Abstract: A device and a process for the functionally combined production, transfer and installation of coils (11a, 11b, 11c) into the stator (12) of electrical machines using installation strips (18a to 20b) provided with spreadable tongues. A ready-wound coil set (11a, 11b, 11c) is taken off the winding machine with its formers (4, 4a), moved to the stator (12), maintaining the spatial stepping and the flat shape of the coil phase windings, transferred directly from the formers (4, 4a) into the installation strips (18a to 20b) inserted into the stator (12), and drawn into the stator (12) as a whole in a single operation. One of the two formers (4) is provided with a preferably detachable support element (13) which lifts the coil heads out of the former chambers by turning the former about the axis of its carrying rod (3). For easier introduction of the coil phase windings into the installation strips ( 18a to 20b), their strip tongues are arranged in different lengths and stepped.

Abstract: Stators are produced by advancing stator workpieces successively to a plurality of work stations. The stators are mounted in holders which each comprises a pair of downwardly depending legs resting on a pair of horizontally spaced conveyor belts. The belts are continuously driven to advance the holders to the work stations. At each station the holder is restrained from movement (e.g., by being lifted off the belts) while the belts continue to be driven. At a winding station, upper and lower winding forms are advanced toward a stator workpiece, the lower form passing between said belts and legs.

Abstract: To introduce wire coils into stators of electric machines, improved isertion strips are proposed. To make the production of the insertion strips (1) cheaper and, in particular, to make it possible to use them for the joint insertion of interconnected coil groups, the insertion strips (1) are made of plastic. They consist of two elastically spreadable tongues, in which guide lamallae (15) made of spring steel are embedded. A foot part (4) is molded on one end of each tongue for releasable mutual connection and for attachment to an insertion tool (E). The foot part adjoins a parallel region of the tongues, which in turn adjoins the spread region of the tongues with an increasing distance between them up to the tongue tips (12).Crosspins engaging into corresponding holes in the adjacent tongue of the next adjacent insertion strip block the wire passage between the strips.

Abstract: A method and apparatus for positioning and transferring stator coil leads in a dynamoelectric stator assembling machine. The apparatus includes holding devices for positioning and retaining the stator coil leads after the coils are wound and before they are inserted into the stator core. The apparatus also includes lead pullers for transferring the leads, during insertion of the coils into the stator core, from the inserting equipment to a stator carrying pallet having lead retaining devices therein. The apparatus further includes lead catchers for capturing the leads from the stator pallet lead retaining devices and for transferring the leads from the stator pallet to a lead finishing apparatus.

Abstract: A working process for the winding of stators (1) of electric motors, in which the coils (12) are inserted between two spreadable elastic tongues (4a and 4b) of draw-in needles and are introduced into the stator grooves (2) in this way and the coils (12) are interconnected according to the polarity before being drawn-in, is improved in terms of its applicability to small and very small-size motors and of greater economy.

Abstract: A device for inserting pre-wound coils into electric motors, the device having an annular series of coil-guide bars for receiving pre-wound coils for insertion into the slots of the stator, an annular series of key-guide bars surrounding the coil-guide bars and terminating a short distance beyond the free ends of the coil-guide bars, so as to permit the stator to bear on the free ends of the key-guide bars and surround the coil-guide bars with the pole faces of the stator in engagement with the external faces of the coil-guide bars. The device also has a pusher member slidable through the series of coil-guide bars to insert the coils in the stator slots. Each coil-guide bar engages the stator only in correspondence with the respective pole face and correct angular positioning of the stator with respect to the two series of bars is effected by orienting means, such as terminal projections on the key-guide bars, engageable with the sides of the stator slots.

Abstract: A coil winding machine comprising a spindle adapted to be driven in rotational motion and to have one or more coil wound thereupon, wire supply apparatus for supplying wire to the spindle for producing the wound coil, insulative sleeve release apparatus for selectably retaining and releasing insulative sleeves through which the wire is drawn to form the coil, such that the sleeves are properly positioned on the wound coils and control apparatus for governing the operation of the spindle and of the release apparatus whereby release of the insulative sleeve takes place at the correct time for proper positioning of the sleeve on the coil.

