Abstract: The invention relates to a process for producing a stator for an electric machine, comprising the following steps in the given sequence: Providing a cylindrical stator body having several stator slots, inserting at least one first coil in the stator slots, the first coil having a first coil end on at least one face of the stator body, and inserting the first coil end in at least one molded body for electrically insulating the first coil end.

Abstract: A rotating electric machine includes a stator, a rotor, and a stator core. The stator core includes a plurality of teeth. Each of the teeth includes at least one of a through hole axially piercing the tooth and a recess extending from one end of the tooth to another end of the tooth in an axial direction.

Abstract: A rotating electric machine includes a stator, a rotor, and a stator core. The stator core includes a plurality of teeth. Each of the teeth includes at least one of a through hole axially piercing the tooth and a recess extending from one end of the tooth to another end of the tooth in an axial direction.

Abstract: A core segment sub-assembly has a first holding groove, which holds a start part of a coil wire of a three-phase winding, and a second holding groove, which holds an end part of the coil wire of the three-phase winding, at positions on an axial end surface of an annular covering part and shifted in a circumferential direction relative to a tooth covering part, on which the winding is provided. The first holding groove and the second holding groove sandwiches the tooth covering part and are separated more from each other as extending in a radially outward direction. The positions and the directions of the first holding groove and the second holding grooves are matched to the paths of the coil wire wound by a flyer type winding machine. The stator can thus be made suited to a winding process by the flyer type winding machine.

Abstract: A resolver includes a stator core (3), winding wires (12) and a resin mold (6). The resin mold (6) contains a ring portion (4), a connector (5) and a stress reduction structure (9). The ring portion (4) covers the stator core (3). The stress reduction structure is arranged at the connecting portion between the ring portion (4) and the connector (5).

Abstract: A spool including a barrel extending up from a bottom portion, a plurality of flanges extending from an outer circumferential surface of the barrel, a plurality of retaining arms extending up from an annular portion of the bottom portion, the annular portion extending radially away from the outer circumferential surface of the barrel, engagement mechanisms on at least one of the plurality of flanges and the plurality of retaining arms, wherein the engagement mechanisms cause the plurality of flanges and the plurality of retaining arms to become engaged, and a hinge on each of the plurality of retaining arms.

Abstract: Apparatus and method for winding coils (B) of conductor wire (W) around respective poles (10c) of a core (10) of a component of a electric dynamo machine, wherein a dispenser arm (11) rotates around the poles to deliver the wire (W) to form wire turns; a first wire guide (32) is positioned and moved during winding adjacent to an axial end (A) of a pole (10c) being wound; a second wire guide (36) is positioned and moved in a first slot (10a) adjacent to the pole (10c) being wound; a third wire guide (37) is positioned and moved in a second slot (10b) adjacent to the pole (10c) being wound. A termination member (80) is capable of achieving connection of the coil leads to termination structures (91) of the core (FIG. 5).

Abstract: A core segment sub-assembly has a first holding groove, which holds a start part of a coil wire of a three-phase winding, and a second holding groove, which holds an end part of the coil wire of the three-phase winding, at positions on an axial end surface of an annular covering part and shifted in a circumferential direction relative to a tooth covering part, on which the winding is provided. The first holding groove and the second holding groove sandwiches the tooth covering part and are separated more from each other as extending in a radially outward direction. The positions and the directions of the first holding groove and the second holding grooves are matched to the paths of the coil wire wound by a flyer type winding machine. The stator can thus be made suited to a winding process by the flyer type winding machine.

Abstract: A drum core for a wire-wound component having a pair of flange parts provided on both ends of an axis core around which a winding wire is wound, with tapered surfaces of roughly conical shape formed on their facing inner surfaces in such a way that the interval of the inner surfaces increases toward the outer sides of the flange parts. The flange parts have roughly a rectangular shape and the sides along which their long side faces contact the tapered surfaces have the curved shapes that convex roughly at the center. The curved shapes make the height of the corners of the flange parts from the reference surface lower than the height of the convex parts of the curved shapes from the reference surface, and the loads received by the wire during winding are reduced as a result.

