Abstract: A wound stator for a dynamo-electric machine comprising a stator stack having a unitary cylindrical yoke and a plurality of circumferentially spaced, radially inward extending stator teeth defining stator slots therebetween. A winding is formed by a strand of wire forming turns around each stator tooth, each winding including a first lead end extending from a stator slot on a first side of a respective stator tooth and a second lead end extending from a stator slot on a second side of the respective stator tooth. An insulation system is provided including an insulating structure septum extending through each stator slot between windings located on two adjacent stator teeth, the turns of each winding located between a respective stator tooth and a first surface of the insulating structure septum engaged with the winding.

Abstract: A wound stator for a dynamo-electric machine comprising a stator stack having a unitary cylindrical yoke and a plurality of circumferentially spaced, radially inward extending stator teeth defining stator slots therebetween. A winding is formed by a strand of wire forming turns around each stator tooth, each winding including a first lead end extending from a stator slot on a first side of a respective stator tooth and a second lead end extending from a stator slot on a second side of the respective stator tooth. An insulation system is provided including an insulating structure septum extending through each stator slot between windings located on two adjacent stator teeth, the turns of each winding located between a respective stator tooth and a first surface of the insulating structure septum engaged with the winding.

Abstract: A wound stator includes a plurality of windings, each winding including a primary lead and a secondary lead defined by free ends of the winding. Each of the windings being associated with a first, second or third phase. For each phase, a plurality of the primary leads are wrapped around a termination side of the stator to a common primary base lead to form a primary lead connection for the phase. For each phase, a plurality of the secondary leads are wrapped around the termination side of the stator to a common secondary base lead to form a secondary lead connection for the phase.

Abstract: A wound stator includes a plurality of windings, each winding including a primary lead and a secondary lead defined by free ends of the winding. Each of the windings being associated with a first, second or third phase. For each phase, a plurality of the primary leads are wrapped around a termination side of the stator to a common primary base lead to form a primary lead connection for the phase. For each phase, a plurality of the secondary leads are wrapped around the termination side of the stator to a common secondary base lead to form a secondary lead connection for the phase.

Abstract: A method and apparatus for applying a solid particulate powder coating to a stator stack having a plurality of longitudinally extending stator slots. The apparatus includes a coating application station for applying powder particles to the stator stack, a coating removal station for displacing the powder particles from selected areas of the stator stack and a curing oven for curing the powder particles onto the stator stack. A collection hopper is provided for receiving recycled powder particles and includes a porous structural side wall for permitting air to exit the hopper while retaining the powder particles from passing into the environment around the system.

Abstract: An apparatus is provided for forming field coils on a stator stack including a plurality of slots defined by stator teeth. The apparatus includes a stator nest for holding a stator stack and a winding tool extending through the stator nest for locating wire in the stator stack. The winding tool includes a wire feed aperture for feeding wire into slots of the stator stack. A drifting tool is supported on the winding tool and includes radially extending drift blades for extending into the slots of the stator stack for forming or shaping wire coils that are wound on the stator teeth by the winding tool. Longitudinal movement of the winding tool causes the drifting tool to move into and out of engagement with the stator stack.

Abstract: A method and apparatus for applying a solid particulate powder coating to a stator stack having a plurality of longitudinally extending stator slots. The apparatus includes a coating application station for applying powder particles to the stator stack, a coating removal station for displacing the powder particles from selected areas of the stator stack and a curing oven for curing the powder particles onto the stator stack. A collection hopper is provided for receiving recycled powder particles and includes a porous structural side wall for permitting air to exit the hopper while retaining the powder particles from passing into the environment around the system.

Abstract: A winding machine for winding wire on a stator stack for a dynamo-electric machine including a wire supply, a stripper station for selectively stripping wire at predetermined locations, a wire feed mechanism and winding station including a winding spindle movable in reciprocating and oscillating movement. The feed mechanism is capable of conveying plural wires to the winding spindle including three pairs of wires to respective exit apertures on the winding spindle. The winding station includes twisting assemblies, where a twisting assembly is provided for each pair of wires for twisting the pair of wires together and for gripping and manipulating the wires during a winding operation.

