Abstract: An apparatus and method for performing and final forming the winding end turns of a stator. The apparatus includes an elongated arbor on the end of which includes a plurality of radially moveable blades and a cam. A pair of outer diameter jaws is positioned around the end turns whereby the arbor initially can move through the end turns to preform the end turns. After the arbor is moved into position, the end turns are final formed by reducing the volume of the end turn spaces defined by the outer diameter jaws. The coils are final formed by the movement of an end turn heights ring into the end turn spaces defined by the outer diameter jaws.

Abstract: A wire positioning mechanism and method for positioning a start wire of a coil bundle from the bottom of the coil bundle to the top of the coil bundle during winding of the coil. The mechanism includes a pivotable and retractable arm with a clamp assembly, a contacting finger, and a wire hook on one end thereof. The start wire is first deflected into the space between the two separated sections of a coil form by the contacting finger. The wire is then lightly clamped. The coil is then wound on the coil form so that the start wire will be positioned inside the coil. The wire hook is then activated to reposition the start wire through the coil bundle and out over the top of the coil bundle. The start wire positioning mechanism is then moved out of the way of the coil and the winding operation is completed.

Abstract: An apparatus for inserting coils and wedges into the stator core of an electric motor. The apparatus includes a plurality of elongated blades arranged in a circular array, a plurality of wedge guides arranged in a circular array, and a stripper. Additionally, a wedge guide support is provided which moves axially together with the blades and which supports the wedge guides when coils are inserted into a long stator core. The wedge guide support prevents deflection of the wedge guides radially inward by pressure of the coil end turns on the wedge guides when the blade pack is axially moved out of the wedge guides.

Abstract: A releasable clamp holds a stator with a closed end turn while a resilient plug, covered with a rigid smooth walled sleeve, is inserted through the central opening of the stator to spread the winding at the closed end turn. The sleeve is then withindrawn, the stator is unclamped, and the plug is compressed to further speed the windings at the closed end, after which the plug is removed.