Abstract: The present invention concerns forming wire coils by simultaneously winding a plurality of wires onto a dynamo-electric machine component. In order to maximize the amount of wire that can be placed in the spacings of the dynamo-electric machine component, the turns of the wire coil must be regularly disposed without twisting the plurality of wires onto each other. Current winding apparatus may allow certain portions of the wire turns to unevenly accumulate and locally bulge outward from the collection of wire coils. Such bulges, especially in consideration of the limited spacings available on an dynamo-electric machine component, may interfere with or access to the spacings by a wire dispensing member during the winding process. The present invention proposes to perform multiple-wire winding processes that avoid wire twisting and improper disposition of the wires. Further, the present invention proposes to improve the ability of the wire dispensing member to traverse the spacings on the component.

Abstract: The present invention concerns forming wire coils by simultaneously winding a plurality of wires onto a dynamo-electric machine component. In order to maximize the amount of wire that can be placed in the spacings of the dynamo-electric machine component, the turns of the wire coil must be regularly disposed without twisting the plurality of wires onto each other. Current winding apparatus may allow certain portions of the wire turns to unevenly accumulate and locally bulge outward from the collection of wire coils. Such bulges, especially in consideration of the limited spacings available on an dynamo-electric machine component, may interfere with or access to the spacings by a wire dispensing member during the winding process. The present invention proposes to perform multiple-wire winding processes that avoid wire twisting and improper disposition of the wires. Further, the present invention proposes to improve the ability of the wire dispensing member to traverse the spacings on the component.

Abstract: The present invention is concerned with the driving mechanism of winding needles which dispense wire to form the wire coils of a dynamo-electric machine component. Generally, such wire winding is achieved by providing translational, rotational, and radial motions to the winding needle relative to a reference structure of the component. The present invention provides wire winding solutions for causing the winding needles to accomplish predetermined motions with respect to the component so that wire is predictably positioned on the component to form the wire coils. In particular, the present invention provides a driving mechanism with coaxial hollow shafts that impart the necessary motions to the winding needle. In one aspect of the invention, the inner shaft is able to mirror the rotation of the outer shaft to provide rotational motion to the winding needle.

Abstract: An improved needle solution is provided for winding wire coils onto dynamo-electric machine components such as electric motor stators and armatures. The improved needle solution decreases the opportunity for collision between the needle apparatus and the machine component onto which wire coils are being wound and enables the winding of machine components with small interior hollows that may not allow conventional needle solutions to pass through. The improved needle solution further provides increased accuracy in wire coil stratification by stabilizing the stratification motion of the apparatus using guide structures that engage the needle arm. The needle solution further provides open access to the wire being fed through the apparatus for winding onto the machine component. Multiple needles may be accommodated by the apparatus to simultaneously wind multiple wire coils onto a machine component using the improved needle solution.

Abstract: The present invention is concerned with the driving mechanism of winding needles which dispense wire to form the wire coils of a dynamo-electric machine component. Generally, such wire winding is achieved by providing translational, rotational, and radial motions to the winding needle relative to a reference structure of the component. The present invention provides wire winding solutions for causing the winding needles to accomplish predetermined motions with respect to the component so that wire is predictably positioned on the component to form the wire coils. In particular, the present invention provides a driving mechanism with coaxial hollow shafts that impart the necessary motions to the winding needle. In one aspect of the invention, the inner shaft is able to mirror the rotation of the outer shaft to provide rotational motion to the winding needle.

Abstract: Methods and apparatus for insulating interior walls of lamination slots of dynamo-electric machine components are provided. The relative speeds and sequence of cutting, forming, and inserting a piece of insulation material into the slot of the lamination core of a dynamo-electric machine component may be determined by a central drive mechanism. The central driving mechanism may have a plurality of cams, rotating with a main shaft, to control the translations of cutting, forming and inserting members.

Abstract: Methods and apparatus for insulating interior walls of lamination slots of dynamo-electric machine components are provided. The relative speeds and sequence of cutting, forming, and inserting a piece of insulation material into the slot of the lamination core of a dynamo-electric machine component may be determined by a central drive mechanism. The central driving mechanism may have a plurality of cams, rotating with a main shaft, to control the translations of cutting, forming and inserting members.

Abstract: The present invention concerns forming wire coils by simultaneously winding a plurality of wires onto a dynamo-electric machine component. In order to maximize the amount of wire that can be placed in the spacings of the dynamo-electric machine component, the turns of the wire coil must be regularly disposed without twisting the plurality of wires onto each other. Current winding apparatus may allow certain portions of the wire turns to unevenly accumulate and locally bulge outward from the collection of wire coils. Such bulges, especially in consideration of the limited spacings available on an dynamo-electric machine component, may interfere with or access to the spacings by a wire dispensing member during the winding process. The present invention proposes to perform multiple-wire winding processes that avoid wire twisting and improper disposition of the wires. Further, the present invention proposes to improve the ability of the wire dispensing member to traverse the spacings on the component.

Abstract: In systems for winding wire on electrodynamic machine stators, stators may be transferred between stator conveyance apparatus, winding shroud installation and removal apparatus, wire winding apparatus, wire lead termination apparatus, or other apparatus. Some transfer devices may secure stators in housings fixed to arms that may be rotated around an axis to move stators between stations. Some transfer devices may have stator grasping devices that may be rotated and translated to move stators between stations. Wire winding shrouds may be secured to a stator to facilitate winding and released from stator after wire is wound on the stator. A device for securing shrouds to the stator may be fixed to the stator and may remain fixed to the stator during transfer between different apparatus. Some devices for securing shrouds and stators may be integrated into housings. Some housings may be fixed to transfer devices along one side of the housing.

