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 method of inserting a terminal stud adapter section of a terminal stud into the radial bore of a rotor, involving a tool, which includes an elongated tool body having a head at one end from which a pair of pins project. The head is preferably plated with copper. The head is received in the recess of a stud adapter section with the pins engaging in apertures in the adapter section. By inserting the adapter section in the radial bore of a rotor, the adapter section can be threaded to the bore copper. Upon removal of the tool from the recess of the adapter section, an outer section of the terminal stud is received within the radial bore and an inner end thereof makes electrical connection with the adapter section.

Abstract: Insertion devices may be used to insert portions of pre-wound coils into the slots of dynamoelectric machine components. Some machine components may have poles that have pole tips that extend away from the pole in a peripheral direction. Such pole tips may obstruct access to the slots from the axial region of the bore. The coil insertion devices may have a ram that has a longitudinal axis and may be configured to insert a portion of a stretch of pre-wound coil into a bore of the machine component. The coil insertion devices may have pushing members that move in a direction having a circumferential component with respect to the axis. The pushing members may insert portions of stretches of pre-wound coils into machine component slots that are difficult to access from the axial region of the bore.

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: The present invention involves a cable clamp for securing an electrical cable within the aperture or “knock-out” of an electrical distribution panel. The cable clamp is a single piece of molded material, with a wedge-shaped head portion, having a hypotenuse side with at least one angled step, a base side with at least one angled step depending inward, a tail side substantially perpendicular to the base side, and a tail portion extending from the tail side away from the hypotenuse side for hand gripping. The clamp is inserted between a cable and an interior wall of the knock-out opening until a right angled step passes thorough the knock-out opening, thereby locking the clamp into position with the cable firmly and securely held between an obtusely angled step of the clamp and an interior wall of the knock-out opening. The number and size of the obtusely angled and right angled steps on the clamp may be varied to accommodate cables and knock-outs of various sizes.

Abstract: In a stator winding method and a stator winding structure, the ends (4a) of windings (4) are caused to become entangled with terminals (6) through a longitudinal rod member (10) and form slack portions (4aA) when the longitudinal rod member is removed, whereby the vibration resistance and impact resistance of the windings can be improved as well as the break thereof can be prevented.

Abstract: Armature start and finish wires are trimmed after connection to their associated commutator tang by use of a knife edge carried by an otherwise conventional lead guide mechanism. The lead guide mechanism moves the knife edge into position against the coil lead, and the coil lead is drawn across the knife edge by pivotal movement of a wire gripper holding the lead. The knife edge preferably comprise a blade removably secured to a portion of the lead guide mechanism, but the knife edge may alternatively be formed, by machining for example, on a part of the lead guide mechanism itself.

Abstract: Finish leads of coils wound onto stator cores without terminal boards are automatically secured before the stator is removed from the winding apparatus. Tooling is provided that is moved into position adjacent the stator at a lead tuck station to cooperate with a robot end effector to tuck the finish leads between their respective coils and the portion of the stator core adjacent thereto. Because the finish leads are so tucked, the coils do not have a tendency to despool when removed from the winding apparatus, which permits the use of an automated load/unload mechanism.

Abstract: An improved conveying system in a parallel processing production line for dynamo-electric machine components having a magnetic core, the conveying system having a main conveyor extending along all of the processing machines of the production line and a load/unload device for transferring components between the main conveyor and a selected processing machine. Components to be processed are loaded directly from the main conveyor onto the load/unload device without the use of an intermediate conveyor. The load/unload device has a base platform with an alignment area at which transfer between the load/unload device and either the main conveyor or a selected processing machine occurs. Two component holders (e.g., collets) are movably mounted on the base platform for alternate positioning at the alignment area. The load/unload device alternately positions the gripping ends of the component holders adjacent the main conveyor and a selected processing machine.

Abstract: An armature manufacturing line includes one or more manufacturing cells, each having a winder facing a fuser and a rotatable armature transfer apparatus that transfers unwound armatures to the winder and wound armature from the winder directly to the fuser. An elevator at the fuser moves wound and fused armatures from the fuser to a conveyor. Different embodiments are disclosed.

Abstract: In an armature coil conductor arraying apparatus, a cylindrical coil guide tool 25 has a plurality of inner insertion holes or grooves 23a into which inner legs of coil conductors 2 are inserted and a plurality of outer grooves 24a provided radially outwardly of the inner insertion holes in respective outer peripheries of cylindrical inner coil holder 23 and cylindrical outer coil holder 24. A cylindrical holder 26 rotatable about an axis of the coil guide tool is disposed radially outwardly of the coil guide tool, and mounts a plurality of inclined settling plates or guides 29 for guiding outer legs of the coil conductors into the outer grooves when the holder is rotated.

Abstract: A plurality of insulator-coated coils wound in slots of a magnetic core in multiple layers have end portions including at least contact portions without insulator coatings and connected to risers of a commutator, and adjacent portions next to the contact portions but out of the risers. A stepped portion is formed in at least one of the adjacent portion of an upper coil and the adjacent portion of a lower coil of the insulator-coated coils wound in multiple layers at a location where the upper coil and the lower coil face each other in crossing relation. A sufficient gap distance between the upper and lower coils is ensured at the location where the coils cross each other, and the productivity of revolving armatures is improved.

