US20050051661A1 - Apparatus and method for winding stator teeth - Google Patents

Apparatus and method for winding stator teeth Download PDF

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Publication number
US20050051661A1
US20050051661A1 US10/888,564 US88856404A US2005051661A1 US 20050051661 A1 US20050051661 A1 US 20050051661A1 US 88856404 A US88856404 A US 88856404A US 2005051661 A1 US2005051661 A1 US 2005051661A1
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United States
Prior art keywords
stator
stator teeth
winding
stator tooth
tooth
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US10/888,564
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Robert Faulhammer
Mark Bechtold
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ATS Corp
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ATS Automation Tooling Systems Inc
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Priority to US10/888,564 priority Critical patent/US20050051661A1/en
Assigned to ATS AUTOMATION TOOLING SYSTEMS, INC. reassignment ATS AUTOMATION TOOLING SYSTEMS, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BECHTOLD, MARK, FAULHAMMER, ROBERT
Publication of US20050051661A1 publication Critical patent/US20050051661A1/en
Abandoned legal-status Critical Current

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    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K15/00Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/08Forming windings by laying conductors into or around core parts
    • H02K15/095Forming windings by laying conductors into or around core parts by laying conductors around salient poles

Definitions

  • the present invention relates generally to electric machinery and in particular to an apparatus and method for winding stator teeth.
  • Stators of such electric machinery typically include a series of connected electrical wire coils formed on stator teeth mounted around the internal periphery of a ring.
  • the electrical wire coils are wound in alternating orientations on the stator teeth, creating a set of alternating magnetic fields about the internal periphery of the ring when energized by a current.
  • the rotor which carries magnets of alternating polarity about its circumference, is rotated within the stator to generate current in the coils as the magnets align with coils.
  • the strength of the current is dependent on the strength of the magnets, the speed at which the rotor rotates, and the number of loops in each coil.
  • stator teeth supporting the coils leads to more efficient power conversion of the stator.
  • access thereto is restricted.
  • the stator teeth are placed close to one another, little working space is provided to wind the wire around the individual stator teeth to form coils thereon.
  • a number of methods for winding wire around the stator teeth prior to their final positioning in the stator have been considered.
  • U.S. Pat. Nos. 6,121,711 and 6,323,571 to Nakahara et al. disclose a method of manufacturing a stator for magnetic disk drive units.
  • the stator includes a stator body comprising two or more segments that are hingedly connected, allowing the segments to be positioned into either a generally linear arrangement or a generally circular arrangement.
  • Each segment has one or more stator teeth on a side thereof.
  • Wire is coiled about the stator teeth when the segments are generally linearly arranged and the wire ends are connected to terminations.
  • the segments are then formed into an annulus and secured.
  • each segment has more than one stator tooth
  • the relative proximity of the stator teeth is limited by the space required to accommodate the winding mechanism used to wind the wire around each stator tooth.
  • each segment only has one stator tooth, while the winding of wire around each stator tooth is facilitated by swinging adjacent segments away from the segment having the stator tooth being wound, the increased number of hinge connections between segments increases the cost and complexity of the stator.
  • U.S. Published Patent Application No. 2002/0011755 to Shteynberg et al. discloses a method of winding stator teeth that are stacked side-by-side to form a column, with a spacer placed between each adjacent pair of stator teeth, leaving exposed the peripheral edges of the stator teeth about which wire is wound.
  • the column of stator teeth is clamped on opposing ends and mounted onto a rotating platform adjacent a wire dispenser.
  • the wire dispenser winds wire around each stator tooth, one after another, until all of the stator teeth have coils formed thereon.
  • Posts are then inserted into preformed bores around the perimeter of the spacers around which the wire dispenser routes the span of wire.
  • the posts are positioned such that the length of the span of wire extending between two adjacent stator teeth is controlled to some extent.
  • opposing stator teeth surfaces are equipped with mating features to allow the column of stator teeth to be securely clamped at its two opposing ends without spacers.
  • a first set of stator teeth is mounted on a first ring with spaces between the stator teeth equal to the width of a stator tooth. Coils are wound on the stator teeth mounted on the first ring in a first orientation (that is, either clockwise or counter-clockwise).
  • a second set of stator teeth is mounted on a second ring that is complementary to the first ring, with spaces between the stator teeth equal to the width of a stator tooth. Coils are then wound on the stator teeth mounted on the second ring in an orientation opposite to the first orientation. The rings are then coupled, interleaving the stator teeth to form a stator having adjacent stator teeth carrying coils wound in opposite orientations.
  • Shteynberg et al. stator teeth winding methods address some of the problems associated with conventional stator teeth winding methods, a number of problems still exist with the Shteynberg et al. stator teeth winding methods. For example, forming the column of stator teeth and spacers prior to winding is time-consuming and complicated. Further, the method for controlling the span of wire between the stator teeth is complicated and produces a set number of discrete span lengths, thus limiting the number of stator configurations that can be produced.
  • stator teeth winding methodology that overcomes the above disadvantages is desired. It is therefore an object of the present invention to provide a novel apparatus and method for winding stator teeth.
  • an apparatus for winding stator teeth comprising:
  • the stator teeth holder is rotatable to present each stator tooth to the fly winder.
  • the stator tooth retainers are circumferentially spaced about the stator teeth holder and are vertically offset with respect to one another.
  • the stator teeth holder is also vertically adjustable to present each stator tooth to the fly winder.
  • the fly winder winds each stator tooth in a manner so that the coils on the stator teeth have opposite orientations.
  • Each stator tooth retainer includes a channel shaped to accommodate a stator tooth.
