Abstract: A method of manufacturing a motor for a power tool includes providing an armature configured to be coupled to a shaft. The armature includes a yoke and a first tooth and a second tooth that extend radially outward from the yoke to define a slot between the first tooth and the second tooth. Each of the first tooth and the second tooth include an inner end adjacent the yoke and an outer end opposite the inner end. The method further includes coupling a first wire guide member to the outer end of the first tooth, coupling a second wire guide member to the outer end of the second tooth, winding wire into the slot, after winding wire into the slot, compressing the wire radially into the slot, uncoupling the first wire guide member from the first tooth, and uncoupling the second wire guide member from the second tooth.

Abstract: A method and device for wire termination on stators (1) wherein the wire (15) is wound about poles (6) distributed by a flyer (10), guided by shrouds (16) that move radially with respect to the stator (1) overlapping the respective pole (6). Wire termination operations are provided on the wire ends (15) into the terminals (4) with the aid of the flyer (10), carried out by an apparatus equipped with a termination device (20), comprising a first deflector (21), a second deflector (22), a blade (23), and a clamp formed by a movable gripper (24) and a fixed gripper (25). The movable gripper is suitable for closing onto the fixed gripper for gripping the wire (15). The device (20) can carry out the steps of catching, moving, introducing and cutting the wire (15) with movements parallel to its own axis (27), or to the axis (7) of the stator (1).

Abstract: A tool is provided for driving a slide or wedge within a slot of an armature or field of a dynamoelectric machine. The armature or field includes a core, and the core includes one or more vent slots for facilitating ventilation of the armature or field. The tool includes a drive for applying a driving force, and a push block is connected to the drive. At least one guide rail is configured to cooperate with the push block. The drive operates on the push block to drive a slide or wedge. The at least one guide rail reduces deflection or skew of the push block during a driving operation.

Abstract: The method of making an electromagnetically excitable core of an electrical machine with a multiphase winding (13) includes preparing a core (10) having a substantially parallelepiped shape, which is provided with a plurality of parallel grooves (N1 to N36; N1 to N48) in one side in a first step. In at least one subsequent step at least three phase windings (100, 200, 300) are laid in these grooves in such a manner that only one winding overhang is outside of the core.

Abstract: A tool is disclosed for driving a slide under a wedge within a slot of an armature or field of a dynamoelectric machine. The tool comprises a frame including a pair of elongated rail members; a force application block located between the rail members; a drive connected to the frame, substantially intermediate opposite ends of the frame; a lead screw threadably engaged at one end with the force application block and connected at an opposite end to the drive such that the drive rotates the lead screw when actuated. Rotation of the lead screw causes axial movement of the force application block. The armature or field includes a core, and this core may have one or more vent slots for facilitating ventilation of the armature or field. A slot plate for locating the tool relative to the slide is present, and a portion of the slot plate extends into one or more vent slots. The slot plate establishes a reaction point for forces applied by the force application block to the stator slide.

Abstract: A coil forming apparatus includes a twisting formation unit that twist-forms a predetermined number of U-shaped conductor segments. The twisting formation unit includes a first twisting formation jig composed of a first inside ring and a first outside ring and a second twisting formation jig composed of a second inside ring and a second outside ring. Each of the first and second inside rings has the same number of circumferentially disposed holding slots as the stator slots to hold one of each pair of straight portions. Each of the first and second outside rings has the same number of circumferentially disposed holding slots as the stator slots to hold the other of each pair of straight portions of the U-shaped conductor segments. The first and second inside rings and the first and second outside rings are coaxially coupled to shift relative circumferential position between the inside rings and the outside rings by a predetermined angle to twist the turn portions of the U-shaped conductor segments.

Abstract: A technique for separating the stator leads of an electric motor during the manufacturing process. The technique comprises a system having a lead gathering assembly, a lead separator, and a drive mechanism. The lead gathering assembly is adapted to gather together a plurality of stator windings extending from a stator. The lead separator having a plurality of teeth adapted to separate a stator winding from the plurality of stator windings gathered together by the lead gathering assembly. The drive mechanism is adapted to drive the lead separator into the plurality of stator windings. The lead separator has teeth to separate each of the stator windings gathered together by the lead gathering assembly.