Abstract: An apparatus for winding the stator for a dynamoelectric machine is provided. The apparatus includes a stator nest located on a mounting member, the stator nest including a front side for receiving a stator and a back side located opposite from the front side. The stator nest defines a horizontal longitudinal axis and includes a collet located at the front side for engaging and gripping the outer surface of a stator positioned within the collet. A collet actuator is located on a side of the mounting member opposite from the front side, and the collet actuator actuates the collet to engage with and disengage from the stator. A winding tool extends through the stator nest from the back side toward the front side. A reciprocating driver is connected to the winding tool for driving the winding tool in reciprocating movement relative to the stator nest. An oscillating driver connected to the winding tool drives the winding tool in oscillating movement.

Abstract: An apparatus for winding the stator for a dynamoelectric machine is provided. The apparatus includes a stator nest located on a support base for holding a stator. The stator nest defines a horizontal longitudinal axis and includes a front side for receiving a stator and an opposite back side, and a winding tool extends through the stator nest from the back side toward the front side. The winding tool includes a hollow tubular member for guiding wire to a stator located in the stator nest, and a reciprocating driver is connected to the winding tool for driving the winding tool in reciprocating movement relative to the stator nest. An oscillating driver connected to the winding tool drives the winding tool in oscillating movement. A wire feeder for feeding wire through the winding tool is supported adjacent the oscillating driver and is supported for reciprocating movement with the winding tool.

Abstract: An apparatus for forming wire coils on a stator including a winding tool movable in reciprocating and rotating movement and including wire apertures for feeding wire into slots of a stator. A drifting tool is provided adjacent an end of the winding tool and includes drifting blades extending radially outwardly for positioning within the slots of the stator. The drifting tool is movable with the winding tool during the winding operation such that the drifting tool follows the winding tool in its reciprocating movement to provide for displacement of wire in the slots and improve the slot fill during the winding operation. Wire retaining structures are provided above and below the stator to intermittently engage and retain wire located at the ends of the stator. A wire feed mechanism is also provided including a wire feed pulley and a belt cooperating with the pulley to push wire toward the winding tool.

Abstract: A winding tool for forming wire coils in a stator stack for a dynamoelectric machine including a base structure having a cylindrical wall and forming members for forming wire located in the stator stack during the winding operation. The winding tool includes wire apertures for feeding wire into the slots of a stator stack during a winding operation, and the forming members include forming blades for extending into the slots of the stator stack to push the wires positioned therein radially outwardly. In addition, end formers are provided at longitudinal ends of the forming blades for extending across the end faces of the stator stack to position the end turns of the wire coils radially outwardly. An actuator structure is provided for actuating the forming blades and end formers simultaneously at predetermined times throughout a winding operation to thereby form the wire coils radially outwardly and create greater slot fill densities.

Abstract: An apparatus for forming wire coils on a stator including a winding tool movable in reciprocating and rotating movement and including wire apertures for feeding wire into slots of a stator. A drifting tool is provided adjacent an end of the winding tool and includes drifting blades extending radially outwardly for positioning within the slots of the stator. The drifting tool is movable with the winding tool during the winding operation such that the drifting tool follows the winding tool in its reciprocating movement to provide for displacement of wire in the slots and improve the slot fill during the winding operation. Wire retaining structures are provided above and below the stator to intermittently engage and retain wire located at the ends of the stator. A wire feed mechanism is also provided including a wire feed pulley and a belt cooperating with the pulley to push wire toward the winding tool.

Abstract: An apparatus for forming wire coils on a stator including a winding tool movable in reciprocating and rotating movement and including wire apertures for feeding wire into slots of a stator. A drifting tool is provided adjacent an end of the winding tool and includes drifting blades extending radially outwardly for positioning within the slots of the stator. The drifting tool is movable with the winding tool during the winding operation such that the drifting tool follows the winding tool in its reciprocating movement to provide for displacement of wire in the slots and improve the slot fill during the winding operation. Wire retaining structures are provided above and below the stator to intermittently engage and retain wire located at the ends of the stator. A wire feed mechanism is also provided including a wire feed pulley and a belt cooperating with the pulley to push wire toward the winding tool.