Abstract: In a method for manufacturing an axial air-gap electronic motor, a plurality of core member and a plurality of dummy members are prepared, wherein each of the dummy members has a shape same as that of the core members. Then, the plurality of core members is arranged such that teeth surfaces of the core members face each other, and the dummy member is arranged between predetermined core members. Thereafter, a coil is wound from one end side toward the other end side of the core members through the dummy member continuously without cutting. A part of the coil corresponding to a transition wire set between the core members is wound on the dummy member.

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: In a resolver of a motor, a plurality of wires forming a plurality of coils arranged at a resolver stator portion are arranged at a wiring surface which is arranged at a terminal block of a connector portion and extends between an annular shape surface arranged substantially perpendicularly to a central axis at a core back of an insulator and a plurality of terminal pins, and are connected to a control unit via the terminal pins. Each of the wires of the resolver includes a slackened portion formed at a portion thereof between corresponding terminal pins and corresponding coils. The slackened portion is accommodated in a groove portion arranged at the wiring surface of the connector portion in order to minimize the possibility of damaging the wire improving reliability of the connection between the terminal pin and the coil.

Abstract: In a method for winding an electrical machine, a winding auxiliary body is placed on at least one of the end faces of a base body such as to cover at least one of the slot end openings within a circumferential bridging area. Electrical conductors of a winding system are inserted in at least one of the slots whose slot end opening is on one side of the bridging area and passed through an uncovered slot end opening. Subsequently, the electrical conductors are deflected by the winding auxiliary body and guided to a further uncovered one of the slot end openings on another side of the bridging area. After placement of an end plate having an axially projecting separating element and plugging an axial attachment cutout of the winding auxiliary body onto the separating element, the winding auxiliary body is removed, thereby producing a winding element of the winding system.

Abstract: An electrical machine includes a basic bed having a opposite axial end sides and slots, wherein the slots an the end sides have each a slot end opening. A winding system has electrical conductors which are accommodated in the slots wherein the electrical conductors extend out on one of the end sides of at least one of the slot end openings. The electrical conductors are hereby laid within a bridging region extending in a circumferential direction on the at least one end side and are inserted into at least one other one of the slot end openings. Arranged on the at least one end side in the bridging region is a first guide element for guiding the electrical conductors of a first subwinding of the windings stem. An end late is arranged on the at least one end side and has at least one axially protruding separating element with the first guide element having a base bearing a against the separating element.

Abstract: An apparatus for winding wire about a tooth of a core includes an amount of wire, a winding member configured to receive a portion of the amount of wire, and a winding device operatively coupled to the winding member. The winding device being configured to apply a number of wraps of the amount of wire to at least one of a plurality of teeth of the core. The number of wraps including a number of twists that is fewer than the number of wraps.

Abstract: A method of stitching a plurality of interconnect wires on a stator of an electromagnetic machine is disclosed. The stator includes a plurality of discrete and individually wound stator segments having end caps positioned on the segments. The end caps have wire isolation features, including hooks, shelves and ledges, for separating the interconnect wires routed on the stator to electrically interconnect the segments. The method includes routing the interconnect wires between portions of the stator such that portions of the interconnect wires overlap and separating the overlapping portions in an axial direction with the wire isolation elements.

Abstract: An axial air-gap electronic motor has a teeth surface of a stator and a magnet surface of a rotor arranged opposedly along an axis line direction of an output shaft of the rotor with a predetermined gap being provided therebetween. The stator has a plurality of core members connected in a ring form. In manufacturing the electronic motor, after the teeth surfaces of the core members are arranged so as to face to each other and a dummy member is arranged between predetermined core members, a coil is wound from one end side toward the other end side of the core members continuously without being cut, and a coil of a length corresponding to a transition wire set between the core members is wound on the dummy member.

Abstract: In some embodiments, a cable spool includes a hub having an outer surface that is retractable and expandable, and a single end plate affixed to an end of the hub. In other embodiments, an apparatus includes an assembly of cascaded, temporarily interlocked spools that can be used for simultaneous despooling or spooling of multiple cable coils.