Abstract: A device is provided for installing at least one linear motor line in the grooves (14) of an inductor (15) which is situated underneath a cover plate (10). The device includes a vehicle (31) which can be moved on the cover plate (10), a supply (34) of line (16), a device (36, 40) for forming the meander of the line (16), a device (35) for drawing the line (16) from the supply (34) and for delivering the line (16) to the device (36) and a tool (42) for pressing the line (16) into the grooves (14). The line may be installed automatically, even if the spacing of the grooves varies in dimension, by providing for an assembly slide (46) which can be moved in relation to the vehicle (31). The slide is located at least partially under the cover plate (10) and the device (36, 40) and tool (42) are located thereon.

Abstract: An apparatus for gripping temporarily the wire in an armature winding machine. The machine is of the type comprising a gripper formed by an arm (11) having an end (13) connected to a support (14) and the other free end (12) for gripping the wire. The free end (12) moves between a first position where it is approached to a winding zone and a second position where it is withdrawn from the winding zone. The gripper (12) translates then parallel to itself and integrally to the support (14), in vertical direction. The translation is operated by rotation of a driven axis (17) according to a predetermined function movement/time, whereby at each angular position of the axis a position of the gripper (12) univocally corresponds intermediate between the first and second position.

Abstract: A method and a corresponding apparatus provide for both the automatic lacing of a toroidal coil of a stator of a dynamo-electric machine, and the knotting of the end lacing terminal of the lacing cord, by using the same needle and the same thread-guide tube. The apparatus for lacing and knotting comprises an automatic control system that, accomplished the whole lacing operation on the coil, stops the rotation movement of the stator and drives the lacing needle according to a sequence of movements in order to form a plurality of linked rings closed one on the other for obtaining a closing chain on said end lacing terminal. A particular cutting system allows not generating scrap, i.e. undesired cord portions, accelerating the production process and increasing the system reliability.

Abstract: A stator core (11) is mounted to a stationary member (22) and electric wiring on the stator side is carried out, to thereby assemble a first sub-module (20), and a rotor core (12) is mounted to a rotary member (21) and electric wiring on the rotor side is carried out, to thereby assemble a second sub-module (30). Thereafter, the first and second sub-modules are assembled together, with the stator core and the rotor core opposed to each other, whereby a separable transformer is assembled. A guide member (27), having first and second reference faces defining reference positions in diametrical and axial directions of the rotation shaft (21), respectively, is provided in the rotation shaft (21) rotatably supported by the stationary member and mounted with the rotor core. Mounting positions of the cores are determined with use of the guide member, thereby precisely setting a center position between the cores and a gap length g.

Abstract: The invention provides an apparatus for manufacturing a magnetic wound core of a toroidal transformer. The apparatus in accordance with a preferred embodiment of the invention comprises a control device for controlling the apparatus based on parameters of the core material and the wound core, a supplying device for providing the core material ribbon, a grinding device for grinding the lateral edges of the core material ribbon under the control of the control device, and a winding device for receiving and winding the core material ribbon into the wound core.

Abstract: An armature coil winder for winding coils at high density while restricting coil ends within a restricted space in an armature core assembly having a plurality of slots in an outer circumference thereof and a series of continuous coils, the coil winder including a fixed former for guiding one of the continuous coils into two of the slots, and a movable former for restricting a position of a coil end of one of the continuous coils between the two slots by moving in the fixed former along both end surfaces of the armature core assembly toward a center of the core assembly; a former slider including a flyer for winding one of the continuous coils around the fixed former; and a coil shaping mechanism including coil shaping blades for shaping one of the continuous coils in the slots relative to the armature core assembly. The use of such a winder to form coils of an armature core assembly is also described.

Abstract: A method and a corresponding apparatus provide for both the automatic lacing of a toroidal coil of a stator of a dynamo-electric machine, and the knotting of the end lacing terminal of the lacing cord, by using the same needle and the same thread-guide tube. The apparatus for lacing and knotting comprises an automatic control system that, accomplished the whole lacing operation on the coil, stops the rotation movement of the stator and drives the lacing needle according to a sequence of movements in order to form a plurality of linked rings closed one on the other for obtaining a closing chain on said end lacing terminal. A particular cutting system allows not generating scrap, i.e. undesired cord portions, accelerating the production process and increasing the system reliability.

