Abstract: Hollow cylindrical dynamo-electric machine stator cores may be made by superimposing at least two strips of core material to produce a composite strip. One or more of the strips may be run through a pressure roller structure prior to super-positioning of the strips. The composite strip is coiled helically to produce the hollow cylindrical stator core. By pressure rolling at least one strip, the internal diameter of the stator core can be adjusted to reduce irregularities. By superimposing strips prior to coiling, thinner strips can be used without requiring the stator forming machine to operate longer or faster to produce stator cores of a given size. The pressure rolling aspects of the invention are also applicable to coiling apparatus that uses only a single strip. Stator cores may also be made by coaxially assembling and joining two coils with a hollow annular lamination disposed between the two axially spaced coils.

Abstract: Hollow cylindrical dynamo-electric machine stator cores may be made by superimposing at least two strips of core material to produce a composite strip. One or more of the strips may be run through a pressure roller structure prior to super-positioning of the strips. The composite strip is coiled helically to produce the hollow cylindrical stator core. By pressure rolling at least one strip, the internal diameter of the stator core can be adjusted to reduce irregularities. By superimposing strips prior to coiling, thinner strips can be used without requiring the stator forming machine to operate longer or faster to produce stator cores of a given size. The pressure rolling aspects of the invention are also applicable to coiling apparatus that uses only a single strip. Stator cores may also be made by coaxially assembling and joining two coils with a hollow annular lamination disposed between the two axially spaced coils.

Abstract: Apparatus and methods for reducing the likelihood of damage to wire leads of undulated coils for dynamo-electric machine stators are provided. The invention provides a rotating winding head equipped with a coil former that has a wire gripper and an initial wire lead slot. The gripper retains the initial wire lead. The slot permits the initial wire lead to be fed to the gripper from a stationary wire source. The gripper maintains the initial wire lead in a predetermined plane of the coil and can secure the initial wire lead in the plane in which the final lead wire will eventually be disposed. The gripper also rotates the initial wire lead into radial alignment with a lobe of the undulated coil. Once installed in a stator, the initial and final wire leads can both be disposed along the outer radius of the coil and are thus protected from interference with a rotor that is destined to rotate within the stator.

Abstract: Hollow cylindrical dynamo-electric machine stator cores may be made by superimposing at least two strips of core material to produce a composite strip. One or more of the strips may be run through a pressure roller structure prior to super-positioning of the strips. The one or more strips may contain internal apertures. The composite strip is coiled helically to produce the hollow cylindrical stator core. By pressure rolling at least one strip, the internal diameter of the stator core can be adjusted to reduce irregularities. By superimposing strips prior to coiling, thinner strips can be used without requiring the stator forming machine to operate longer or faster to produce stator cores of a given size, even though thinner strip material is being used. By using strips that contain internal apertures, unwanted deformations can be reduced. The pressure rolling aspects of the invention and the strips that may contain internal apertures are also applicable to coiling apparatus that uses only a single strip.

Abstract: Apparatus and methods for reducing the likelihood of damage to wire leads of undulated coils for dynamo-electric machine stators are provided. The invention provides a rotating winding head equipped with a coil former that has a wire gripper and an initial wire lead slot. The gripper retains the initial wire lead. The slot permits the initial wire lead to be fed to the gripper from a stationary wire source. The gripper maintains the initial wire lead in a predetermined plane of the coil and can secure the initial wire lead in the plane in which the final lead wire will eventually be disposed. The gripper also rotates the initial wire lead into radial alignment with a lobe of the undulated coil. Once installed in a stator, the initial and final wire leads can both be disposed along the outer radius of the coil and are thus protected from interference with a rotor that is destined to rotate within the stator.

Abstract: Apparatus and methods for reducing the likelihood of damage to wire leads of undulated coils for dynamo-electric machine stators are provided. The invention provides a rotating winding head equipped with a coil former that has a wire gripper and an initial wire lead slot. The gripper retains the initial wire lead. The slot permits the initial wire lead to be fed to the gripper from a stationary wire source. The gripper maintains the initial wire lead in a predetermined plane of the coil and can secure the initial wire lead in the plane in which the final lead wire will eventually be disposed. The gripper also rotates the initial wire lead into radial alignment with a lobe of the undulated coil. Once installed in a stator, the initial and final wire leads can both be disposed along the outer radius of the coil and are thus protected from interference with a rotor that is destined to rotate within the stator.

Abstract: Multiple wire stator coils are formed by winding multiple wires simultaneously in a non-complicated manner without individual wires of the multiple wire coils twisting, overlapping, or entangling each other during the winding process.