Abstract: A polygonal coil having a substantially square shape is manufactured by winding a conductive wire in the diameter direction of the core on the core in an overlapping manner by the use of a winding jig in which a first collar portion and a second collar portion are disposed at both ends of a core so as to be opposed to each other and four rod-shaped protrusions are disposed on a surface of the first collar portion opposed to the second collar portion so as to protrude in a radial shape centered on an end of the core,. As a result, it is possible to obtain a polygonal coil with high precision.

Abstract: A rotating electric machine includes a stator core of a cylindrical shape, a rotor core coaxially rotating inside the stator core, and a plurality of coils each formed by winding magnet wires using a slot formed axially in either the stator core or the rotor core, or both: it is preferable that each of the coils be split into a plurality of coil groups, that starting sections of winding of the magnet wires in one of the coil groups be wound adjacently to ending sections of winding of the magnet wires in another of the coil groups, and that the starting sections and ending sections of winding of the magnet wires in the two coil groups be connected at respective outgoing wire ends to one another, outside the slots.

Abstract: In a method for winding an electrical machine, a winding auxiliary body is placed on at least one of the end faces of a base body such as to cover at least one of the slot end openings within a circumferential bridging area. Electrical conductors of a winding system are inserted in at least one of the slots whose slot end opening is on one side of the bridging area and passed through an uncovered slot end opening. Subsequently, the electrical conductors are deflected by the winding auxiliary body and guided to a further uncovered one of the slot end openings on another side of the bridging area. After placement of an end plate having an axially projecting separating element and plugging an axial attachment cutout of the winding auxiliary body onto the separating element, the winding auxiliary body is removed, thereby producing a winding element of the winding system.

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: A number of embodiments of rotating electrical machines and methods for winding them that provides a high space utilization and very effective winding with less likelihood of damage to the insulation of the wire of the winding during the winding process. The arrangement basically does not require the winding needle to be moved back and forth in the slot between the poles but rather employs insulating inserts that are positioned on the axial faces of the poles outside of the gaps for guiding the wire from one end to the other so as to provide the high space utilization. In one embodiment the insulating insert effectively changes the circumferential length of the coil winding that decreases in an axial direction along their length.

Abstract: A stator stack and stator jig assembly provide a consistent amount of slack in stator coil wires without increasing the complexity of coil-winding machines or adding production steps, and prevent crossing of the stator coil wires in the slack areas. A stator stack having magnetic pole teeth is mounted in a stator installation jig, and the ends of slack forming plates having grooves are made to project above the top surface of the stator stack to thrust stator coil wires upwardly. The coil-winding machine winds stator coil wires around the magnetic pole teeth, and after the stator coil wires are wound, the ends of the stator coil wires are passed through grooves in the ends of the plates to output pins. The coil-winding machine wraps the ends of the stator coil wires around the output pins. On removing the stator from the stator installation jig, the parts of the stator coil wires which where thrust upward become slack areas.

Abstract: A slack-forming mechanism for stator coils that is able to impart slack of appropriate size to the stator coil without imposing an excessively heavy burden on the coiling machine. The slack-forming mechanism includes a coiling machine attachment jig having a protruding member that passes through a clearance formed between a stator body and connector, and has a top edge positioned higher than a clearance pass-through part of a stator coil. As it is possible to form slack in the stator coil without changing the configuration of the coiling machine, deficiencies in prior art slack-forming mechanisms are overcome such as the difficulty of maintaining uniform slack amounts, and unreliability. Moreover, since design-related restrictions are few, an adequately large slack is imparted to the stator coil to adequately suppress breakage of the stator coil induced by temperature change.

Abstract: Methods and apparatus for terminating dynamoelectric machine component wire coil leads in situ in automated wire coil winding machines are provided. A shape-forming wire-termination fixture is disposed about the front face of the dynamoelectric machine component. After the wire coils have been wound, a movable wire gripper is used to grasp and manipulate the starting and ending wire leads of the wound coils one at a time. The wire leads are terminated by deforming them around the wire-termination fixture to form freestanding geometrical patterns in them. Machine component-holding pick and place devices may be used to remove components with terminated wire leads from the winding machine for further processing.