Abstract: Apparatus for manufacturing piles of magnetic plates of annular shape from stamped sheet metal segments having slots open toward the inside and formed by radially directed arms having enlarged inner ends comprises six operating stations namely a first station in which sheet metal segmented are fed from magazines to build up a stack of plates in which successive layers of segments are angularly staggered, a second station at which the height of a partially formed stack of segments is measured, third and fourth stations for feeding additional thinner segments or thicker segments to the stack according to the measurement in order to obtain a stack of predetermined thickness, a fifth station at which the segments are centered and fitted with rivets and a sixth station at which the stack of segments is compressed and the rivets are set.

Abstract: An apparatus and method for inserting field windings in axial flux electric machines. Preferably each field winding is wound in the form of a spiral of wire on an elongate former. The former is then reduced in external dimensions and a press member moves along the former to push the turns into a pair of slots.Apparatus for forming and inserting both insulating sleeve members for the slots and insulating wedges to maintain the windings in position in the slots, is also disclosed.

Abstract: A method of and apparatus for inserting coils into slots formed in the stator core of a dynamoelectric machine such as an electric motor, with the stator core having open type slots each of which cooperates with blades of the apparatus for guiding the coil and a stripper for forcing the coil out of the blades. A closed space has a volume sufficient to avoid any disorder of coil wire layers when the coil is received by the closed space. After placing the coils in the closed spaces, the coils are pushed into the respective slots and, as desired, the coils are further compressed until the coil wires assume a non-circular cross-section. By so doing, it is possible to remarkably increase the space factor of each slot.

Abstract: Apparatus for winding and insertion of coils in stators or rotors of electrical machines has a winding station and an insertion station, between which insertion tools 14 are transported by means of a rotary table 10. At the winding station, there is a template 24 which cooperates with a winding nozzle 26. Covering strip mechanism 44 has a rotationally movable guide duct 62 and guide portion 70, by means of which insulating strips 58 are introduced successively into ducts 52 provided for them between the tongues 50 of insertion tool 14. To reach with the guide duct 62 and guide portion 70, all the ducts 52 are situated on circumferences of different size depending on the particular insertion tool 14. Guide portion 70 is rotatable about the central longitudinal axis of insertion tool 14 by means of an adjusting motor 48, and is adjustable radially by means of an adjusting motor 46.

Abstract: Automatic system and method for compressing coil turns and insulators in stator core slots. Stator cores initially provided with end cuffed slot liners and a set of loosely inserted windings are loaded by the system operator sequentially into holding stations in a circular indexing, rotatable worktable. Each holding station comprises a cuff support assembly that serves simultaneously to precisely position and irremovably hold the stator cores as the worktable indexes the cores through a plurality of work stations. Automatic apparatus is provided at the work stations to initially press the turns into the slots, insert phase insulators, insert slot separator wedge insulators and further compress both the coil turns and insulators in the slots. A plurality of phase insulator work stations are gang operated to maintain high speed production rates despite relatively slow reloading of phase insulators into the insertion arbor of each work station.

Abstract: Apparatus for assembling a stator for a dynamoelectric machine with an end frame therefor. The stator includes a bore having an axis, and a set of beams secured to the stator and having at least one end portion, respectively, and the end frame includes alignable bearing means associated therewith for defining a generally central axis of the end frame. The apparatus comprises means for supporting the stator with the stator being movable thereon, and locating means having a predetermined reference axis is operable generally for locating engagement with the stator bore to align the axis thereof with the predetermined reference axis.

Abstract: A method and a device for forming the rotor winding coils of a dynamoelectric machine and for anchoring the ends of the coils in slots provided in a commutator associated with the rotor. The method comprises the steps of winding a copper wire around pairs of rotor slots to form the various coils of the winding, inserting each coil end in a commutator slot, the starting end of each coil being inserted in the same slot as that in which the end of the previously wound coil is inserted, and bending the portion of copper wire that is adjacent the end of the coil and extends between the rotor and the commutator, towards the rotor shaft immediately before the insertion of each coil end in the corresponding commutator slot. The said step of insertion of each coil end in the corresponding commutator slot and the preceding step of bending the portion of copper wire adjacent the end of the coil towards the rotor shaft, are carried out during the winding of the wire in the rotor slots.