  • the channel is defined by a clamp assembly accommodated by the stator teeth holder.
  • the clamp assembly includes a pair of side clamps for engaging opposite sides of a stator tooth.
  • the clamp assembly may further include a biasing member actuable between engaged and disengaged states. In the engaged state, the biasing member biases the stator tooth into engagement with the side clamps.
  • the channel may be sized to form a friction fit with the stator tooth.
  • the stator teeth holder may include a main body including a pair of cutouts formed therein with each of the cutouts accommodating a respective clamp assembly.
  • the main body presents a generally arcuate outer surface bridging the cutouts.
  • an apparatus for winding stator teeth comprising:
  • the present invention provides advantages in that since the length of the span of wire between two stator teeth is controlled during winding, the stator teeth can be positioned in a stator side-by-side with substantially no excess wire extending therebetween. Also, by vertically offsetting the stator teeth relative to one another during winding, the stator teeth can be positioned further apart, thus facilitating winding, and allowing the length of wire extending between the stator teeth to be more easily controlled. Further, the present invention allows for stator teeth to be wound in alternating orientations while retaining control over the span of wire extending between pairs of stator teeth.
  • FIG. 1 is a side elevation view of an apparatus for winding stator teeth in accordance with the present invention
  • FIG. 2 is a perspective view of a portion of the apparatus of FIG. 1 ;
  • FIG. 3 is a perspective view of a sub assembly forming part of a stator teeth holding tool
  • FIG. 4 is a perspective view of a turret forming part of the stator teeth holding tool
  • FIG. 5 is a top plan view of the turret
  • FIG. 6 shows two stator teeth in their relative positions when mounted on the turret
  • FIG. 7 shows the two stator teeth of FIG. 6 when removed from the turret and positioned side-by-side.
  • Apparatus 10 includes a plurality of fly winders 12 and a stator teeth holding tool 14 .
  • fly winders 12 For ease of illustration only one fly winder 12 is shown. Also, since fly winders are well known in the art, for ease of illustration, some of the components of the fly winder have been omitted from the figures.
  • Each fly winder 12 includes a flyer head 24 having a flyer arm 28 and a counterweight 32 joined by a central body section 34 .
  • a nozzle 36 is positioned at the distal end of the flyer arm 28 and is operable to dispense wire to be wound around stator teeth when flyer head 24 is rotated about a central horizontal axis.
  • a pair of redirector pulleys 40 and 44 allow wire to be routed to nozzle 36 .
  • Pulley 40 is positioned within a channel 46 provided in the flyer arm 28 , adjacent the nozzle 36 , and pulley 44 is positioned on the central body section 34 .
  • Flyer head 24 is mounted on a rotating hollow shaft (not shown), providing flyer head 24 with rotational movement in both directions about an axis coaxial with opening 48 in the central body section 34 . Further, the fly winder 12 is operable to move flyer head 24 along the two axes of a horizontal plane. Wire to be dispensed by the fly winder 12 passes over redirector pulley 44 , through channel 46 in the flyer arm 28 , over redirector pulley 40 and through nozzle 36 .
  • stator teeth holding tool 14 presents stator teeth to the fly winders 12 to enable the fly winders 12 to wind coils thereon.
  • stator teeth holding tool 14 includes a sub assembly 50 supporting a plurality of posts 52 .
  • Sub assembly 50 includes a pair of motors 54 and a motor 56 .
  • Each motor 54 is associated with a pair of posts 52 and is coupled to the pair of posts by a transmission. In this manner, each motor 54 is operable to rotate each post 52 in its associated pair about the central longitudinal axis of each post 52 .
  • Motor 56 is operable to raise and lower the posts 52 .
  • a fixturing detail 60 is disposed on the top of each post 52 .
  • a turret 62 is slidably received by and rests on each post 52 . Only one turret 62 is shown in the figures for ease of illustration.
  • turret 62 includes a pair of pegs 64 around which wire is turned in preparation for termination.
  • a stationary tie-off post 66 is positioned on the sub assembly 50 adjacent each post 52 .
  • Each turret 62 is associated with one of the fly winders 12 . In conjunction with the two degrees of movement of turret 62 by virtue of the movement of the posts 52 , flyer head 24 of its associated fly winder 12 has five degrees of movement relative to the turret 62 .
  • FIGS. 4 and 5 better illustrate one of the turrets 62 .
  • the turret 62 includes a main body 70 that is generally cylindrical in shape when viewed in top plan.
  • a pair of clamp assemblies 72 are accommodated by cutouts 74 provided in the main body 70 to receive and retain a pair of stator teeth 100 a and 100 b to be wound.
  • the cutouts 74 are positioned 90 degrees apart relative to the outer peripheral surface 76 of the turret 62 and are vertically offset.
  • the outer peripheral surface 76 of the turret 62 bridging the cutouts 74 is arcuate.
  • Each clamp assembly 72 includes a back plate 80 and a pair of side clamps 82 that define a dove-tailed channel 84 accessible from the top and bottom.
  • the side clamps 82 are designed to engage a stator tooth 100 to be wound that is inserted into the dove-tailed channel 84 .
  • the back plate 80 accommodates a cam-shaped member (not shown).
  • the cam-shaped member is actuable between an engaged state wherein the stator tooth 100 is engaged by the side clamps 82 and retained by the clamp assembly 72 and a disengaged state wherein the stator tooth is moveable along the dove-tailed channel 84 .
  • the cam-shaped member projects outwardly from the back plate 80 to contact and bias the stator tooth 100 into engagement with the side clamps 82 thereby to retain the stator tooth.
