Abstract: A stator assembly includes a strip stator core, a three-phase coil winding, and an end insulator. The strip stator core includes twelve stator core units, twelve connection parts, and twelve slots; every two adjacent stator core units are connected by one of the twelve connection parts; each slot is disposed between every two adjacent stator core units, and each stator core unit includes a yoke and a tooth protruding from one end of the yoke; every two adjacent teeth are abutted against each other to form one of the twelve slots. The three-phase coil winding includes a U-phase winding, a V-phase winding, and a W-phase winding. The end insulator includes a first end insulator and a second end insulator; the first end insulator includes a first coil-in pin, a second coil-in pin, a third coil-in pin, and a coil-out pin.

Abstract: An annular conductor retaining device has a retention guide portion formed by blades arranged in a cylindrical shape with gaps therebetween. An annular conductor is inserted into two of the gaps across a plurality of the blades. The next annular conductor is inserted into the gaps to partially overlap the previously arranged annular conductor. This step is repeated so that the annular conductors are arranged in a spiral shape in the retention guide portion. The retention guide portion and the inner circumferential part of the core are fitted to each other, and the gaps and the slots of the core are made to coincide with each other. A pusher is inserted into the inner circumferential part of the retention guide portion so that the annular conductors are caught on the pusher, to move them in the axial direction into the slots of the core, and thus become the coils.

Abstract: According to some aspects of the present disclosure, example stator assemblies for three phase dynamoelectric machines and related winding methods are disclosed. An example stator assembly generally includes a non-segmented stator core including a stator yoke and a plurality of teeth. The stator assembly also includes a plurality of coil portions electrically coupled in a delta winding pattern, with each coil portion extending around a different one of the plurality of teeth. The stator assembly further includes a plurality of connection portions each extending between two adjacent ones of the plurality of coil portions. A first set of consecutive ones of the plurality of coil portions is defined by a first continuous length of winding wire having two wire ends. Second and third sets of consecutive ones of the plurality of coil portions are each defined by respective continuous lengths of winding wire each having two ends.

Abstract: A coil shaping device includes a plurality of rollers having an outer circumference formed with a concave groove having an arc-shaped cross section, a roller moving mechanism making the rollers move between a gripping position, at the gripping position the plurality of rollers grips the coil from surroundings of the coil, and a separating position, at the separating position the plurality of rollers is separated from the coil, and a rolling movement mechanism making the plurality of rollers positioned in the gripping position move, by the plurality of rollers being rolled in a longitudinal direction of the coil.

Abstract: A winding method for producing, for example, electric coils, wherein strand-shaped winding material (8) fed by means of a feeding device (7) is wound onto a carrier body having a non-circular cross-section by means of moving the winding material (8) and the carrier body relative to each other. Prior to placing the winding material (8) onto the surface to be wound, a force is applied onto the material transversely to the longitudinal extension thereof such that the strand-shaped winding material conform to the shape of the surface of the carrier body having a non-circular cross-section.

Abstract: A method and device for winding a rotor or a stator (2), of a rotary electrical machine, having a series of teeth (21) which are delimited by notches (22). In each notch there are inserted M continuous electric wires (3) constituting a turn; M being equal to 1 or more, characterised in that n×M wires (3) are wound simultaneously in a number n of notches (22), n corresponding to the number of phases and being ?2. The assembly of the M wires (3) constituting a phase, being inserted in a single notch (22). The device for winding has at least two carriages (4, 5), with a series of teeth, delimited by n notches (40, 50). And, likewise corresponding to the winding, each set of M continuous electric wires (3) constituting a turn, is characterised in that M×n wires (3) are inserted simultaneously in the extension of the n notches (22) of the rotary electrical machine in the n notches (40, 50) in the respective carriages (4, 5).

