Abstract: Winding machine and method for shielding the winding machine relative to debris during a winding operation are provided. The method allows providing at least one winding assembly. The method further allows feeding a respective strand of wire to the winding assembly, wherein the strand of wire is fed into the assembly through the bottom thereof. A shield is provided for the winding assembly. The shield is configured to include a window at the bottom thereof for allowing passage of the strand of wire. The shield further includes lateral and top sections configured to partially enclose the assembly, wherein the lateral section extends sufficiently beneath the assembly so that any debris therein egresses from the assembly through the window and is prevented from being propelled into any adjacent assemblies, thus reducing the occurrence of debris-induced faults.

Abstract: Method and winding apparatus for winding a coil that may be used in a high voltage coil assembly. The method allows providing a bobbin. The bobbin may include at one end thereof a start wedge having a wedge angle relative to the longitudinal axis of the bobbin. Relative alignment is provided between the bobbin and a wire feeder device so that a strand of wire from the wire-feeder device is fed perpendicular relative to a layer of winding that, upon rotation of the bobbin, progressively propagates along the longitudinal axis of the bobbin with a predefined winding angle.

Abstract: Method and winding apparatus for winding a coil that may be used in a high voltage coil assembly. The method allows providing a bobbin. The bobbin may include at one end thereof a start wedge having a wedge angle relative to the longitudinal axis of the bobbin. Relative alignment is provided between the bobbin and a wire feeder device so that a strand of wire from the wire-feeder device is fed perpendicular relative to a layer of winding that, upon rotation of the bobbin, progressively propagates along the longitudinal axis of the bobbin with a predefined winding angle.

Abstract: Winding machine and method for shielding the winding machine relative to debris during a winding operation are provided. The method allows providing at least one winding assembly. The method further allows feeding a respective strand of wire to the winding assembly, wherein the strand of wire is fed into the assembly through the bottom thereof. A shield is provided for the winding assembly. The shield is configured to include a window at the bottom thereof for allowing passage of the strand of wire. The shield further includes lateral and top sections configured to partially enclose the assembly, wherein the lateral section extends sufficiently beneath the assembly so that any debris therein egresses from the assembly through the window and is prevented from being propelled into any adjacent assemblies, thus reducing the occurrence of debris-induced faults.

Abstract: A coil winding system includes a scale configured to determine a weight of new spool of wire destined for inclusion in the system. The scale is electrically coupled to a controller portion of the system to automatically provide the determined weight. The controller is configured to automatically receive the weight information and associate it with a particular spindle. The controller calculates the maximum number of complete winding cycles possible, based on the weight, and stops winding after such maximum number has been completed.