  • the main body 70 of the turret only includes structure to engage stator teeth at the desired positions thereby to reduce the weight of the turret. By reducing the weight of turret 62 , less stress is placed on automation machinery that is used to mount and dismount turrets 62 on the posts 52 .
  • Each stator tooth 100 includes an outer arc plate 102 , an inner arc plate 104 and a winding core 106 between the plates 102 and 104 about which wire is to be wound.
  • the outer arc plate 102 is shaped generally complimentary to the dove-tailed channel 84 to facilitate insertion of the outer arc plate therein.
  • stator teeth 100 a and 100 b that have not yet been wound with coils are loaded onto each turret 62 by sliding them into the dove-tailed channels 84 of the clamp assemblies 72 before each turret 62 is secured to a respective post 52 .
  • the cam-shaped members within back plates 80 are then actuated to engage and bias stator teeth 100 a and 100 b firmly against side clamps 72 .
  • the turrets 62 are then mounted onto the fixturing details 60 disposed on the posts 52 and preferably locked in place to avoid vertical movement of the turrets 62 during winding.
  • one stator tooth 100 a is positioned towards a lower end of the turret 62
  • the other stator tooth 100 b is positioned towards an upper end of the turret 62 , and spaced 90 degrees about the circumference of the turret 62 .
  • the stator teeth 100 a and 100 b are mounted on perpendicular surfaces of each turret 62 , a wire spanning the two stator teeth must undergo a 90 degree change of direction.
  • the arcuate outer peripheral surface 76 of the main body 70 spanning the cutouts allows a span of wire to be gradually routed from the top of one of stator tooth to the bottom of the other stator tooth, thus avoiding unnecessary sharp bends in the wire, which can damage the wire enamel and cause downstream rejects in the electric machinery in which the stator teeth 100 a and 100 b are utilized.
  • Each post 52 and associated turret 62 are then lowered to present one of the pegs 64 to the flyer head 24 of its associated fly winder 12 .
  • a wire extending from stationary tie-off post 66 to the nozzle 36 of the flyer head 24 is turned around the presented peg 64 by moving the flyer head 24 along the two horizontal axes of movement.
  • the wire protruding from the nozzle 36 which was terminated to the stationary tie-off post 66 or clamped at the end of the last wind cycle, is thus wound around peg 64 under tension.
  • the post 52 and turret 62 is rotated and raised to present a first stator tooth 100 a to the flyer head 24 for winding.
  • stator tooth 100 a it is preferable to position stator tooth 100 a in the axis of rotation of the flyer head 24 so that the wire is distributed evenly about stator tooth and is generally evenly tensioned thereabout.
  • Flyer head 24 is then positioned in front of stator tooth 100 a and a pre-set number of loops of wire are coiled around stator tooth in a counter-clockwise direction, with the flyer 24 head moving incrementally further from turret 62 with each loop of wire thereby to evenly distribute the wire about winding core 106 .
  • flyer head 24 moves slowly toward turret 62 all while flyer head 24 continues to rotate about the stator tooth 100 a to wind a second set of loops of wire about winding core 106 .
  • flyer head 24 is operated in a clockwise direction to wind a first set of loops of wire around stator tooth 100 b , all while flyer head 24 moves incrementally away from turret 62 with each loop.
  • flyer head 24 begins to move slowly toward turret 62 to distribute a second set of loops of wire evenly around winding core 106 .
  • flyer head 24 Upon completion of the second set of loops, turret 62 is lowered and flyer head 24 is moved through the two horizontal axes to form a set of turns about a second of the pegs 64 . Upon completion of the set of turns, flyer head 24 moves to wind a set of loops of wire around the stationary tie-off post 66 . The wire is then cut between the pegs 64 and the stationary tie-off post 66 .
  • turret 62 having two wound stator teeth is removed from post 52 by unsecuring it and lifting it, making room for another turret 62 bearing a set of stator teeth to be wound.
  • Completed stator teeth are then removed from turret 62 by actuating the cam-shaped members to allow the completed stator teeth to slide out of the dove-tailed channels 84 .
  • FIG. 6 shows a pair of stator teeth 100 a and 100 b having coils 108 formed thereon and joined by the span of wire 110 .
  • a terminating wire end 112 extends from each stator tooth for connection in a stator.
  • Arrows 114 depict the direction in which stator teeth are moved to arrive at their final relative position side-by-side, as shown in FIG. 7 , wherein span of wire 110 is taut and includes substantially no excess length.
  • adjacent stator teeth have coils of opposite orientation; that is, one is wound clockwise and another is wound counter-clockwise.
  • stator teeth supports While the present invention has been described with specificity to mounting stator teeth onto a turret that presents the stator teeth to the fly winder for winding, other types of stator teeth supports will occur to those of ordinary skill in the art.
  • a plate having a number of positions for securing stator teeth in a similar fashion as employed in the described embodiment can be used.
  • the plate can be raised and lowered relative to the fly winder just as the turret, and can be moved relative to the fly winder along a longitudinal axis to present a different stator tooth to the flyer head, simulating the rotation of the turret.
  • the positions of the stator teeth on the turret can be made adjustable to allow different dimensioned stator teeth to be coiled using the same turret. Further, the turret can be made expandable, through additional concentric surface layers on its periphery, through the placement of each stator tooth on a separate arcuate plate whose distance from the center of the turret can be adjustable, or through some other means.
  • stator teeth are shown as being positioned ninety degrees apart about the circumference of the turret, it is to be appreciated that the stator teeth can be positioned in other configurations.
