Abstract: A molded finished part includes a finish insert (172) with a finish disposed upon a front insert side and a body portion of the molded part. The insert (172) has a substantially rigid yet resilient layer of moldable material. The layer has opposing front and back insert sides. The part body portion has a body surface that corresponds to the back insert side. The body portion is also formed of moldable material. Further, the body surface and the back insert side are melded together in a substantially indistinguishable interface.

Abstract: An upholstery system for a vehicle accessory includes a substrate with a U-shaped channel adjacent an edge and including a lip extending from one wall. A trim member includes spaced locking tabs which underlie the lip for compressibly holding an edge of upholstery material in the channel. In one embodiment, pins in the trim ring extend through the material and into apertures in an outer flange of the channel. In another embodiment, the locking tabs are formed on the substrate and the trim member includes interengaging locking slots.

Abstract: A torque control for providing a desired frictional resistance to a pivotally mounted vehicle accessory, such as an armrest or headrest, which includes a resilient member having an irregular arcuate slot. A resistance element extends in the slot to move along the length thereof as the pivoted component pivots about the pivot axis. In one modification, the shape of the slot provides a desired predetermined frictional resistance and in another modification a cutout is made in one of the walls of the slot permitting such wall to flex.

Abstract: An upholstery system for a vehicle accessory includes a substrate with a U-shaped channel adjacent an edge and including alternately staggered apertures and slots in its floor. A trim member with alternately staggered pins and locking tabs compressibly holds an edge of upholstery material in the channel with the pins extending through the material and into the apertures and the tabs lockably holding the trim member by fitting into the slots.

Abstract: A torque control for providing a desired frictional resistance to a pivotally mounted vehicle accessory, such as an armrest or headrest, which includes a resilient member having an irregular arcuate slot. A resistance element extends in the slot to move along the length thereof as the pivoted component pivots about the pivot axis. The shape of the slot provides a desired predetermined frictional resistance.

Abstract: A connection insulator for a dynamoelectric machine having a magnetic core and at least one winding arranged thereon comprising a plurality of coils of wire conductors with end turns thereof projecting beyond side faces of the core and being subject to pressure forces during compacting and forming and with lead wires extending therefrom. The insulator is formed of a flexible heat-shrinkable electrical insulating material and comprises a tubular portion with an open end adapted to receive an electrical connection joining at least one of the lead wires with another wire and a closed end with an integral flat tab portion extending axially therefrom at a junction with the tubular portion. A substantial part of the tab portion spaced from the junction is adapted to be grippingly engaged by the end turns of one of the coils and a substantial part of the tubular portion spaced from the junction is adapted to be grippingly engaged by the end turns of an adjoining coil.

Abstract: A hermetic compressor unit driven by a dynamoelectric machine therein adapted to be energized from a source of power has a housing with a chamber therein, and means associated with the housing and communicating with the chamber is adapted for connection with the power source. A stator of the dynamoelectric machine mounted to the housing within the chamber includes winding means having a set of lead ends integral therewith. Plug means is removably associated with the connection means for receiving the lead ends and for connecting them in circuit relation with the connection means. A set of means are associated with the lead ends of the winding means for insulating them electrically from each other with the insulating means and lead ends twisted together into a twisted bundle thereof.

Abstract: A connection insulator for a dynamoelectric machine having a magnetic core and at least one winding arranged thereon comprising a plurality of coils of wire conductors with end turns thereof projecting beyond side faces of the core and being subject to pressure forces during compacting and forming and with lead wires extending therefrom. The insulator is formed of a flexible heat-shrinkable electrical insulating material and comprises a tubular portion with an open end adapted to receive an electrical connection joining at least one of the lead wires with another wire and a closed end with an integral flat tab portion extending axially therefrom at a junction with the tubular portion. A substantial part of the tab portion spaced from the junction is adapted to be grippingly engaged by the end turns of one of the coils and a substantial part of the tubular portion spaced from the junction is adapted to be grippingly engaged by the end turns of an adjoining coil.

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: 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: Crimp connection equipment includes 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. In addition, a universal wheelfeed for feeding a connector strip and selectively replaceable means for guiding such strip are disclosed.

Abstract: Dynamoelectric machine stator assemblies are disclosed in which end turns of the different windings are separated by winding end turn insulating portions of a plurality of individual phase insulators. The end turn insulating portions of the phase insulators are disposed in overlapping pinwheel configuration with overlapping portions of the insulators being disposed adjacent each other along the entire extent of the overlap.

