Abstract: Finish leads of coils wound onto stator cores without terminal boards are automatically secured before the stator is removed from the winding apparatus. Tooling is provided that is moved into position adjacent the stator at a lead tuck station to cooperate with a robot end effector to tuck the finish leads between their respective coils and the portion of the stator core adjacent thereto. Because the finish leads are so tucked, the coils do not have a tendency to despool when removed from the winding apparatus, which permits the use of an automated load/unload mechanism.

Abstract: A stator coil lead wire is extended over the end turns of coil from which the lead wire is extended and inserted into a terminal member adjacent the opposite side of the same coil. A tooling assembly is provided having a coil shield which prevents the lead wire from becoming disengaged from the coil end turn and moving toward the center of the stator core. Additionally, a wire guide finger is provided which is movable toward and away from the stator core for enabling the lead wire to be inserted between closely spaced terminal members.

Abstract: Connection of stator coil lead wires to terminals with channels is accomplished using an industrial robot and tooling for guiding the lead wires into the terminal channels and for protecting the terminals from being snagged by the wire or being bent by the pulling of the wire by the robot. During an early stage of movement of the robot to effect connection of a lead wire to a terminal, the tooling is partly retracted to expose part of the terminal in order to simplify the movements of the robot. The lead wires are cut and crimped by tabs on the terminals using the end effector of the robot.

Abstract: Connection of stator coil lead wires to terminals with channels is accomplished using an industrial robot and tooling for guiding the lead wires into the terminal channels and for protecting the terminals from being snagged by the wire or being bent by the pulling of the wire by the robot. During an early stage of movement of the robot to effect connection of a lead wire to a terminal, the tooling is partly retracted to expose part of the terminal in order to simplify the movements of the robot. The lead wires are cut and crimped by tabs on the terminals using the end effector of the robot.