  • the stator teeth can be placed along the circumference of the turret at varying degrees, depending on the circumference of the turret, the relative vertical separation of the stator teeth positions along the vertical length of the turret, and any variation in the radial distance of the stator teeth positions along the surface of the turret.
  • the turrets can be equipped with clamps in place of pegs to engage the wire ends during the start and end of the winding process.
  • This method of termination is well-suited to work with both a wire which has been previously terminated on a stationary tie-off post, and one which is loosely hanging out of the flyer nozzle, and is especially beneficial for use with heavier gauge wires.
  • clamp assemblies are described as including cam-shaped members to bias the stator teeth into engagement with the side clamps, other means of securing the stator teeth to the turrets during the winding process can be used.
  • the stator teeth can be frictionally fit into the dove-tailed channels.
  • the apparatus is described as including a fly winder associated with each turret, fewer fly winders that are moveable laterally between multiple turret locations can be used.

Abstract

An apparatus for winding stator teeth includes at least one fly winder for winding wire around stator teeth. At least one stator teeth holder includes stator tooth retainers at spaced locations for retaining stator teeth thereon. The at least one stator tooth holder and fly winder are moveable relative to one another to present each stator tooth to the at least one fly winder for winding a wire coil thereon. The stator tooth retainers are relatively positioned on the at least one stator teeth holder to control a span of wire extending between the stator teeth after the stator teeth have been presented to the at least one fly winder and wound.

Description

    REFERENCE TO CROSS-RELATED APPLICATIONS
  • This application claims the benefit of U.S. Provisional Patent Application No. 60/484,649 filed on Jul. 7, 2003.
  • FIELD OF THE INVENTION
  • The present invention relates generally to electric machinery and in particular to an apparatus and method for winding stator teeth.
  • BACKGROUND OF THE INVENTION
  • Electric machinery that includes stators accommodating rotors, such as for example electric motors and generators, is well known in the art. Stators of such electric machinery typically include a series of connected electrical wire coils formed on stator teeth mounted around the internal periphery of a ring. The electrical wire coils are wound in alternating orientations on the stator teeth, creating a set of alternating magnetic fields about the internal periphery of the ring when energized by a current.
  • In the case of electric generators, the rotor, which carries magnets of alternating polarity about its circumference, is rotated within the stator to generate current in the coils as the magnets align with coils. The strength of the current is dependent on the strength of the magnets, the speed at which the rotor rotates, and the number of loops in each coil.
  • Conversely, in the case of electric motors, an alternating current is run through the coils, creating a combination of magnetic attraction and repulsion forces that rotate the magnet-carrying rotor.
  • It has been found that close relational placement of the stator teeth supporting the coils leads to more efficient power conversion of the stator. As the stator teeth reside on the inside periphery of the ring, access thereto is restricted. Further, when the stator teeth are placed close to one another, little working space is provided to wind the wire around the individual stator teeth to form coils thereon. As a result, a number of methods for winding wire around the stator teeth prior to their final positioning in the stator have been considered.
  • For example, U.S. Pat. Nos. 6,121,711 and 6,323,571 to Nakahara et al. disclose a method of manufacturing a stator for magnetic disk drive units. The stator includes a stator body comprising two or more segments that are hingedly connected, allowing the segments to be positioned into either a generally linear arrangement or a generally circular arrangement. Each segment has one or more stator teeth on a side thereof. Wire is coiled about the stator teeth when the segments are generally linearly arranged and the wire ends are connected to terminations. The segments are then formed into an annulus and secured. Unfortunately, a number of problems exist with this stator teeth winding approach. In situations where each segment has more than one stator tooth, the relative proximity of the stator teeth is limited by the space required to accommodate the winding mechanism used to wind the wire around each stator tooth. In situations where each segment only has one stator tooth, while the winding of wire around each stator tooth is facilitated by swinging adjacent segments away from the segment having the stator tooth being wound, the increased number of hinge connections between segments increases the cost and complexity of the stator.
  • U.S. Published Patent Application No. 2002/0011755 to Shteynberg et al. discloses a method of winding stator teeth that are stacked side-by-side to form a column, with a spacer placed between each adjacent pair of stator teeth, leaving exposed the peripheral edges of the stator teeth about which wire is wound. The column of stator teeth is clamped on opposing ends and mounted onto a rotating platform adjacent a wire dispenser. As the column of stator teeth is rotated, the wire dispenser winds wire around each stator tooth, one after another, until all of the stator teeth have coils formed thereon. As the wire dispenser moves from stator tooth to stator tooth, a span of wire is extended between them. Posts are then inserted into preformed bores around the perimeter of the spacers around which the wire dispenser routes the span of wire. The posts are positioned such that the length of the span of wire extending between two adjacent stator teeth is controlled to some extent. In an alternative embodiment, opposing stator teeth surfaces are equipped with mating features to allow the column of stator teeth to be securely clamped at its two opposing ends without spacers. In a further embodiment, a first set of stator teeth is mounted on a first ring with spaces between the stator teeth equal to the width of a stator tooth. Coils are wound on the stator teeth mounted on the first ring in a first orientation (that is, either clockwise or counter-clockwise). Likewise, a second set of stator teeth is mounted on a second ring that is complementary to the first ring, with spaces between the stator teeth equal to the width of a stator tooth. Coils are then wound on the stator teeth mounted on the second ring in an orientation opposite to the first orientation. The rings are then coupled, interleaving the stator teeth to form a stator having adjacent stator teeth carrying coils wound in opposite orientations.