Abstract: A cutter mounting bar (18) is attached between both left and right side walls of an outer shield (16) in an armature winding apparatus to be swingably rotatable, and it is biased in a direction in which a movable blade (21) provided integrally with a tip end portion is away from an axis X by a compression spring (19). When an inner shield (15) is rotated, a cam surface presses an adjustment screw (23) outward to swing a cutter mounting bar (18) in a direction in which the movable blade (21) approaches the axis X. In this state, when an armature (1) is rotated and a wire (7) connecting a hook wire connection portion and a gripper (30) is inserted between the movable blade (21) and a backing blade (22) to advance the outer shield (16) rightward, the backing blade (22) abuts against a groove bottom surface of the inner shield (15) and stops, and only the movable blade (21) advances rightward and severs the wire (7) at a position close to the hook wire connection portion.

Abstract: A technique for separating the stator leads of an electric motor during the manufacturing process. The technique comprises a system having a lead gathering assembly, a lead separator, and a drive mechanism. The lead gathering assembly is adapted to gather together a plurality of stator windings extending from a stator. The lead separator having a plurality of teeth adapted to separate a stator winding from the plurality of stator windings gathered together by the lead gathering assembly. The drive mechanism is adapted to drive the lead separator into the plurality of stator windings. The lead separator has teeth to separate each of the stator windings gathered together by the lead gathering assembly.

Abstract: A device is provided for installing at least one linear motor line in the grooves (14) of an inductor (15) which is situated underneath a cover plate (10). The device includes a vehicle (31) which can be moved on the cover plate (10), a supply (34) of line (16), a device (36, 40) for forming the meander of the line (16), a device (35) for drawing the line (16) from the supply (34) and for delivering the line (16) to the device (36) and a tool (42) for pressing the line (16) into the grooves (14). The line may be installed automatically, even if the spacing of the grooves varies in dimension, by providing for an assembly slide (46) which can be moved in relation to the vehicle (31). The slide is located at least partially under the cover plate (10) and the device (36, 40) and tool (42) are located thereon.

Abstract: In order to realize thinned armatures, a winder which winds coils at a high density while restricting coil ends within a restricted space is provided. An armature coil winder for winding coils in an armature core assembly having a plurality of slots in an outer circumference thereof comprising a winding former equipped with a fixed former which guides a coil into two slots and a movable former which restricts a position of a coil end between the slots by moving in the fixed former along both end surfaces of an armature core toward a center thereof, a former slider which shifts the movable former to a specified position, and coil shaping mechanism which is disposed at location other than that of the former slider and equipped with coil shaping blades functioning to shape the coil in the slots, thereby making it possible to wind coils at a high density by effectively utilizing winding spaces.

Abstract: A system of manufacturing a stator is provided. The system comprises: a pallet, which includes, a base portion, a first ring rotatably disposed within the base portion for supporting the stator, a second ring rotatably disposed in the base portion, the second ring including a plurality of clips for releasably securing a plurality of leads extending from the stator; a conveyor system for supporting the pallet and moving the pallet between a plurality of stations; and a means for sleeving at least one of the plurality of leads of the stator at one of the plurality of stations.

Abstract: A cutter mounting bar (18) is attached between both left and right side walls of an outer shield (16) in an armature winding apparatus to be swingably rotatable, and it is biased in a direction in which a movable blade (21) provided integrally with a tip end portion is away from an axis X by a compression spring (19). When an inner shield (15) is rotated, a cam surface presses an adjustment screw (23) outward to swing a cutter mounting bar (18) in a direction in which the movable blade (21) approaches the axis X. In this state, when an armature (1) is rotated and a wire (7) connecting a hook wire connection portion and a gripper (30) is inserted between the movable blade (21) and a backing blade (22) to advance the outer shield (16) rightward, the backing blade (22) abuts against a groove bottom surface of the inner shield (15) and stops, and only the movable blade (21) advances rightward and severs the wire (7) at a position close to the hook wire connection portion.

Abstract: A methodology of grouping a plurality of leads of a stator is provided. The methodology includes the steps of positioning a lead secured to a first lead securing device to a predetermined position, removing the lead from the first lead securing device, rotating a second lead securing device to a predetermined position, and securing the lead to the second lead securing device.

Abstract: A semi-automated method for forming armature coils comprising a plurality of transposed wire pairs includes joining a plurality of pairs of wires having offset segments along their lengths, insulating each of the transposed pairs of wires, assembling the plurality of the insulated transposed pairs of wires with the transpositions being staggered to create a pack, and forming the pack into an armature coil in an automated coil forming machine by bending the pack in two planes. The joining of the plurality of pairs of wires having the offset segments along their lengths is effectuated at a transposition point. Each pair of wires has a transposition at a unique point relative to others of the plurality of the pairs of wires forming the coils.