Abstract: In systems for winding wire on electrodynamic machine stators, stators may be transferred between stator conveyance apparatus, winding shroud installation and removal apparatus, wire winding apparatus, wire lead termination apparatus, or other apparatus. Some transfer devices may secure stators in housings fixed to arms that may be rotated around an axis to move stators between stations. Some transfer devices may have stator grasping devices that may be rotated and translated to move stators between stations. Wire winding shrouds may be secured to a stator to facilitate winding and released from stator after wire is wound on the stator. A device for securing shrouds to the stator may be fixed to the stator and may remain fixed to the stator during transfer between different apparatus. Some devices for securing shrouds and stators may be integrated into housings. Some housings may be fixed to transfer devices along one side of the housing.

Abstract: An improved needle solution is provided for winding wire coils onto dynamo-electric machine components such as electric motor stators and armatures. The improved needle solution decreases the opportunity for collision between the needle apparatus and the machine component onto which wire coils are being wound and enables the winding of machine components with small interior hollows that may not allow conventional needle solutions to pass through. The improved needle solution further provides increased accuracy in wire coil stratification by stabilizing the stratification motion of the apparatus using guide structures that engage the needle arm. The needle solution further provides open access to the wire being fed through the apparatus for winding onto the machine component. Multiple needles may be accommodated by the apparatus to simultaneously wind multiple wire coils onto a machine component using the improved needle solution.

Abstract: A workstation is provided for concurrently processing dynamo-electric machine core subassemblies that are at different stages of a dynamo-electric machine core manufacturing process. The workstation is configured to include a sequence of step processing units. Different units receive and process subassemblies that are at different stages of manufacture. A movable transferor substantially simultaneously advances a group of subassemblies forward through the sequence of units. The workstation can be integrated with conventional assembly line transport systems. These transport systems may be used to deliver input subassemblies to the workstation and to carry away output subassemblies. Subassemblies may be loaded into the workstation at the same time as finished subassemblies are unloaded from the workstation.

Abstract: Methods and apparatus for insulating interior walls of lamination slots of dynamo-electric machine components are provided. The relative speeds and sequence of cutting, forming, and inserting a piece of insulation material into the slot of the lamination core of a dynamo-electric machine component may be determined by a central drive mechanism. The central driving mechanism may have a plurality of cams, rotating with a main shaft, to control the translations of cutting, forming and inserting members.

Abstract: In systems for winding wire on electrodynamic machine stators, stators may be transferred between stator conveyance apparatus, winding shroud installation and removal apparatus, wire winding apparatus, wire lead termination apparatus, or other apparatus. Some transfer devices may secure stators in housings fixed to arms that may be rotated around an axis to move stators between stations. Some transfer devices may have stator grasping devices that may be rotated and translated to move stators between stations. Wire winding shrouds may be secured to a stator to facilitate winding and released from stator after wire is wound on the stator. A device for securing shrouds to the stator may be fixed to the stator and may remain fixed to the stator during transfer between different apparatus. Some devices for securing shrouds and stators may be integrated into housings. Some housings may be fixed to transfer devices along one side of the housing.

Abstract: A workstation is provided for concurrently processing dynamo-electric machine core subassemblies that are at different stages of a dynamo-electric machine core manufacturing process. The workstation is configured to include a sequence of step processing units. Different units receive and process subassemblies that are at different stages of manufacture. A movable transferor substantially simultaneously advances a group of subassemblies forward through the sequence of units. The workstation can be integrated with conventional assembly line transport systems. These transport systems may be used to deliver input subassemblies to the workstation and to carry away output subassemblies. Subassemblies may be loaded into the workstation at the same time as finished subassemblies are unloaded from the workstation.

Abstract: Armature winders which include a mounting apparatus, a holder assembly and a transporting apparatus and methods for shroud changing. The mounting apparatus is used for mounting the shroud on a support structure so that the shroud is held firmly relative to the support structure but is also readily removable from the support structure. The holder assembly holds the shroud and any replacement shroud when not in use. The transporting apparatus transports the shroud in either direction to and from the mounting apparatus and the holder assembly.

Abstract: Insulating strip material for dynamo-electric machine parts (e.g., for armature core slot liners) is fed out intermittently by a reciprocating assembly which releasably clamps the strip material during at least a portion of the assembly's stroke in one direction. The material that has been fed out is cut off, formed into the desired shape (if necessary), and inserted into the dynamo-electric machine part during further motion of the reciprocating assembly.

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: 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: Methods and apparatus are provided for generating and connecting an intermediate lead wire extending between multiple portions of a coil wound on a pole of a stator core to a slotted terminal mounted on the stator core. Such stator cores, wound by coil winding shuttles, are used in electric motors, generators and similar devices. An intermediate lead wire extending between multiple portions of a coil is first captured by a hook mechanism, aligned with a slotted terminal, and then inserted in the terminal by a wire insertion device. The wire is then held in engagement with the terminal while the next portion of the coil is begun, producing an intermediate lead wire connection wherein a first portion of the lead wire is engaged within a slot in the terminal and the portion extending from the terminal to the next coil portion is wrapped tightly against the exterior of the terminal. In accordance with the principles of this invention, no cutting of the intermediate lead wire is required.