  • While the Shteynberg et al. stator teeth winding methods address some of the problems associated with conventional stator teeth winding methods, a number of problems still exist with the Shteynberg et al. stator teeth winding methods. For example, forming the column of stator teeth and spacers prior to winding is time-consuming and complicated. Further, the method for controlling the span of wire between the stator teeth is complicated and produces a set number of discrete span lengths, thus limiting the number of stator configurations that can be produced.
  • As will be appreciated, an improved stator teeth winding methodology that overcomes the above disadvantages is desired. It is therefore an object of the present invention to provide a novel apparatus and method for winding stator teeth.
  • SUMMARY OF THE INVENTION
  • Accordingly, in one aspect of the present invention, there is provided an apparatus for winding stator teeth, comprising:
      • at least one fly winder for winding wire around stator teeth; and
      • at least one stator teeth holder including stator tooth retainers at spaced locations for retaining stator teeth thereon, said at least one stator tooth holder and fly winder being moveable relative to one another to present each stator tooth to said at least one fly winder for winding a wire coil thereon, wherein said stator tooth retainers are relatively positioned on said at least one stator teeth holder to control a span of wire extending between said stator teeth after said stator teeth have been presented to said at least one fly winder and wound.
  • In one embodiment, the stator teeth holder is rotatable to present each stator tooth to the fly winder. The stator tooth retainers are circumferentially spaced about the stator teeth holder and are vertically offset with respect to one another. The stator teeth holder is also vertically adjustable to present each stator tooth to the fly winder. In the case where the stator teeth holder includes a pair of stator tooth retainers each for retaining a single stator tooth, the fly winder winds each stator tooth in a manner so that the coils on the stator teeth have opposite orientations.
  • Each stator tooth retainer includes a channel shaped to accommodate a stator tooth. The channel is defined by a clamp assembly accommodated by the stator teeth holder. The clamp assembly includes a pair of side clamps for engaging opposite sides of a stator tooth. The clamp assembly may further include a biasing member actuable between engaged and disengaged states. In the engaged state, the biasing member biases the stator tooth into engagement with the side clamps. Alternatively, the channel may be sized to form a friction fit with the stator tooth.
  • The stator teeth holder may include a main body including a pair of cutouts formed therein with each of the cutouts accommodating a respective clamp assembly. The main body presents a generally arcuate outer surface bridging the cutouts.
  • According to another aspect of the present invention, there is provided an apparatus for winding stator teeth, comprising:
      • a fly winder for winding wire around stator teeth; and
      • a stator teeth holder including a rotatable turret having a main body and stator tooth retainers at spaced locations on said main body for retaining stator teeth, said turret being rotatable to present each stator tooth to said fly winder for winding a wire coil thereon, wherein said stator tooth retainers are relatively positioned on said turret in a manner such that after said stator teeth have been wound by said fly winder to include coils of opposite orientation, removed from said turret and placed side-by-side, the span of wire extending between said stator teeth includes substantially no excess length.
  • According to yet another aspect of the present invention there is provided a method of winding stator teeth, comprising:
      • mounting a first stator tooth and a second stator tooth at spaced locations on a tool;
      • presenting said first stator tooth to a winding device and winding a coil having a first orientation thereon;
      • biasing said tool to present said second stator tooth to said winding device; and
      • winding a coil on said second stator tooth having an orientation opposite that of the coil wound on said first stator tooth, wherein the relative locations of said first stator tooth and said second stator tooth on said tool are such that the span of wire extending from said first stator tooth to said second stator tooth includes substantially no excess length when said first stator tooth and second stator tooth are positioned side-by-side.
  • The present invention provides advantages in that since the length of the span of wire between two stator teeth is controlled during winding, the stator teeth can be positioned in a stator side-by-side with substantially no excess wire extending therebetween. Also, by vertically offsetting the stator teeth relative to one another during winding, the stator teeth can be positioned further apart, thus facilitating winding, and allowing the length of wire extending between the stator teeth to be more easily controlled. Further, the present invention allows for stator teeth to be wound in alternating orientations while retaining control over the span of wire extending between pairs of stator teeth.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • An embodiment of the present invention will now be described, more fully with reference to the accompanying drawings in which:
  • FIG. 1 is a side elevation view of an apparatus for winding stator teeth in accordance with the present invention;
  • FIG. 2 is a perspective view of a portion of the apparatus of FIG. 1;
  • FIG. 3 is a perspective view of a sub assembly forming part of a stator teeth holding tool;
  • FIG. 4 is a perspective view of a turret forming part of the stator teeth holding tool;
  • FIG. 5 is a top plan view of the turret;
  • FIG. 6 shows two stator teeth in their relative positions when mounted on the turret; and
  • FIG. 7 shows the two stator teeth of FIG. 6 when removed from the turret and positioned side-by-side.
  • DETAILED DESCRIPTION OF THE INVENTION
  • Turning now to FIGS. 1 to 3, an apparatus for winding stator teeth in accordance with the present invention is shown and is generally identified by reference numeral 10. Apparatus 10 includes a plurality of fly winders 12 and a stator teeth holding tool 14. For ease of illustration only one fly winder 12 is shown. Also, since fly winders are well known in the art, for ease of illustration, some of the components of the fly winder have been omitted from the figures. Each fly winder 12 includes a flyer head 24 having a flyer arm 28 and a counterweight 32 joined by a central body section 34. A nozzle 36 is positioned at the distal end of the flyer arm 28 and is operable to dispense wire to be wound around stator teeth when flyer head 24 is rotated about a central horizontal axis. A pair of redirector pulleys 40 and 44 allow wire to be routed to nozzle 36. Pulley 40 is positioned within a channel 46 provided in the flyer arm 28, adjacent the nozzle 36, and pulley 44 is positioned on the central body section 34. Flyer head 24 is mounted on a rotating hollow shaft (not shown), providing flyer head 24 with rotational movement in both directions about an axis coaxial with opening 48 in the central body section 34. Further, the fly winder 12 is operable to move flyer head 24 along the two axes of a horizontal plane. Wire to be dispensed by the fly winder 12 passes over redirector pulley 44, through channel 46 in the flyer arm 28, over redirector pulley 40 and through nozzle 36.