Abstract: A stator winding system and method includes a winding pallet on transport pallet arrangement, with the winding pallet holding the stator and being removed from the transport pallet for a winding operation.

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: In systems for winding wire on electrodynamic machine stators, stators may be transferred between stator conveyance apparatus, winding shroud installation and removal apparatus, wire winding apparatus, wire lead termination apparatus, or other apparatus. Some transfer devices may secure stators in housings fixed to arms that may be rotated around an axis to move stators between stations. Some transfer devices may have stator grasping devices that may be rotated and translated to move stators between stations. Wire winding shrouds may be secured to a stator to facilitate winding and released from stator after wire is wound on the stator. A device for securing shrouds to the stator may be fixed to the stator and may remain fixed to the stator during transfer between different apparatus. Some devices for securing shrouds and stators may be integrated into housings. Some housings may be fixed to transfer devices along one side of the housing.

Abstract: In systems for winding wire on electrodynamic machine stators, stators may be transferred between stator conveyance apparatus, winding shroud installation and removal apparatus, wire winding apparatus, wire lead termination apparatus, or other apparatus. Some transfer devices may secure stators in housings fixed to arms that may be rotated around an axis to move stators between stations. Some transfer devices may have stator grasping devices that may be rotated and translated to move stators between stations. Wire winding shrouds may be secured to a stator to facilitate winding and released from stator after wire is wound on the stator. A device for securing shrouds to the stator may be fixed to the stator and may remain fixed to the stator during transfer between different apparatus. Some devices for securing shrouds and stators may be integrated into housings. Some housings may be fixed to transfer devices along one side of the housing.

Abstract: In a process for insertion of wire (30) in the form of a field coil (56) between the pole horns (38, 40) and the stator wall (36) of a double-pole stator (14) of an electric motor, the stator (14) consists of two stator halves (12a, b) and the wire (30) to form the coil (56) is inserted by way of a winding arm (16) rotating about a rotation axis (y) lying perpendicular to the stator axis (x), where during the winding process, for temporary formation of an enlarged insert groove (34, 35) for the wire (30), a winding accessory (32) is laid against the outer edge of the stator (14) and the free ends of the pole horns (38, 40) are covered with a wire guide sleeve (42). The process allows the winding of stators in which the pole horns largely cover the rotor external diameter of collector motors, leading to a higher motor power.

Abstract: A wire-winding machine for forming coils (20) on individual magnetic pole teeth (11a) of a core member (13) which is produced by joining a plurality of core segments (11), each of the core segments (11) having a yoke portion (11c) and a magnetic pole tooth (11a) projectingly formed on an inside surface (11d) of the yoke portion (11c), comprises a core member positioner including a rotating roller (14), large-diameter guide rollers (21) and small-diameter guide rollers (22) which together serve to bend the core member (13) and hold it in a position where the core segments (11.3, 11.5) adjacent to the core segment (11.4) on which the coil (20) is currently wound do not project in the direction of its magnetic pole tooth (11a) beyond a boundary surface (S) of the yoke portion (11c) of the core segment (11.4) on which the coil (20) is currently wound.

Abstract: A retaining jig 11 is provided comprising a retaining part 15 which moves together with a nozzle 33 performing a cyclic motion, and holds a wire W paid out from the nozzle 33, a displacing means 13 which transports the wire W in the outer circumferential direction of a stator 1 while the wire is held, and a releasing means 15a which releases the hold on the wire W transported to a predetermined position in the outer circumferential direction by the displacing means. A core guide 21 is further disposed which guides the wire W into the stator when the wire W held by the retaining jig 11 is guided in the outer circumferential direction relative to an opening 4 in the stator 1.

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: An apparatus for forming wire coils on a stator including a winding tool movable in reciprocating and rotating movement and including wire apertures for feeding wire into slots of a stator. A drifting tool is provided adjacent an end of the winding tool and includes drifting blades extending radially outwardly for positioning within the slots of the stator. The drifting tool is movable with the winding tool during the winding operation such that the drifting tool follows the winding tool in its reciprocating movement to provide for displacement of wire in the slots and improve the slot fill during the winding operation. Wire retaining structures are provided above and below the stator to intermittently engage and retain wire located at the ends of the stator. A wire feed mechanism is also provided including a wire feed pulley and a belt cooperating with the pulley to push wire toward the winding tool.