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: An insulated internal connection arrangement between a terminal end of a winding of a dynamoelectric machine and at least one other wire conductor is disclosed. The connection arrangement includes an insulator having at least one elongated generally tubular receptacle with one end thereof open and the other end closed and having an internal restriction between the open and closed ends. A connector disposed within the at least one receptacle, electrically joins winding and wire conductor ends. The connector has a flared portion which cooperates with the internal restriction to firmly capture the connector within the receptacle. The insulator may include a plurality of receptacles formed from a single sheet of insulating material with the receptacles disposed generally coplanar and with each receptacle opening in the same direction. The internal restriction may comprise a depression extending transverse to each of the receptacles.

Abstract: Methods and apparatus for developing a plurality of coils of conductive wire for use in magnetic cores are disclosed. In one embodiment, a coil turn forming assembly having a coil form portion with a plurality of turn-gauging steps thereon is employed to develop a plurality of coils. A flyer generates turns of wire about the coil turn forming assembly and a jump mechanism locates the turn-gauging steps in the path of the wire generating the turns. The jump mechanism includes a cam surface with a plurality of axially and radially displaced stops thereon. A cam follower which is movable with the coil form portion is provided to sequentially engage the cam stops. A control arrangement actuates the jump mechanism to move the cam surface radially allowing engagement of the cam follower with different stops of the cam surface to place different turn-gauging steps of the coil form in the path of the wire generating the turns.

Abstract: Methods and apparatus are disclosed for fabricating dynamoelectric machine stator assemblies in which end turns of the different windings are separated by winding end turn insulation. In one disclosed method, a plurality of phase insulators are deformed and constrained in a substantially cylindrical configuration and moved axially into a stator core bore. The phase insulators are moved radially outward of the substantially cylindrical configuration with connectors of the insulators moving into predetermined slots of the core. In one disclosed apparatus, a substantially cylindrical arbor is provided with longitudinally extending grooves therein for positioning and accommodating connectors of the phase insulators. The phase insulators are deformed about a peripheral surface of the arbor and then retained adjacent thereto during insertion of the arbor into the bore of a core. The connectors are aligned and moved from the arbor grooves into predetermined core slots.

Abstract: Permanent insulators made from known insulator material (e.g., polyethylene terephalate) are used in lieu of temporary fiber wedges, even though such wedges are not axially centered in core slots, without requiring the performance of manual labor in order to axially reposition the "final" wedges along the core slots. By use of one preferred form of a disclosed apparatus, previously positioned wedges are repositioned axially along core slots automatically and generally contemporaneously with the performance of some other necessary manufacturing process to avoid the expenditure of additional incremental time associated with such repositioning step. Equipment usable for other preselected manufacturing operations may be used in the automated practice of the invention. In one specific exemplification, previously positioned wedges are repositioned along core slots during a previously known wire moving, wire shaping, or wedge setting operation.

Abstract: Method of making at least two different electrical interconnections with at least two wires extending from windings supported on a dynamoelectric machine core. The method includes moving the core, windings, and at least two wires toward a wire connecting device; orienting and positioning a first one of the at least two wires relative to the device; and thereby conditioning the device to establish a first one of at least two different connection configurations. A first electrical interconnection involving a first wire and having a first connection configuration is formed. A second winding lead then is oriented and positioned relative to the device, thereby to condition the device to form an interconnection having a second connection configuration, and such interconnection is made. Indicia that indicate the relative orientation of the stator assembly (or parts thereof) are utilized to condition the device to establish connections of desired different configurations.

Abstract: Method of making at least two different electrical interconnections with at least two wires extending from windings supported on a dynamoelectric machine core. The method includes moving the core, windings, and at least two wires toward a wire connecting device; orienting and positioning a first one of the at least two wires relative to the device; and thereby conditioning the device to establish a first one of at least two different connection configurations. A first electrical interconnection involving a first wire and having a first connection configuration is formed. A second winding lead then is oriented and positioned relative to the device, thereby to condition the device to form an interconnection having a second connection configuration, and such interconnection is made. Indicia that indicate the relative orientation of the stator assembly (or parts thereof) are utilized to condition the device to establish connections of desired different configurations.

Abstract: An upholstery system for a vehicle accessory includes a substrate with a U-shaped channel adjacent an edge and including alternately staggered apertures and slots in its floor. A trim member with alternately staggered pins and locking tabs compressibly holds an edge of upholstery material in the channel with the pins extending through the material and into the apertures and the tabs lockably holding the trim member by fitting into the slots.