Abstract: A coil fitting system including a pressing member for fitting in slots of an iron core of an electric rotary machine in one operation step a plurality of coils arranged in such a manner that a portion of one coil end portion overlaps a portion of another coil end portion. The pressing member which is formed at its peripheral edge portion with a plurality of grooves includes a first pressing surface and a second pressing surface. A portion of the pressing member constituting the first pressing surface extends into a region located on an extension in a coil pressing direction of the grooves located radially of such portion, and the first pressing surface corresponds to the coil end portion of one coil. The second surface portion supports, in spaced-apart relation to the first pressing surface in the coil pressing relation, the coil end portion of another coil arranged such that a portion thereof overlaps a portion of the coil end portion corresponding to the first pressing surface.

Abstract: A method of inserting coils into the slots of a stator iron core by moving a pressing piece and a blade supporter which are formed as separate bodies comprises a step of holding said coils by first blades fixed to said pressing piece and second blades fixed to said blade supporter, a step of moving forward said pressing piece and said blade supporter together to insert said coils into the slots of said iron core by means of said first and second blades, and a step of moving backward only said blade supporter for a predetermined distance followed by causing said pressing piece to move backward together with said blade supporter whereby said second blades are firstly retracted while keeping said first blades momentarily at a position.

Abstract: A laminated core product producing apparatus wherein a projection is formed on part of a strip of core sheet material and core sheets are punched out of the strip and assembled in a linearly moving stack into the laminated core product by making use of the mutual fitting and crimping of the projections on the core sheets. The dimension of the laminated core product in the direction of the thickness of the core sheets is determined by controlling the intermittent punching out of the projections. A marking mechanism selectively marks a portion of the lateral side edge of a core sheet to be punched out, and at least one proximity sensor provided adjacent the stacked core sheets being assembled into the core product produces a signal corresponding to the distance of a marked core sheet from the head of the stack during movement of the marked core sheet along the stack.

Abstract: A method of assembling a dynamoelectric machine having at least one end frame and a stator assembly. The end frame has a set of apertures extending therethrough, and the stator assembly includes a stator core, a set of beams mounted thereto, and at least one set of tabs on the beams, respectively. In practicing this method, the end frame is disposed in an assembly position with respect to the stator core, and the tabs are received in the apertures in spaced apart relation therefrom with free end portions of the tabs extending beyond the end frame. The free end portions are displaced into overlaying relation with confronting parts of the end frame, and overlaying sections of the free end portions and the confronting parts of the end frame in the overlaying relation thereof are clinched together.

Abstract: A device of the known type comprising an annular series of coil-guide blades intended to receive pre-wound coils to be inserted into stator slots, an annular series of wedge-guide blades surrounding the series of coil-guide blades and terminating a short distance before the free ends of the coil-guide blades in such a way as to allow the stator to rest on the free ends of the wedge-guide blades by disposing it about the coil-guide blades and a thrust member which is slidable through the series of coil-guide blades for inserting the coils into the stator slots. The wedge-guide blades are axially displaceable in the direction opposite their free ends, against the action of resilient means. Due to this characteristic, when the stator is pressed on the free ends of the wedge-guide blades and fixed in position for the insertion of the coils, the said free ends of the wedge-guide blades are automatically disposed at a distance from the free ends of the coil guide blades corresponding to the length of the stator.

Abstract: An axial flux induction electric motor and method and apparatus for the production thereof, said motor having a rotor and stator, each formed of a core consisting of metal strip having holes punched therein at longitudinally spaced locations so that holes on the core form radially extending slots on a radial face of the core, and wherein said core has the radially inner coils and the radially outer two coils fixed together by deformations thereby preventing unwinding of the core.

Abstract: A coil inserting apparatus for inserting coils into slots of a stator core of an electric rotary machine. The apparatus includes a plurality of groups of blades for guiding the coils into the slots, a plurality of blade holders, a coil pusher, a rotary driving means for driving the coil pusher and the plurality of the blade holders and a mechanism for converting a rotary motion into a linear reciprocating motion, so that the coil pusher and the plurality of the blade holders are caused to make linear reciprocating motions in the axial direction of the plurality of the blade holders.

