Abstract: The invention relates to a method for producing a coil winding (70) for insertion into radially open slots (82) in a rotor or stator (80) of an electrical machine, wherein the coil winding (70) has a wire pack (60) consisting of a number of wires (32), wherein the wires (32) of the wire pack (60) run parallel to one another and are connected to one another in pairs at one end of the wire pack (60), and wherein the coil winding (70) is formed by a flat winding former which can be rotated about an axis of rotation (26). According to the method, the wire pack (60) is fixed on a winding former (26) and winding heads (42) are produced by displacing fixations of the wire pack (60). The winding shaft (26) can be rotated so that, after carrying out the method, a coil winding (70) is present in the form of a wave winding having wires (32) of the wire pack (60) preconnected in pairs at one end.

Abstract: The disclosed stator or rotor has a distributed wave winding, in which the wires are associated in pairs lying with straight segments in the same slots. Head portions of two successive straight segments of each wire of a pair protrude from opposite ends of slots. For forming two wire groups, a plurality of coil windings are simultaneously created by winding up n parallel wires with intermediate spacing onto a striplike former that is rotatable about its longitudinal axis. From each of the parallel wires one straight segment and one end turn are doubled by being bent over with the wire length of a head portion, and then head portions are formed and the wires interlaced. Finally, the two wire groups are wound onto one another and thereby intertwined with one another, and then introduced as an entire intertwined wave winding strand into the stator or rotor slots.

Abstract: The disclosed method produces a stator or rotor having a distributed wave winding, in which the wires are associated in pairs lying with straight segments in the same slots. Head portions of two successive straight segments of each wire of a pair protrude from opposite ends of slots. For forming two wire groups, a plurality of coil windings are simultaneously created by winding up n parallel wires with intermediate spacing onto a striplike former that is rotatable about its longitudinal axis. From each of the parallel wires one straight segment and one end turn are doubled by being bent over with the wire length of a head portion, and then head portions are formed and the wires interlaced. Finally, the two wire groups are wound onto one another and thereby intertwined with one another, and then introduced as an entire intertwined wave winding strand into the stator or rotor slots.

Abstract: An apparatus for producing a coil winding for stators is described, in which each coil turn rests, with one fillet (14) each, in two stator slots, and the two fillets (14) are joined by a head portion (16). A plurality of coil turns are made simultaneously by winding up n parallel wires (10) with intermediate spacing onto a rotatable former (20). To obtain small winding heads, alternatingly in a work step A, one fillet (14) and the wire length of one head portion (16) are made from each of the n parallel wires (10) on the former (20). Then in a work step B, the resultant fillets (14) together with the adjoining first end of the respective associated head portions (16), and the wire guide together with the second end of these head portions (16), are displaced relative to one another along the former (20) by n times the intermediate spacing of the wires (10).

Abstract: An apparatus for producing a coil winding for stators is described, in which each coil turn rests, with one fillet (14) each, in two stator slots, and the two fillets (14) are joined by a head portion (16). A plurality of coil turns are made simultaneously by winding up n parallel wires (10) with intermediate spacing onto a rotatable former (20). To obtain small winding heads, alternatingly in a work step A, one fillet (14) and the wire length of one head portion (16) are made from each of the n parallel wires (10) on the former (20). Then in a work step B, the resultant fillets (14) together with the adjoining first end of the respective associated head portions (16), and the wire guide together with the second end of these head portions (16), are displaced relative to one another along the former (20) by n times the intermediate spacing of the wires (10). After work steps A and B have been repeated multiple times, the fillets (14) for the last n stator slots are then also made on the former (20).

Abstract: A method for producing a pattern of coil windings in which each coil turn has one fillet each in two slots, and the two fillets are joined by a head portion. A plurality of coil turns are made simultaneously by winding n parallel wires with intermediate spacing onto a rotatable former. To obtain small winding heads, there is a repeating of: a laying work step where one fillet and the wire length of one head portion are laid on the former; and a displacing work step where the resultant fillets together with the adjoining first end of the respective associated head portions, and the wire guide together with the second end of these head portions, are displaced relative to one another along the former by n times the intermediate spacing of the wires. Next, the winding is removed from the former, and pressed flat.

