Abstract: Methods and apparatus are disclosed for relatively positioning coils within winding coil groups for a magnetic core to facilitate insertion of the coil group into axially extending slots of the magnetic core of a stator assembly.One method that is disclosed involves intercepting the end turn portion of a first relatively large coil having a lateral position outward relative to the end turn portion of a second relatively smaller coil with yieldable means as the coils are moved toward a magnetic core for subsequent insertion of the first and second coils into respective axially extending slots of the magnetic core. The arrangement of the first coil end turns inside of the second coil reduces the interengagement pressure between the first coil and the second coil normally occurring during the insertion of the coils into their respective slots of the magnetic core.Apparatus is illustrated for inserting one or more windings into a magnetic core of a stator assembly.

Abstract: Pushers or push rods for insulator and/or insulator and winding placing apparatus are manufactured by selecting an aluminum based alloy and extruding it to establish a length of material having an extruded cross-sectional configuration approximately corresponding to any cross-sectional configuration desired for an insulator pusher. Thereafter, a final desired length of insulating pushers is established, e.g., by cutting and finish milling sections of the extrusion to a desired finished length. Thereafter, the wedge pushing or leading end of the insulator pusher is machined when it is to have a shape other than the raw extrusion shape; and a trailing portion of the pusher is also machined so that it will interfit with a pusher drive mechanism. The extruded member is then treated to remove any sharp edges, burrs, or foreign matter occlusions in the extruded stock (e.g., by passing it over a nylon textured wheel).

Abstract: One disclosed method includes positioning a stator assembly at a first station in a desired relationship to a wedge setting device and winding shaping mechanism; holding the stator assembly in the desired relative position (e.g. by clamping means); substantially simultaneously setting the wedges and shaping winding end turns along at least one end or side of the stator assembly; and then removing the stator assembly from the first station. The wedge setting device includes a number of outwardly movable wedge setting blades; and the winding shaping mechanism includes one or more winding pressing surfaces that are driven by camming elements which are actuated during movement of the blades. In specific apparatus, the camming elements take the form of cam surfaces which are carried by a plurality of the blades; and when a single driving member actuates the blades, the blades themselves power (through the cam surfaces) the winding shaping mechanism.

Abstract: Disclosed method includes positioning a stator assembly at a first station in a desired relationship to a wedge setting device and winding shaping mechanism; holding the stator assembly in the desired relative position (e.g. by clamping means); substantially simultaneously setting the wedges and shaping winding end turns along at least one end or side of the stator assembly; and then removing the stator assembly from the first station. The wedge setting device includes a number of outwardly movable wedge setting blades; and the winding shaping mechanism includes one or more winding pressing surfaces that are driven by camming elements which are actuated during movement of the blades. In specific apparatus, the camming elements take the form of cam surfaces which are carried by a plurality of the blades; and when a single driving member actuates the blades the blades themselves power (through the cam surfaces) the winding shaping mechanism.