Abstract: Relatively large coils or windings are positioned in relatively lengthy stator cores with the aid of a coil placing machine by placing coils over certain finger elements of the machine, revolving the set of finger elements and corresponding insulating wedge guides and placing further coils over other of the finger elements. Thereafter, a dynamoelectric machine stator core is positioned in axial alignment with the finger elements with one end face thereof engaging the wedge guide ends and with the finger element free ends just entering the bore of the stator core. A stripper and the plurality of finger elements are moved together along the bore of the core to lead side turn portions of the coils into and along respective core slots whereupon movement of at least some of the finger elements is halted while movement of at least the stripper continues to complete placement of the coils.

Abstract: Improvements in adapting coil placing machines to accommodate cores of differing sizes such as varying stack heights is disclosed wherein a ram actuated stripper which normally engages and urges coils along finger elements into a magnetic core is extended to mechanically couple a portion of a shaft supporting those finger elements with a portion of the stripper actuating rod so as to prevent relative rotation between those two coupled portions and then the coupled portions are rotated together while holding the stripper and finger elements in a rotationally fixed position so as to allow a threaded interconnection coupling the fingers to the finger support shaft as well as a threaded interconnection coupling the stripper to the stripper actuating ram portion to move both the stripper and the fingers axially within the machine.

Abstract: A mounting arrangement for an electromotor having an elongated shaft includes a pair of bearings positioned on two opposite ends of the shaft and a pair of bearing covers closing the openings in an electromotor housing through which the elongated shaft extends. The bearing covers are permanently deformable in the direction of elongation of the shaft to compensate undesirable axial play which may occur in the asembled electromotor.

Abstract: Apparatus and method for winding and inserting coils in slots of a stator or rotor lamination assembly, the coils being produceable on a former, said apparatus and method comprising a transfer tool for transferring said coils from said former onto an insertion tool, said transfer tool comprising annularly arranged parallel bars; and said insertion tool, comprising correspondingly annularly arranged parallel insertion blades, cover strip blades, and an axially mobile insertion ram, said insertion tool being able to introduce said coils into said slots, wherein in said apparatus, said bars are adapted to abut onto the radially internal side of said insertion blades still during at least a part of the insertion operation, and are movable together with said ram.

Abstract: An improved pusher blade and wedge magazine assembly for use in a coil inserting machine and cooperative therewith for inserting the wedges into the elongated slots of a dynamoelectric machine core. The assembly provides pusher blades which are interlockingly and slidably engaged with the wedge magazine during all phases of operation of the machine. The wedge is conjointly rotatably by reason of an operative connection therebetween to eliminate torque or other stresses on the pusher blades. The assembly obviates misalignment between the wedge magazine and the pusher blades and thereby damage or destruction of the pusher blade assembly which can result form such misalignment.

Abstract: A coil forming apparatus of the type in which a coil (16) formed by winding a wire (1) around a winding frame (6, 7) having a plurality of winding steps (6a, 6b, 6c, 6d, 7a, 7b, 7c, 7d) of successively increased diameters is dropped into a coil receiving jig (3) disposed below the winding frame (6, 7) characterized in that pusher plates (21) adapted to vertically slide in slits formed in the winding frame (6, 7) to downwardly push the coil (16) formed on the winding steps are in stepped form corresponding to the contour of the winding of the winding frame and projecting a predetermined amount radially outwardly of the contour of each winding step and the vertical slide stroke is substantially equal to the height of each winding step, thus making it possible to reduce the overall height of the apparatus, shorten the coil forming time and facilitate the wire treatment between oils and at the terminal ends of coils.

Abstract: An apparatus reduces the insertion-required force in a coil inserting apparatus. A coil and an insulating material piece are automatically inserted into the groove of a stator core by the operation of a coil pusher. A current flows from a piezo-electric element accommodated within the coil pusher, when insertion resistance applied upon the coil pusher has increased, through the relay solenoid valve to drive a hydraulic cylinder thereby raising the coil wrapping jig. When the insertion pressure has suddenly increased, the current stops to keep fundamentally the coil wrapping jig synchronous to the motion of the coil pusher.

