the measured force does not fall within predetermined limits, or if the measured force varies during electrode movement, fusing electrode attachment has occurred.

Abstract: Dynamo-electric machine armatures which have commutators and cores that are axially close to one another are wound with the aid of wire guiding hooking plates that are inclined to reach into the portion of the commutator that is axially adjacent to the core where the coil leads must be attached to the commutator. The hooking plate may also perform an additional extension motion in order to press the coil leads out of the way of a subsequent fusing operation. This function may alternatively be performed by a separate pusher member which is either associated with the hooking plate or independent of the hooking plate. The fusing electrode may be specially shaped to facilitate performing fusing operations axially close to the armature core.

Abstract: An objective and non-destructive test of the fused tang/commutator bar joints in an armature, that can be used on every armature being manufactured on an armature manufacturing line, as well as apparatus for performing that test, are provided. The armature is immersed in an acoustic coupling medium. Acoustic pulses, preferably ultrasonic pulses, are beamed onto the joint and the reflected pulses are measured. The quality of the joint can be determined by comparing the reflected amplitude to the known reflected amplitudes for joints of known quality. A testing station on an armature production line includes a mechanism for removing the armature from the production line, immersing it in the coupling medium, and rotating it as each joint in the commutator of that armature is checked.

Abstract: An improved fusing machine is provided that allows commutators to be balanced during the fusing process. Commutator tangs are compressed onto coil leads to form lead connections. The fusing machine compresses the tangs to varying degrees relative to the shaft. The commutator can be balanced during fusing by compressing tangs to a common radial position or by compressing diametrically opposed tangs to the same extent.

Abstract: Electric motor armatures are wound by moving a wire dispensing member relative to the armature so that the wire dispensing member itself guides the wire precisely into position on the armature and so that no additional wire guides or shrouds are needed to guide the wire and keep it out of contact with portions of the armature that it should not contact. The relative motion between the armature and the wire dispensing member is preferably under programmable control so that the apparatus can be readily reprogrammed when different types of armatures are to be wound. Specially shaped wire dispensing members may be employed.

Abstract: In the performance of fusing operations which involve the application of force and heat to a workpiece, the heat being generated at least in part by electrical resistance heating resulting from passage of an electrical current through an electrical circuit which includes the workpiece and typically also a fusing electrode, the fusing cycle is controlled at least in part on the basis of measurements of the resistance of the above-mentioned circuit during the fusing operation. If desired, the resistance measurements may be corrected to eliminate or at least substantially reduce the contribution of electrode resistance so that the fusing operation is controlled on the basis of the resistance of the workpiece.

Abstract: The coils on dynamo-electric machine parts (such as electric motor armatures or stators) are stabilized and coated by electrostatically coating them with resin powder, and then fusing the powder into a continuous resin coating on the coils. For example, the powder may be fused by heat generated by briefly passing a relatively large electrical current through the coils. If desired, the coils may be formed with wire which has an outer layer of bonding material. Activation of the bonding material, which may occur simultaneously with fusing of the resin powder, bonds adjacent coil wires together.

Abstract: Commutators of armatures for electric motors or other dynamo-electric machines are finished by subjecting them to inspection and turning operations. The first inspection operation determines the minimum amount of material that can be cut while producing a high quality armature. This determination may indicate that no formal turning is required, only finishing. The turning operation, if applicable, cuts the commutator to a substantially cylindrical shape which is substantially concentric with the axis of rotation of the armature. The finishing operation, which may be performed by the same mechanism as the turning operation, imparts a desired axial roughness to the cylindrical commutator surface. The commutators may be inspected after the turning and finishing operations to generate data useful for such purposes as automatically modifying the turning and finishing operations performed on subsequent commutators.

Abstract: A resin coating system having an endless conveyor for passing components to be coated with resin successively through a preheating station, a resin coating station, and a gelification station. Coated components are exchanged with uncoated components at a transfer station along the conveyor between the gelification station and the preheating station. If an uncoated component is not ready to be transferred into the coating system or later processing machines are not ready to receive a coated component, then exchange of coated and uncoated components does not take place at the transfer station, and the coated component reapproaches the preheating and coating stations. A system and method for allowing coating of uncoated components to be completed while coated components passing through the coating station are prevented from being recoated is also provided.

Abstract: Methods and apparatus for fusing together electrical conductors to a commutator are provided. A precise, timed, and controlled delivery of electric current to the fusing electrode of the fusing machine is achieved. A generic supply signal is converted into a precise and constant input signal through the use of monitoring and feedback techniques, which compare the current status of the physical and electrical phases of the fusing operation to various predetermined fusing profiles to determine the proper application of current to the fusing electrode.

Abstract: Methods and apparatus for monitoring the temperature of a workpiece during fusing operations are provided. The apparatus includes a temperature sensor which monitors the temperature of a commutator bar being fused and outputs an electrical signal corresponding to that temperature. The electric current supplied to the fusing electrode can be interrupted or modified if the temperature of the commutator bar exceeds a predetermined temperature. In this manner, fusing operations can be interrupted if the temperature of the commutator bar approaches a temperature at which other components of the workpiece, such as the core material will be adversely affected. The temperature sensor preferably contacts the workpiece to conduct heat to a sensing element.