Abstract: In the winding of an armature having a slotted commutator by a flier-type armature winding machine, a finish wire is severed closely adjacent its associated commutator bar slot by clamping a segment of the finish wire to a fixed tooling piece after it is wedged into the commutator bar slot by a linearly movable clamp rod having a finger which extends into the path that the start wire takes at the beginning of the winding of the next armature. The start wire is, accordingly, looped around the finger at the beginning of the winding of the next armature. The clamp rod is thereafter moved away from the fixed tooling piece, carrying the loop of wire with it. During the latter movement, the loop of wire is stripped from the finger by a cam surface past which the finger moves. The machine is provided with quick change wire guide tooling parts and quick change tamping blades so that the machine may be rapidly retooled for maintenance or for winding armatures having different parameters.

Abstract: A wire winding machine is provided that allows the connection of electric motor armature coil leads to slot-type commutators. The machine uses rotations of a flyer and rotations of the armature to perform much of the needed movement during the lead attachment process. The system uses a guide member to guide the wire into the commutator slots during rotation of the flyer. The guide member guides wire from the flyer toward the slots during both the initial insertion of the wire and the subsequent process of forming a loop in the wire.

Abstract: Methods and apparatus are provided for connecting a lead wire extending from a coil portion wound on a pole of a stator core to one or more terminals mounted on the stator core, wherein the method includes the steps of: grasping a lead wire; disposing the lead wire adjacent at least a first terminal; partially and then fully engaging the lead wire with the terminal; repeating the steps of disposing and engaging the lead wire with later terminals, if any; and then cutting the lead wire. Apparatus is provided for performing the method steps for complex lead wire connection patterns.

Abstract: Methods and apparatus for marking and identifying a commutator hook of an electric motor are provided. A preselected commutator hook is marked by deforming the hook while the armature is in a winding machine, with a known angular position. The marked hook is identified by apparatus which determines whether or not the hook has been deformed while in the winding machine, and thereby recognizing the hook.

Abstract: Methods and apparatus for marking and identifying a commutator hook of an electric motor are povided. A preselected commutator hook is marked by deforming the hook while the armature is in a winding machine, with a known angular position. The marked hook is identified by apparatus which determines whether or not the hook has been deformed while in the winding machine, and thereby recognizing the hook.

Abstract: Methods and apparatus are provided for connecting a lead wire extending from a coil portion wound on a pole of a stator core to one or more terminals mounted on the stator core, wherein the method includes the steps of: grasping a lead wire; disposing the lead wire adjacent at least a first terminal; partially and then fully engaging the lead wire with the terminal; repeating the steps of disposing and engaging the lead wire with later terminals, if any; and then cutting the lead wire. Apparatus is provided for performing the method steps for complex lead wire connection patterns.

Abstract: An apparatus and method for preforming and final forming the winding end turns of a stator. The apparatus includes an elongated arbor whose end includes a plurality of radially moveable blades and a cam. A pair of outer diameter jaws is positioned around the end turns whereby the arbor initially can move through the end turns to preform the end turns. After the arbor is moved into position, the end turns are final formed by reducing the volume of the end turn spaces defined by the outer diameter jaws. The coils are final formed by the movement of the end turn height rings into the end turn spaces defined by the outer diameter jaws.

Abstract: A coil winding machine has a pair of gripping means respectively disposed above and under an armature held by a collet for gripping lead of wire at the beginning and end of a winding operation. Each gripping means has a gripping assembly whose gripping portion is inclined by two times as large as an inclination angle of its base portion supported by a gripping frame which is rotated reversely.

Abstract: A continuous coil material is formed on flat unit coils alternating with coupling parts corresponding to coil receivers of a commutator. The coupling parts are coupled to the coil receivers of the commutator, and the unit coils are mounted on the unit coil positioning parts arranged around the commutator, alternately with each other in a predetermined positional order. The coupling parts and the receiving parts coupled to each other are electrically connected, and the unit coils overlapped in position around the commutator are connected at contact parts thereof, thereby forming an armature for a flat motor.

Abstract: A discoidal, flat coil armature for a flat disc motor is formed by winding coils of wire on mutually spaced inner and outer ring structures. The inner ring structure surrounds a commutator body having segments with tangs. Automatic apparatus, including a rotating flier, a preform clamp and rotator, and a wire guide assembly, winds the coils and makes coil terminal connections to the commutator tangs before, during, and after the winding of the coils. The coils are tightly wound on the ring structures so that they form, along with the ring structures and the commutator body, an armature preform having a self-supporting shape. The parts of the finished preform are bonded together and to an armature shaft by a matrix of resinous material.