Abstract: Apparatus for placing coils and phase insulation in the slots of a dynamoelectric machine stator core member includes a core member loading and unloading station, a coil and phase insulation placing station, a preliminary end turn forming station, and a coil drifting station. An unwound core member at the loading/unloading station is loaded in mounting apparatus on a transfer arm which transfers the core to the placing station where coils and phase insulation are placed in the core member slots. The core is then transferred by the transfer arm to the preliminary end turn forming station where the end turns of the coils are formed away from the bore of the core member. The core member is then transferred by the transfer arm to the drifting station where the coils are drifted into the slots. The transfer arm ultimately transfers a fully wound core back to the loading/unloading station where the wound core is unloaded from the transfer arm and then inverted.

Abstract: A process making it possible to manufacture and locate a winding of an undulating shape, more especially for an alternator stator of a motor vehicle.Initially externally of the stator and for each phase, a circular flat coil is formed having the desired number of turns. This coil is then preformed, still externally of the stator, so as to give it an undulating flat star shape, whose undulations correspond to the number of poles and notches of the stator. Then this preformed coil is moved against the bundle of sheets of the stator and wires are inserted into the notches by preforming a tilting action which deforms the coil out of its plane. The apparatus for practicing the process of insertion by tilting particularly comprises a mandrel, which is introduced into the bundle of sheets along the axis of the stator.

Abstract: A coil winding and inserting machine suitable for winding stator coils of 3-phase multipolar motors. The machine has a plurality of independently liftable tooling blades and auxiliary plates. Three winding forms are formed simultaneously or in a predetermined sequence, each being constituted by two tooling blades and one selectively lifted auxiliary plate. Three flyers corresponding to the three winding forms are rotated around these winding forms to form coils of the first pole of respective phases. Then, the flyers make a 180.degree. indexing rotation and coils of the second pole are formed in the same manner as the coils of the first pole. After the winding of all coils, the coils are inserted into the stator core together with the wedges. Accordingly, it is possible to form the coils of u, v and w phases without cutting wires between two poles of respective phases, while ensuring an equal circumferential length of coils of all phases.

Abstract: Automatic system and method for compressing coil turns and insulators in stator core slots. Stator cores initially provided with end cuffed slot liners and a set of loosely inserted windings are loaded by the system operator sequentially into holding stations in a circular indexing, rotatable worktable. Each holding station comprises a cuff support assembly that serves simultaneously to precisely position and irremovably hold the stator cores as the worktable indexes the cores through a plurality of work stations. Automatic apparatus is provided at the work stations to initially press the turns into the slots, insert phase insulators, insert slot separator wedge insulators and further compress both the coil turns and insulators in the slots. A plurality of phase insulator work stations are gang operated to maintain high speed production rates despite relatively slow reloading of phase insulators into the insertion arbor of each work station.

Abstract: A method of, and an apparatus for, constructing a laminated rotor for use in high speed stepping motors or the like. The apparatus consists of a rotatable carousel having a plurality of rotatable work stations each of which is carried to a plurality of operating stations. Lamina are punched from sheet metal stock and brought back into the stock and held in a friction fit. Sheet stock is then advanced to a stacking station where a lamina is forced onto a rotor shaft. The shaft is rotated thereafter in order to uniformly distribute any local metalurgical or planarity inconsistencies in the sheet stock throughout the laminated structure.

Abstract: An improved coil insertion apparatus for inserting coils, for example, into stator cores of electrical rotary machines, in which blades and a coil pusher of the apparatus are arranged to be movable at optimum timing and speed suitable for various winding specifications of stators so as to make it possible to efficiently insert coils having low coil ends and a short circumferential length into stator cores, with simultaneous reduction of coil inserting resistance.

Abstract: A coil inserter including a plurality of tooling devices for inserting a coil and a plurality of wedges into each slot of an iron core, an actuator for driving the tooling devices and which is detachably connected to said tooling device, a tool stocker for selectively movably receiving the tooling devices depending upon the shape of said iron core, and a tooling device supporter having one end supported by a shaft mounted on the tool stocker so as to move are of the tooling devices to the tool stocker and to remove the another of the tooling devices from the tool stocker to engage the former with the actuator.