Abstract: A method of manufacturing a stator includes a first winding step of, with annular conductors of a first coil portion being placed in a coil holding unit, inserting the annular conductors into the respective slots by a coil pushing-out unit; and a second winding step of, after the first coil winding step, with annular conductors of a second coil portion placed in the coil holding unit, moving a positioning unit in an axial direction at least from one end of the stator core to the other end of the stator core in the axial direction, and inserting the annular conductors into the respective slots by the coil pushing-out unit while a part of the first coil portion, which is located in the slots, is pressed in a direction from the opening of the slot toward an inside of the slot by the radial end faces of the projecting teeth.

Abstract: There is provided a system for readily and efficiently fabricating a wound coil composed of a bobbinless coil. The system includes a coil winding device having an upper jig to which an upper plate is attached and a lower jig to which a lower plate is attached which are provided so as to be relatively displaceable and a tension device for applying predetermined tension to a wire rod fed from a wire rod supplying source. The coil winding device is provided with a claw section having first through third split claws that function as a winding section around which the wire rod is wound between the upper and lower plates and that slide in a radial direction when the upper jig is assembled coaxially with the lower jig.

Abstract: The multiple winding apparatus for coil includes a winding core, a spindle shaft on a tip end of which the winding core is removably mounted and which rotates together with the winding core, a wire rod feeding flyer which feeds a wire rod while rotating around the winding core mounted on the spindle shaft, a winding core removal mechanism which removes the winding core from the spindle shaft by moving the winding core in an axial direction, a supporting member which faces the spindle shaft and supports a plurality of the winding cores removed by the winding core removal mechanism at desired intervals in the axial direction, and a support member moving mechanism which moves the supporting member supporting the winding cores from a position facing the spindle shaft in a direction away from the spindle shaft.

Abstract: An in-slot winding machine for winding a winding of a stator includes a winding head including at least one movable needle which is positionable between a retracted position and an extended position, the retracted position being oriented generally axially relative to a longitudinal axis of the winding head, the extended position being oriented generally radially relative to the longitudinal axis.

Abstract: A weaving machine for an rotary electric machine coil assembly is disclosed including a rotating and driving section having timing belts causing rotary pulleys to rotate about their axes under the same attitudes while causing the rotary pulleys to rotate about an axis of a stationary pulley, movable members placed on the rotary pulleys to be movable in X- and Y-directions, coil feed magazines inclined such that coil wire segments have one ends slidably supported on the movable members and axes of the coil wire segments cross on a rotating axis of the rotary table, an orbit specifying member for specifying an orbit, in which the coil feed magazines are caused to rotate, in a rectangular shape, a rotating and driving member for permitting the coil feed magazines to perform synchronized rotating movements, and a coil transfer device operative to grip the coil wire segment for transfer.

Abstract: An apparatus and a method for winding wire coils (W) in cores (10) of dynamo electric machine using needles (15) that are relatively movable with respect to the cores (10). Wire guides (17) are provided that are also relatively movable with respect to the needle (15) and the core (10) so that the wire (W) leaving the needle (15) can be delivered to predetermined positions around the poles (14) of the core (10) to wind the wire coils. The wire guides (17) are supported adjacent to the ends of the core (10) by support means which have portions occupying positions of the needle (15) trajectory during winding. The portion of the support means (21, 22) are movable as a function of the position occupied by the needle (15) around the poles (14) so that the needle (15) can move without being obstructed. The arrangement enhances accuracy of guiding and positioning of the wire to form the wire coils and is suitable for compactly sized cores.

Abstract: A coil forming and insertion apparatus includes plural coil winding frames, a winding jig for forming a multipole coil, plural coil receiving portions, and an inserter jig for inserting and arranging the multipole coil in slots of a stator core. The coil forming and insertion apparatus has each coil receiving portion opposed to a coil winding frame, the multipole coil is formed by connecting the monopole coils wound on the coil winding frames and the multipole coil is transferred from the winding jig to the inserter jig.