Abstract: A winding tool for forming wire coils in a stator stack for a dynamoelectric machine including a base structure having a cylindrical wall and forming members for forming wire located in the stator stack during the winding operation. The winding tool includes wire apertures for feeding wire into the slots of a stator stack during a winding operation, and the forming members include forming blades for extending into the slots of the stator stack to push the wires positioned therein radially outwardly. In addition, end formers are provided at longitudinal ends of the forming blades for extending across the end faces of the stator stack to position the end turns of the wire coils radially outwardly. An actuator structure is provided for actuating the forming blades and end formers simultaneously at predetermined times throughout a winding operation to thereby form the wire coils radially outwardly and create greater slot fill densities.

Abstract: An apparatus for forming wire coils on a stator including a winding tool movable in reciprocating and rotating movement and including wire apertures for feeding wire into slots of a stator. A drifting tool is provided adjacent an end of the winding tool and includes drifting blades extending radially outwardly for positioning within the slots of the stator. The drifting tool is movable with the winding tool during the winding operation such that the drifting tool follows the winding tool in its reciprocating movement to provide for displacement of wire in the slots and improve the slot fill during the winding operation. Wire retaining structures are provided above and below the stator to intermittently engage and retain wire located at the ends of the stator. A wire feed mechanism is also provided including a wire feed pulley and a belt cooperating with the pulley to push wire toward the winding tool.

Abstract: An apparatus and method for winding dynamoelectric machine field windings including a winding tool supported for longitudinal and rotational movement relative to a stator supported by a stator nest assembly. Upper and lower wire holders are supported on the winding, tool and are slidably movable relative to the winding tool. The upper and lower wire holders are located on opposite sides of a stator to be wound and are biased by compression springs in a direction toward a respective end of the stator. As the winding tool reciprocates in a longitudinal direction, the upper and lower wire holders alternately engage the upper and lower ends of the stator to alternately clamp upper and lower end loops of field windings being formed by the apparatus.

Abstract: A method of winding stators having skewed slots and an apparatus for performing the method. The method includes the steps of positioning a stator in a stator winding machine wherein the winding machine includes a winding spindle having a wire exit aperture. Wire is fed through the wire exit radially outwardly for placement on the stator while the winding spindle is simultaneously moved in rotating and reciprocating movement to direct wire into the slots and around the ends of the teeth of the stator. The wire is fed at a predetermined rate from a feed mechanism located upstream from and mounted for movement with the winding spindle. The rate at which the wire is fed may be varied depending on the position of the winding spindle in a winding cycle and the desired position for placement of the wire within the stator.

Abstract: A tool for forming wire windings located in stator slots defined between radially extending stator teeth. The tool includes a fixture supporting a plurality of elongated fingers wherein each finger includes a plurality of sections spaced longitudinally along the finger, each section defining a width dimension different from the width dimension of an adjacent section. The width dimensions of the sections progressively increase from a distal end of the finger to a proximal end of the finger. A linear actuator is provided for moving the fixture toward and away from a stator whereby the fingers are inserted between the teeth in the stator to cause wire wound around the teeth to be pressed against the teeth.

Abstract: An apparatus for winding wire onto a magnetic ring structure defining slots for receiving wire coils formed thereon. The apparatus includes a mounting structure for holding the ring structure and a platform supported within the peripheral area defined by the ring structure, the platform supporting a wire feed mechanism and a wire forming mechanism. A guide member is supported on an end of the platform adjacent to the ring structure and includes a face plate which is spring biased into engagement with the ring structure to thereby prevent wire from slipping out of the slots in the ring structure as the coils are wound. The guide member, along with the platform carrying the wire feed mechanism and wire forming mechanism, is mounted for rotational movement about a rotational axis, and is further supported for movement in horizontal and vertical directions, perpendicular and parallel to the rotational axis, respectively.