Abstract: Apparatus for connecting the ends of stator windings to stator supply terminals comprises a stator holding device which holds a wound stator with each winding end held by a holding element and an insertion and clamping device which is displaceable toward the stator holding device and which comprises a tong-like gripper for each winding end which is swivelable toward and away and laterally with respect to the stator holding device under variable tension. The grippers engage the winding ends and displace them into the respective supply terminals, whereupon the terminals are clamped by a clamping device.

Abstract: Apparatus for forming coils of magnet wire and for inserting that magnet wire along the insulating wedges into the core of a stator comprises a transfer tool of circumferentially disposed wedge guides which receives wedges at a wedging station, is wound with coils of magnet wire by a push winding technique at a winding station, and then moves to an insertion station wherein the windings and wedges are pushed into a stator core. The wedge guides are designed to hold the wedges during the winding operation and also to receive the coils being formed as wire is pushed out of a nozzle rotating over the transfer tool. The coils fall by gravity between predetermined pairs of wedge guides. Finger elements are then inserted upwardly through the bore of the transfer tool. An empty stator core is placed on the finger elements, and the formed coils and wedges are pushed from the transfer tool into the stator core.

Abstract: A device for placing prewound coils into stator slots comprises an annular series of fingers housed in respective longitudinal grooves of the outer surface of a hollow cylindrical finger holder. The fingers project beyond one end of the holder for placement thereon of prewound coils. A stripper member axially movable through the stator is provided on its periphery with a series of longitudinal grooves in which the portion of each finger which projects beyond the holder is received. Some fingers, and preferably at least one or both fingers of each couple of adjacent fingers between which a prewound coil is interposed is slidably mounted both within said stripper member and within said holder.

Abstract: Apparatus for winding stators or the like includes a winding form and a winding nozzle, rotatable about the form, for winding a wire on the form. A collecting tool or transfer tool is provided for receiving windings from the form, a stripper is provided to strip windings from the form onto the collecting tool and a clamping means is provided for clamping a wire between individual winding operations. The apparatus includes means for simultaneously moving the winding nozzle, stripping means and clamping means during the stripping of the windings from the form onto the collecting tool. Thus, the wire from the last-wound windings will be prevented from being drawn to a finer diameter when stripped from the form or it will not be necessary to pull additional wire out of the winding nozzle in which event, on starting the next winding process, there would be a strong jerk which could result in breakage.

Abstract: Coils are manually inserted into respective guide paths of a coil inserting jig which is placed with respect to an advancing mechanism. A coil advancing pusher is movably located inside the jig to move the inner portions of the coils toward a core structure mounted on the jig. A coil holding device is provided externally of the jig for engaging the outer portions of the coils when the inner coil portions are initially advanced toward the core structure. The inner coil pusher and the outer coil holding device are simultaneously moved by the advancing mechanism for coaction with each other to advance the inner and outer coil portions toward the core structure with the coil orientations substantially aligned with the grooves of the core structure to ensure smooth insertion of the coils respectively into the core grooves.

Abstract: A process and device for forming the winding core of a stator or rotor. The winding core is only partially exposed to shaping pressure. Shaping is then continued progressively over the core periphery. A device for effecting the method includes a single or multipartite pressing tool for the winding core. The tool is rotatable relative to the long axis of a stator or rotor. In a preferred embodiment, the tool has a narrow shaping part positioned adjacent to a wrapping tool used to provide a wrapping about the shaped coil.

Abstract: Method and apparatus for forming a multi-pole winding for a dynamo-electric machine wherein a skein of magnet wire is wound and mounted on spaced retaining jaws biased outwardly to keep the wire under light tension during a subsequent forming process. Forming tools are moved inwardly against the wire between the retaining jaws to produce a petalled, serpentine form with a series of apices between the retaining jaws. Holding pins are inserted between the wire and the forming tools at the apices, and the forming tools are retracted. While the wire is held between the retaining jaws and holding pins, it is loaded onto a fingered transfer tool.