  • The stator teeth holding tool 14 presents stator teeth to the fly winders 12 to enable the fly winders 12 to wind coils thereon. As shown in FIG. 3, stator teeth holding tool 14 includes a sub assembly 50 supporting a plurality of posts 52. Sub assembly 50 includes a pair of motors 54 and a motor 56. Each motor 54 is associated with a pair of posts 52 and is coupled to the pair of posts by a transmission. In this manner, each motor 54 is operable to rotate each post 52 in its associated pair about the central longitudinal axis of each post 52. Motor 56 is operable to raise and lower the posts 52.
  • A fixturing detail 60 is disposed on the top of each post 52. A turret 62 is slidably received by and rests on each post 52. Only one turret 62 is shown in the figures for ease of illustration. In this embodiment, turret 62 includes a pair of pegs 64 around which wire is turned in preparation for termination. A stationary tie-off post 66 is positioned on the sub assembly 50 adjacent each post 52. Each turret 62 is associated with one of the fly winders 12. In conjunction with the two degrees of movement of turret 62 by virtue of the movement of the posts 52, flyer head 24 of its associated fly winder 12 has five degrees of movement relative to the turret 62.
  • FIGS. 4 and 5 better illustrate one of the turrets 62. As can be seen, the turret 62 includes a main body 70 that is generally cylindrical in shape when viewed in top plan. A pair of clamp assemblies 72 are accommodated by cutouts 74 provided in the main body 70 to receive and retain a pair of stator teeth 100 a and 100 b to be wound. The cutouts 74 are positioned 90 degrees apart relative to the outer peripheral surface 76 of the turret 62 and are vertically offset. The outer peripheral surface 76 of the turret 62 bridging the cutouts 74 is arcuate.
  • Each clamp assembly 72 includes a back plate 80 and a pair of side clamps 82 that define a dove-tailed channel 84 accessible from the top and bottom. The side clamps 82 are designed to engage a stator tooth 100 to be wound that is inserted into the dove-tailed channel 84. In order to enable the side clamps 82 to engage the stator tooth, the back plate 80 accommodates a cam-shaped member (not shown). The cam-shaped member is actuable between an engaged state wherein the stator tooth 100 is engaged by the side clamps 82 and retained by the clamp assembly 72 and a disengaged state wherein the stator tooth is moveable along the dove-tailed channel 84. In the engaged state, the cam-shaped member projects outwardly from the back plate 80 to contact and bias the stator tooth 100 into engagement with the side clamps 82 thereby to retain the stator tooth.
  • Since the turret 62 is designed to support only two stator teeth 100, the main body 70 of the turret only includes structure to engage stator teeth at the desired positions thereby to reduce the weight of the turret. By reducing the weight of turret 62, less stress is placed on automation machinery that is used to mount and dismount turrets 62 on the posts 52.
  • Each stator tooth 100 includes an outer arc plate 102, an inner arc plate 104 and a winding core 106 between the plates 102 and 104 about which wire is to be wound. The outer arc plate 102 is shaped generally complimentary to the dove-tailed channel 84 to facilitate insertion of the outer arc plate therein.
  • During operation, two stator teeth 100 a and 100 b that have not yet been wound with coils are loaded onto each turret 62 by sliding them into the dove-tailed channels 84 of the clamp assemblies 72 before each turret 62 is secured to a respective post 52. The cam-shaped members within back plates 80 are then actuated to engage and bias stator teeth 100 a and 100 b firmly against side clamps 72. The turrets 62 are then mounted onto the fixturing details 60 disposed on the posts 52 and preferably locked in place to avoid vertical movement of the turrets 62 during winding. In this condition for each turret 62, one stator tooth 100 a is positioned towards a lower end of the turret 62, whereas the other stator tooth 100 b is positioned towards an upper end of the turret 62, and spaced 90 degrees about the circumference of the turret 62. As the stator teeth 100 a and 100 b are mounted on perpendicular surfaces of each turret 62, a wire spanning the two stator teeth must undergo a 90 degree change of direction. The arcuate outer peripheral surface 76 of the main body 70 spanning the cutouts allows a span of wire to be gradually routed from the top of one of stator tooth to the bottom of the other stator tooth, thus avoiding unnecessary sharp bends in the wire, which can damage the wire enamel and cause downstream rejects in the electric machinery in which the stator teeth 100 a and 100 b are utilized.
  • Each post 52 and associated turret 62 are then lowered to present one of the pegs 64 to the flyer head 24 of its associated fly winder 12. For each turret and fly winder pair, a wire extending from stationary tie-off post 66 to the nozzle 36 of the flyer head 24 is turned around the presented peg 64 by moving the flyer head 24 along the two horizontal axes of movement. The wire protruding from the nozzle 36, which was terminated to the stationary tie-off post 66 or clamped at the end of the last wind cycle, is thus wound around peg 64 under tension. Next, the post 52 and turret 62 is rotated and raised to present a first stator tooth 100 a to the flyer head 24 for winding. It is preferable to position stator tooth 100 a in the axis of rotation of the flyer head 24 so that the wire is distributed evenly about stator tooth and is generally evenly tensioned thereabout. Flyer head 24 is then positioned in front of stator tooth 100 a and a pre-set number of loops of wire are coiled around stator tooth in a counter-clockwise direction, with the flyer 24 head moving incrementally further from turret 62 with each loop of wire thereby to evenly distribute the wire about winding core 106. Once a first set of loops has been wound around the winding core 106, flyer head 24 moves slowly toward turret 62 all while flyer head 24 continues to rotate about the stator tooth 100 a to wind a second set of loops of wire about winding core 106.