Abstract: A method of and an apparatus for producing an armature winding of a flat type motor is disclosed having a motor, a flyer rotated by the motor for feeding a wire for the armature winding out of a nozzle thereof, a bobbin member for winding the wire fed out from the flyer around the outer periphery thereof when the flyer is rotated around it to thereby form a unit coil, first and second moving members for moving the nozzle of the flyer to directions in parallel with and directions perpendicular to a plane formed by the rotation of the nozzle, a turn table capable of mounting a commutator of the center thereof and placing plural unit coils around the commutator, a pushing member for pushing the unit coil wound around the bobbin member to place on the turn table, a guide member for catching a portion of the wire connected between the nozzle and the unit coil placed on the turn table and guiding the catched portion of the wire near corresponding one of hooks of the commutator mounted on the turn table, a revolutio

Abstract: A method and apparatus for the production of armatures for small electric motors is provided wherein the armatures are clamped in specially designed workpiece holders and continuously processed in successive work stations. The stations may include an armature loading station, a collector pressure-fitting station, a winding station, a welding station, an electrical testing station and an armature discharge station. The transportation of the workpiece holders through the apparatus is effected by a revolving conveyor belt which moves the workpiece holders individually or in groups to the successive work stations. At each work station, the workpiece holder is raised from the conveyor belt, secured in the work station, and connected by clutch devices to corresponding actuating devices within the work station.

Abstract: To increase the slot fill of armatures wound on a flier type armature winding machine of the type having inner and outer commutator shields, the outer shield is retracted during a portion of each winding cycle for each coil to permit the rotating fliers to draw the wires nearer to the armature shaft and thus deeper into the coil receiving slots. The inner shield, which has notches for exposing a pair of commutator hooks, is rotated to position the notches outside of the paths of the wire when the outer shield is retracted. A tamper assembly is provided for engaging the coil ends immediately after they are wound. The tamper assembly includes tamper rods slidably supported by the winding forms and also includes actuators for pushing the tamper rods into engagement with the coil ends. The tamper assembly may be operated after each winding cycle or only after selected winding cycles.

Abstract: Armatures for electric machines of the direct current type conventionally include a slotted core and commutator on a common shaft. This apparatus is for winding coils in the core slots and for connecting the coil leads to the commutator. The commutator is provided with bars and risers and the risers with slots. The apparatus includes a supporting frame and a support on the frame for holding an armature in winding position. Lead-connecting mechanism is mounted on the frame adjacent to the armature support in juxtaposition to the commutator of the armature for locating two coil leads in two riser slots, respectively. The lead-connecting mechanism is further supported for limited rotational movement about the axis of the armature shaft. Coil-winding mechanism is provided on the frame for winding a coil on the core of the armature.

Abstract: A double-flier armature winding machine includes a pair of opposing non-rotating winding chucks or forms for engaging the armature core. Each winding form is supported by a bearing mounted on a rotary flier assembly which is mounted on a shaft supported for both rotary and axial movement. Each winding form supports a wire deflector finger for pivotal movement in response to axial movement of an actuator carried by the flier assembly. While the flier assembly is rotating, each actuator is movable axially relative to its corresponding flier assembly by actuation of a fluid cylinder to insure engagement of a wire lead with a predetermined tang on the armature commutator.

Abstract: A machine and method for winding coils of wire on a slotted core of an armature assembly. The machine has a holder for releasably supporting the armature core assembly in an upright position. Rotatable annular members located adjacent opposite sides of the core have holes for accommodating wires that are wound on the core. Chucks mounted on the annular members guide the wires moving from the annular members into two pairs of slots in the core. A motor connected to the annular members with a common drive structure rotates the annular members in opposite directions to wind two coils of wire on the core. A core indexing motor drivably connected to the holder operates to sequentially index the core during the winding operation.

Abstract: A flier-type armature winder winds armatures consisting of a commutator with circumferentially gapped tangs and an armature core, co-axially mounted on a common shaft. In operation, at least one flier winds coils of wire successively onto the armature core and a shield covers the commutator tangs to prevent them from being accidentally engaged by the wire. After each winding of the wire coils, a wire lead from the last wound coil is looped about a corresponding one of the commutator tangs. The wire loop is formed by first securing the wire lead to wire-engaging means located on the shield. Then the shield is moved to substantially align its wire engaging means and the secured wire lead with a first one of first and second gaps in the commutator which are disposed at opposite sides of the corresponding tang. Next, the shield is retracted from the commutator tangs to lay a trailing portion of the wire lead in the first gap.

Abstract: An armature includes a shaft which supports a slotted core and a commutator having peripherally spaced hook-like tangs. The armature is automatically wound on a flyer-type winding machine which incorporates a novel lead forming and connecting mechanism. The mechanism includes a set of finger members each adapted to hook a lead wire extending from a wire coil to a rotating flyer after the winding of the last wire turn for the coil. Each finger member is then rotated approximately 180.degree. for twisting the wire to form a twisted wire loop which is transferred from the finger member to a predetermined tang, forming an alpha-type connection of the lead wire with the tang. A movable wire gripping member is associated with the finger members to control when each lead wire loop is released from a finger member for transfer to a tang, thereby controlling the slack within each lead wire.