Abstract: The disclosure relates to a method and apparatus for compressing winding elements in the slot of an electric machine with a pneumatic compressing element, which, in a preferred embodiment, consists of a rubber bellows, configured for insertion in the slot, with a rigid conduit disposed inside the bellows for delivering pressurized fluid to the bellows.

Abstract: An armature includes a shaft supporting a slotted core and a commutator having peripherally spaced hook-like tangs. The armature is automatically wound on a flyer-type winding machine which has a set of concentric tubular shields surrounding the commutator and a pair of wire gripper units diametrically arranged relative to the shields. The gripper units are pivotally supported by a member which surrounds the shields and is supported for rotation on the axis of the armature shaft. A set of fluid cylinders are arranged to rotate or index the member and gripper units between a lead pick-up position and a lead terminating position through an intermediate winding position to provide for faster winding of each armature.

Abstract: A method for assembling a stator for an electric machine having a permanent magnet for generating a magnetic field in an air gap. Assembly of the stator is performed with the aid of a plunger, the cross section of which corresponds to the cross section of the air gap. The permanent magnet is slid into the interior of the plunger, whereas the flux return ring is slid over the same. The so formed sub-assembly is put into a casting mold adapted to be filled with a plastic material, which in its cured or hardened state forms a casing intimately surrounding the outer surface of the flux return ring and forming a face plate, to which the permanent magnet adheres. When the plastic material has set, the casting mold is opened and the plunger is retracted from the sub-assembly, resulting in a close toleranced cylindrical air gap space. After insertion of a bell-shaped rotor, a brush cover is assembled opposite the face plate.

Abstract: A process and device for forming the winding core of a stator or rotor. The winding core is only partially exposed to shaping pressure. Shaping is then continued progressively over the core periphery. A device for effecting the method includes a single or multipartite pressing tool for the winding core. The tool is rotatable relative to the long axis of a stator or rotor. In a preferred embodiment, the tool has a narrow shaping part positioned adjacent to a wrapping tool used to provide a wrapping about the shaped coil.

Abstract: Method involves programming crimp connection equipment to automatically and sequentially establish a plurality of desired different connection configurations. Information representing a series of desired connection configurations is transferred to a control means. Such information is carried by a card that also illustrates a desired final stator assembly configuration. An operator sets thumb wheel switches so that digital information on the card is entered into a control panel. The control means automatically sequences and conditions the apparatus to establish different connections. The card both directly controls machine operation and also is used as a process control card. Also disclosed is a means for positioning a crimp height controlling eccentric shaft in virtually an infinite number of different predetermined angular positions and virtually continuously monitoring the actual instantaneous position of such shaft.

Abstract: A device for placing prewound coils into stator slots comprises an annular series of fingers housed in respective longitudinal grooves of the outer surface of a hollow cylindrical finger holder. The fingers project beyond one end of the holder for placement thereon of prewound coils. A stripper member axially movable through the stator is provided on its periphery with a series of longitudinal grooves wherein the portion of each finger which projects beyond the holder is received. Some fingers, and preferably at least one finger of each couple of adjacent fingers between which a prewound coil is interposed is slidably mounted both within said stripper member and within said holder.

Abstract: A stepped combination apparatus comprises transferring means for moving a bundle of component wires arranged in plural rows and plural lines in the longitudinal direction; pushing means for pushing the component wires to the line direction to put out a component wire at the opposite side; shifting means for shifting the component wire which is put out by the pushing means, to the other row; and stepped-bending means for stepped-bending the component wire which is put out. The operation time can be significantly shortened and a U-shape bundle of component wires can be treated by the apparatus.

Abstract: An injection shuttle system is disclosed for fabricating stator core assemblies. Injection tooling and a stator core are selected and positioned on a shuttle means at a selection station for moving to coil loading stations and a transfer station. The injection tooling is positioned, aligned and manipulated relative to a winding machine at each coil loading station for disposing winding turns thereon. At the transfer station, the injection tooling is transferred to a wedge guide housing of a turntable arrangement which includes wedge making and injection stations. A stator height adjustment arrangement is provided for adjusting the wedge making and injection stations in accordance with the axial length of the core. The injection tooling is moved or indexed to the wedge making stations where insulating wedges are fabricated and inserted into wedge guides of the wedge guide housing.