  • Once the second set of loops is complete, turret 62 is rotated and lowered to present the second stator tooth 100 b to flyer head 24 for winding. As this is done, a span of wire 110 is extended from the top of the first stator tooth 100 a to the bottom of the second stator tooth 100 b. At this point, flyer head 24 is operated in a clockwise direction to wind a first set of loops of wire around stator tooth 100 b, all while flyer head 24 moves incrementally away from turret 62 with each loop. Once the first set of loops is complete, flyer head 24 begins to move slowly toward turret 62 to distribute a second set of loops of wire evenly around winding core 106.
  • Upon completion of the second set of loops, turret 62 is lowered and flyer head 24 is moved through the two horizontal axes to form a set of turns about a second of the pegs 64. Upon completion of the set of turns, flyer head 24 moves to wind a set of loops of wire around the stationary tie-off post 66. The wire is then cut between the pegs 64 and the stationary tie-off post 66.
  • At this point, turret 62 having two wound stator teeth is removed from post 52 by unsecuring it and lifting it, making room for another turret 62 bearing a set of stator teeth to be wound. Completed stator teeth are then removed from turret 62 by actuating the cam-shaped members to allow the completed stator teeth to slide out of the dove-tailed channels 84.
  • FIG. 6 shows a pair of stator teeth 100 a and 100 b having coils 108 formed thereon and joined by the span of wire 110. A terminating wire end 112 extends from each stator tooth for connection in a stator. Arrows 114 depict the direction in which stator teeth are moved to arrive at their final relative position side-by-side, as shown in FIG. 7, wherein span of wire 110 is taut and includes substantially no excess length. As will be appreciated, in this final position, adjacent stator teeth have coils of opposite orientation; that is, one is wound clockwise and another is wound counter-clockwise.
  • While the present invention has been described with specificity to mounting stator teeth onto a turret that presents the stator teeth to the fly winder for winding, other types of stator teeth supports will occur to those of ordinary skill in the art. For example, a plate having a number of positions for securing stator teeth in a similar fashion as employed in the described embodiment can be used. The plate can be raised and lowered relative to the fly winder just as the turret, and can be moved relative to the fly winder along a longitudinal axis to present a different stator tooth to the flyer head, simulating the rotation of the turret.
  • The positions of the stator teeth on the turret can be made adjustable to allow different dimensioned stator teeth to be coiled using the same turret. Further, the turret can be made expandable, through additional concentric surface layers on its periphery, through the placement of each stator tooth on a separate arcuate plate whose distance from the center of the turret can be adjustable, or through some other means.
  • Although the stator teeth are shown as being positioned ninety degrees apart about the circumference of the turret, it is to be appreciated that the stator teeth can be positioned in other configurations. For instance, the stator teeth can be placed along the circumference of the turret at varying degrees, depending on the circumference of the turret, the relative vertical separation of the stator teeth positions along the vertical length of the turret, and any variation in the radial distance of the stator teeth positions along the surface of the turret.
  • While specific reference is made to the posts upon which the turrets are mounted being controlled by a set of motors, other methods of controlling the posts will occur to those skilled in the art. For example, pneumatic or hydraulic means can be alternatively employed to control movement of the posts.
  • The turrets can be equipped with clamps in place of pegs to engage the wire ends during the start and end of the winding process. This method of termination is well-suited to work with both a wire which has been previously terminated on a stationary tie-off post, and one which is loosely hanging out of the flyer nozzle, and is especially beneficial for use with heavier gauge wires.
  • Although the clamp assemblies are described as including cam-shaped members to bias the stator teeth into engagement with the side clamps, other means of securing the stator teeth to the turrets during the winding process can be used. For example, the stator teeth can be frictionally fit into the dove-tailed channels.
  • Also, although the apparatus is described as including a fly winder associated with each turret, fewer fly winders that are moveable laterally between multiple turret locations can be used.
  • Although embodiments of the present invention have been described, those of skill in the art will appreciate that the variations and modifications may be made without departing from the spirit and scope thereof as defined by the appended claims.

Claims (37)

1. An apparatus for winding stator teeth, comprising:
at least one fly winder for winding wire around stator teeth; and
at least one stator teeth holder including stator tooth retainers at spaced locations for retaining stator teeth thereon, said at least one stator tooth holder and fly winder being moveable relative to one another to present each stator tooth to said at least one fly winder for winding a wire coil thereon, wherein said stator tooth retainers are relatively positioned on said at least one stator teeth holder to control a span of wire extending between said stator teeth after said stator teeth have been presented to said at least one fly winder and wound.
2. An apparatus for winding stator teeth according to claim 1 wherein said stator teeth holder is rotatable to present each stator tooth to said fly winder.
3. An apparatus for winding stator teeth according to claim 2 wherein said stator tooth retainers are circumferentially spaced about said stator teeth holder.
4. An apparatus for winding stator teeth according to claim 3 wherein said stator tooth retainers are vertically offset with respect to one another, said stator teeth holder also being vertically adjustable to present each stator tooth to said fly winder.