Abstract: The present invention discloses methods and apparatus for winding wire onto the slots on armature lamination stacks. More specifically, the present invention is directed to methods and apparatus for increasing time the winding components are operating on an armature winding system. The invention includes a loading/unloading unit and a holding unit that may be operated independently under most circumstances. The independent operation enables the winders of the present invention to operate at increased duty cycles, thereby increasing throughput. Additionally, the apparatus of the present invention increases the likelihood that armatures remain properly indexed during the loading transfer process to further increase system efficiency.

Abstract: In the described device a wire (18), which is fed in by a wire guide (20), is wound on a shaping body (10) provided with recesses (16), of a rotatably driveable template (10, 12) and, in the course of the rotation of the latter, is cyclically pushed into the recesses (16) by radially movable outer shaping elements (12). Subsequently the wave-shaped wire windings are transferred into longitudinal slits of a coil receiver (34), which is positioned axially in front of the shaping body (10) and is essentially maintained fixed against relative rotation during the winding movement. In order to obtain complete wave windings over the circumference in a simple manner, it is provided that the shaping of the end of the last winding of a wave winding is finished in the allocated recess (16) by means of an additional inward movement of at least one of the shaping elements (12) in a different angle of rotation position of the template (10, 12) than during the cyclically performed shaping movement.

Abstract: In a dynamo-electric machine, a stator having a terminal board with at least one pair of slots located along its inside circumference, includes at least one pair of coil holders. Each coil holder is cantilevered from the terminal board at the ends of a pair of slots, and a wire guide is positioned on each coil holder. A wire depositing needle and the stator are placed in relative motion, which causes the guide to support the wire as it is transported along its surface. Coils of wire are created as each pair of slots is wound. The invention will typically be used to form multiple coil windings on a single stator.

Abstract: A winding form assembly for a stator winding machine includes a pair of winding forms mounted on a stator pole piece and a latch assembly for latching the winding forms to one another. Two ways to support the forms on the pole piece and two latch mechanisms are disclosed.

Abstract: In systems for winding wire on electrodynamic machine stators, stators may be transferred between stator conveyance apparatus, winding shroud installation and removal apparatus, wire winding apparatus, wire lead termination apparatus, or other apparatus. Some transfer devices may secure stators in housings fixed to arms that may be rotated around an axis to move stators between stations. Some transfer devices may have stator grasping devices that may be rotated and translated to move stators between stations. Wire winding shrouds may be secured to a stator to facilitate winding and released from stator after wire is wound on the stator. A device for securing shrouds to the stator may be fixed to the stator and may remain fixed to the stator during transfer between different apparatus. Some devices for securing shrouds and stators may be integrated into housings. Some housings may be fixed to transfer devices along one side of the housing.

Abstract: A stator winding machine has a turret plate mounted for rotation about a vertical axis with stator clamp mechanisms mounted at spaced locations around its periphery for clamping stators to the turret plate with the axes of the stators coplanar with the axis of reciprocation and oscillation of the winding shuttle used to wind coils on the stators. The turret plate is repeatedly indexed in one direction about its vertical center axis to repeatedly sequentially move each of the stator clamp mechanism to a load/unload station, an optional idle station, a winding station, a coil lead terminating station, and then back to the load/unload station. Parts of the machine are quickly replaceable and other parts are programmably adjustable to accommodate different stator configurations.

Abstract: An apparatus and method for winding dynamoelectric machine field windings including a winding tool supported for longitudinal and rotational movement relative to a stator supported by a stator nest assembly. Upper and lower wire holders are supported on the winding, tool and are slidably movable relative to the winding tool. The upper and lower wire holders are located on opposite sides of a stator to be wound and are biased by compression springs in a direction toward a respective end of the stator. As the winding tool reciprocates in a longitudinal direction, the upper and lower wire holders alternately engage the upper and lower ends of the stator to alternately clamp upper and lower end loops of field windings being formed by the apparatus.