Abstract: An apparatus is provided for forming field coils on a stator stack including a plurality of slots defined by stator teeth. The apparatus includes a stator nest for holding a stator stack and a winding tool extending through the stator nest for locating wire in the stator stack. The winding tool includes a wire feed aperture for feeding wire into slots of the stator stack. A drifting tool is supported on the winding tool and includes radially extending drift blades for extending into the slots of the stator stack for forming or shaping wire coils that are wound on the stator teeth by the winding tool. Longitudinal movement of the winding tool causes the drifting tool to move into and out of engagement with the stator stack.

Abstract: Apparatus and methods for winding wire coils on a plurality of poles to be assembled to form a dynamo-electric machine component are provided. A plurality of holding members that each hold a respective pole while the wire coils are wound may be provided. Each holding member may be configured to rotate its respective pole about a central axis of the holding member. A plurality of wire dispensing members may be provided that each dispense wire onto a respective pole as each pole rotates about the central axis of its respective holding member. A support structure configured to support the plurality of wire dispensing members may be provided. The wire may be stratified on each pole by the simultaneous radial movement of the plurality of wire dispensers with respect to a central axis of the support structure.

Abstract: The invention relates to winding wire around a magnetic core. The invention includes forming corners on the wire that align with inside corners of the magnetic core such that the wire is more tightly wound around the magnetic core. The invention also includes pinching a portion of wire that is positioned on the internal diameter of a magnetic core when the wire is wound around the core to provide more turns of the wire around the magnetic core. A magnetic inductor made in accordance with the present invention can have increased inductance, lower temperature rise, smaller size, and exhibit less EMI noise than the prior art.

Abstract: A winder for winding wire onto coil supports of dynamo-electric cores with translational, rotational, and stratification motions with respect to a central longitudinal axis of the dynamo-electric core is provided. The rotational motion may preferably be provided by the rocking motion of a gear sector. The stratification motion may preferably be provided by the implementation of a spiral groove. The spiral groove preferably shares the same longitudinal axis as the winder. The rotation of the spiral groove preferably creates a relative motion between the groove and the needles, thereby producing the radial stratification motion of the needles. Additionally, the winder includes a motor arrangement which is programmable and controllable. The motor arrangement may also provide a dampening effect to limit unwanted stratification motion.

Abstract: The present invention concerns solutions for disposing the wire leads of a wire coil along trajectories that have predetermined positional references relative to the dynamo-electric machine component. The present invention proposes to provide a wire lead manipulator that operates to dispose the wire lead by entering within extremely narrow gaps on a dynamo-electric machine component at high speed and with a lower risk of the wire lead manipulator colliding with the accessory parts of the component. Using the solutions of this invention, these achievements are possible for dynamo-electric machine components with very small spaces between accessory components that do not allow the passage of conventional wire lead manipulator apparatus.

Abstract: An improved needle solution is provided for winding wire coils onto dynamo-electric machine components such as electric motor stators and armatures. The improved needle solution decreases the opportunity for collision between the needle apparatus and the machine component onto which wire coils are being wound and enables the winding of machine components with small interior hollows that may not allow conventional needle solutions to pass through. The improved needle solution further provides increased accuracy in wire coil stratification by stabilizing the stratification motion of the apparatus using guide structures that engage the needle arm. The needle solution further provides open access to the wire being fed through the apparatus for winding onto the machine component. Multiple needles may be accommodated by the apparatus to simultaneously wind multiple wire coils onto a machine component using the improved needle solution.

Abstract: A winder for winding wire onto coil supports of dynamo-electric cores with translational, rotational, and stratification motions with respect to a central longitudinal axis of the dynamo-electric core is provided. The rotational motion may preferably be provided by the rocking motion of a gear sector. The stratification motion may preferably be provided by the implementation of a spiral groove. The spiral groove preferably shares the same longitudinal axis as the winder. The rotation of the spiral groove preferably creates a relative motion between the groove and the needles, thereby producing the radial stratification motion of the needles. Additionally, the winder includes a motor arrangement which is programmable and controllable. The motor arrangement may also provide a dampening effect to limit unwanted stratification motion.