Abstract: A method for producing a coil winding for stators is described, in which each coil turn rests, with one fillet (14) each, in two stator slots, and the two fillets (14) are joined by a head portion (16). A plurality of coil turns are made simultaneously by winding up n parallel wires (10) with intermediate spacing onto a rotatable former (20). To obtain small winding heads, alternatingly in a work step A, one fillet (14) and the wire length of one head portion (16) are made from each of the parallel wires (10) on the former (20). Then in a work step B, the resultant fillets (14) together with the adjoining first end of the respective associated head portions (16), and the wire guide together with the second end of these head portions (16), are displaced relative to one another along the former (20) by n times the intermediate spacing of the wires (10). After work steps A and B have been repeated multiple times, the fillets (14) for the last n stator slots are then also made on the former (20).

Abstract: The method serves to produce a stator or rotor having a distributed wave winding, in which the wires (15) are associated in pairs lying with straight segments (20) in the same slots. Head portions (22) of two successive straight segments of each wire of a pair protrude from opposite ends of slots past the end faces of the stator or rotor. For forming two wire groups (10, 12) in each case a plurality of coil windings are simultaneously created by winding up n parallel wires (15), paid out from a wire guide, with intermediate spacing onto a striplike former that is rotatable about its longitudinal axis. In this process in alternation in a work step A from each of the parallel wires (15) one straight segment (20) and one end turn doubled by being bent over, with the wire length of a head portion (22), are created.

Abstract: A method for producing a coil winding for stators is described, in which each coil turn rests, with one fillet (14) each, in two stator slots, and the two fillets (14) are joined by a head portion (16). A plurality of coil turns are made simultaneously by winding up n parallel wires (10) with intermediate spacing onto a rotatable former (20). To obtain small winding heads, alternatingly in a work step A, one fillet (14) and the wire length of one head portion (16) are made from each of the parallel wires (10) on the former (20). Then in a work step B, the resultant fillets (14) together with the adjoining first end of the respective associated head portions (16), and the wire guide together with the second end of these head portions (16), are displaced relative to one another along the former (20) by n times the intermediate spacing of the wires (10). After work steps A and B have been repeated multiple times, the fillets (14) for the last n stator slots are then also made on the former (20).

Abstract: The stator for electrical machines has stator slots that are open radially inward, at least some of which contain coils made from round wire and have side walls (10, 12) of equal length that each extend parallel to their center radial plane. To attain an especially high fill factor, the entrances (16) of the stator slots have a width, measured transversely to their center radial plane, that is slightly greater than the diameter d of the round wire (18). A further condition is that the width of the stator slots, measured between the parallel side walls (10, 12), amounts to (1+cos 30°)d, and the radially outer slot wall (14) forms angles of 60° and 120°, respectively, with each of the two side walls (10, 12).

Abstract: A method and apparatus in which wave windings, cut from a continuously formed wave winding band, are brought with a defined number of waves essentially tangentially to a rotor or stator lamination packet or a rotorlike transfer tool having radially outwardly open slots. During a rotary motion of the lamination packet or transfer tool and a substantially tangential relative motion, at a speed corresponding to the circumferential speed of the rotary motion, the straight portions of the bandlike wave windings are pressed into the slots.

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 coil placing machine having an improved operating sequence for positioning coil separating insulators in certain core slots is disclosed. The insulators are supported about a coil placing machine super structure and stripped therefrom into the respective slots by movement of the stator core into position for receiving coils from the placing machine. In the preferred apparatus a stator gage and blade aligning tool has a first portion for engaging blades of a coil placing apparatus and the second portion for axially and radially aligning a stator core with the coil placing apparatus as well as a portion intermediate the first and second portions for supporting insulators in a position to be transferred to a stator core by relative motion between the core and tool. With this arrangement, the motion normally required to position the stator core preparatory to receiving coils is also effective to locate the intermediate insulators in the stator core.

Abstract: A coil placing machine having an improved operating sequence for positioning prewound coils and coil separating insulators in certain core slots is disclosed. A portion of each insulator is supported obliquely to the core axis and then both insulators and coils are moved toward the core, coil movement is interrupted while the insulators continue to move into their ultimate position within the core and thereafter coil movement is resumed to complete the coil and insulator placing operation. In the preferred aparatus a conventional coil stripper and insulation inserting gauge and blade alignment tool are separately actuated to pass into the core so that the axial separation between the stripper and tool is at first constant and then increases and finally decreases as the coil and insulator insertion progresses.

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: 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.