Abstract: A winding device winds a wire (90) onto a core (8) having a plurality of teeth (8b) protruding from a yoke and having slots (8a) formed between each tooth (8b). The winding device winds the wire (90) by causing a nozzle (3) which lets out the wire (90) to perform a relative motion. The winding device is provided with pusher plates (72) which guide the wire (90) into the slots (8a), and inserts the wire (90) into the slots (8a) by causing the pusher plates (72) to move relative to the core (8).

Abstract: A device (10) for winding wire around pole horns of a rotationally symmetrical multipole stator (12) of an electrical machine has a wire guide for the supply of the wire and for performing a winding movement made up of individual movements around the pole horn and a traversing movement in the longitudinal direction of the pole horn. To perform a first traversing movement in a vertical direction (z) the wire guide is actively connected to a stroke rod (60) which is axially movable in the vertical direction (z), to perform a second traversing or rotational movement in a horizontal direction an indexing device is actively connected to the stator (12) to be wound, and to perform the traversing movement in a radial direction (x) corresponding to the longitudinal direction of the pole horn to be wound, the wire guide is connected to a winding rod (32) which is movable in the radial direction (x).

Abstract: A winding tool for forming wire coils in a stator stack for a dynamoelectric machine including a base structure having a cylindrical wall and forming members for forming wire located in the stator stack during the winding operation. The winding tool includes wire apertures for feeding wire into the slots of a stator stack during a winding operation, and the forming members include forming blades for extending into the slots of the stator stack to push the wires positioned therein radially outwardly. In addition, end formers are provided at longitudinal ends of the forming blades for extending across the end faces of the stator stack to position the end turns of the wire coils radially outwardly. An actuator structure is provided for actuating the forming blades and end formers simultaneously at predetermined times throughout a winding operation to thereby form the wire coils radially outwardly and create greater slot fill densities.

Abstract: An automatic machine and method of winding of armatures having maximum coil density because the winding nozzle does not enter into the slots between the pole teeth and the wire is restrained at at least one the ends of the core portion of the armature to facilitate winding.

Abstract: This invention provides a coil winder which can shorten the time required to wind coils. The coil winder has a nozzle for feeding out a wire, a stator support base, a head for supporting the nozzle free to move radially relative to the rotation axis of the stator support base, a head support shaft which supports the head and extends axially, a head support shaft displacement mechanism for moving the head support shaft to and fro axially, a head support shaft rotating mechanism for rotating the head support shaft around the axis, a traverse shaft which passes through the head support shaft, a traverse shaft rotating mechanism for rotating the traverse shaft, and a nozzle displacement device for displacing the nozzle radially relative to the axis due to the relative rotation of the traverse shaft with respect to the head support shaft. Motors provided for the head support shaft rotating mechanism and the traverse shaft rotating mechanism are supported by a frame.

Abstract: A winding device winds a wire (90) onto a core (8) having a plurality of teeth (8b) protruding from a yoke and having slots (8a) formed between each tooth (8b). The winding device winds the wire (90) by causing a nozzle (3) which lets out the wire (90) to perform a relative motion. The winding device is provided with pusher plates (72) which guide the wire (90) into the slots (8a), and inserts the wire (90) into the slots (8a) by causing the pusher plates (72) to move relative to the core (8).

Abstract: A winder and system for winding wire onto core supports of dynamo-electric cores with translational, rotational and radial motions with respect to a central longitudinal axis of the dynamo-electric core is provided. The radial motion may preferably be provided by an independent assembly. In one embodiment of the invention, the radial motion may be provided by rotating a cam disk which is movably connected to, and causes radial motion of, a pair of rollers. The pair of rollers are mounted on support arms which are connected to a needle for dispensing the wire such that movement of the pair causes similar movement of the needle. In another embodiment of the invention, an inclined way is coupled to a slide portion of the needle. When the inclined way is moved parallel to the axis, it causes a radial motion of the slide portion.