5. An apparatus for winding stator teeth according to claim 4 wherein said stator teeth holder includes a pair of stator tooth retainers, each for retaining a single stator tooth.
6. An apparatus for winding stator teeth according to claim 5 wherein said fly winder winds each stator tooth in a manner so that the coils on said stator teeth have opposite orientations.
7. An apparatus for winding stator teeth according to claim 6 wherein each stator tooth retainer includes a channel shaped to accommodate a stator tooth.
8. An apparatus for winding stator teeth according to claim 7 wherein said channel is defined by a clamp assembly accommodated by said stator teeth holder.
9. An apparatus for winding stator teeth according to claim 8 wherein said clamp assembly includes a pair of side clamps for engaging opposite sides of a stator tooth.
10. An apparatus for winding stator teeth according to claim 9 wherein said clamp assembly further includes a biasing member actuable between engaged and disengaged states, in said engaged state said biasing member biasing said stator tooth into engagement with said side clamps.
11. An apparatus for winding stator teeth according to claim 9 wherein said channel is sized to form a friction fit with said stator tooth.
12. An apparatus for winding stator teeth according to claim 8 wherein said stator teeth holder includes a main body including a pair of cutouts formed therein, each of said cutouts accommodating a respective clamp assembly, said main body presenting a generally arcuate outer surface bridging said cutouts.
13. An apparatus for winding stator teeth according to claim 12 wherein said clamp assembly includes a pair of side clamps for engaging opposite sides of a stator tooth.
14. An apparatus for winding stator teeth according to claim 13 wherein said clamp assembly further includes a biasing member actuable between engaged and disengaged states, in said engaged state said biasing member biasing said stator tooth into engagement with said side clamps.
15. An apparatus for winding stator teeth according to claim 13 wherein said channel is sized to form a friction fit with said stator tooth.
16. An apparatus for winding stator teeth according to claim 1 including a plurality of stator teeth holders, each of said stator teeth holders being moveable to present each stator tooth held thereby to said at least one fly winder for winding a wire coil thereon.
17. An apparatus for winding stator teeth according to claim 16 wherein each stator teeth holder is rotatable to present each stator tooth held thereby to said fly winder.
18. An apparatus for winding stator teeth according to claim 17 wherein the stator tooth retainers on each of said stator teeth holders are circumferentially spaced about said stator teeth holding tool.
19. An apparatus for winding stator teeth according to claim 18 wherein said stator tooth retainers on each of said stator teeth holders are vertically offset with respect to one another, each stator teeth holder also being vertically adjustable to present each stator tooth held thereby to said fly winder.
20. An apparatus for winding stator teeth according to claim 19 wherein each stator teeth holder includes a pair of stator tooth retainers, each for retaining a single stator tooth.
21. An apparatus for winding stator teeth according to claim 20 wherein said fly winder winds each stator tooth in a manner so that the coils on said stator teeth have opposite orientations.
22. An apparatus for winding stator teeth according to claim 1 including a plurality of stator teeth holders and fly winder pairs, each stator teeth holder being moveable to present each stator tooth held thereby to its associated fly winder for winding a wire coil thereon.
23. An apparatus for winding stator teeth according to claim 22 wherein each stator teeth holder is rotatable to present each stator tooth held thereby to its associated fly winder.
24. An apparatus for winding stator teeth according to claim 23 wherein said stator tooth retainers on each stator teeth holder are circumferentially spaced about said stator teeth holder.
25. An apparatus for winding stator teeth according to claim 24 wherein said stator tooth retainers on each stator teeth holder are vertically offset with respect to one another, each stator teeth holder also being vertically adjustable to present each stator tooth held thereby to its associated fly winder.
26. An apparatus for winding stator teeth according to claim 25 wherein each stator teeth holder includes a pair of stator tooth retainers, each for retaining a single stator tooth.
27. An apparatus for winding stator teeth according to claim 26 wherein each fly winder winds each stator tooth in a manner so that the coils on said stator teeth have opposite orientations.
28. An apparatus for winding stator teeth, comprising:
a fly winder for winding wire around stator teeth; and
a stator teeth holder including a rotatable turret having a main body and stator tooth retainers at spaced locations on said main body for retaining stator teeth, said turret being rotatable to present each stator tooth to said fly winder for winding a wire coil thereon, wherein said stator tooth retainers are relatively positioned on said turret in a manner such that after said stator teeth have been wound by said fly winder to include coils of opposite orientation, removed from said turret and placed side-by-side, the span of wire extending between said stator teeth includes substantially no excess length.
29. An apparatus for winding stator teeth according to claim 28 wherein said stator tooth retainers are vertically offset with respect to one another, said turret also being vertically adjustable to present each stator tooth to said fly winder.
30. An apparatus for winding stator teeth according to claim 29 wherein said turret includes a pair of stator tooth retainers, each for retaining a single stator tooth.
31. An apparatus for winding stator teeth according to claim 30 wherein each stator tooth retainer includes a channel shaped to accommodate a stator tooth.
32. An apparatus for winding stator teeth according to claim 31 wherein said channel is defined by a clamp assembly accommodated by said main body.
33. An apparatus for winding stator teeth according to claim 32 wherein said clamp assembly includes a pair of side clamps for engaging opposite sides of a stator tooth.
34. An apparatus for winding stator teeth according to claim 33 wherein said clamp assembly further includes a biasing member actuable between engaged and disengaged states, in said engaged state said biasing member biasing said stator tooth into engagement with said side clamps.
35. An apparatus for winding stator teeth according to claim 33 wherein said channel is sized to form a friction fit with said stator tooth.
36. An apparatus for winding stator teeth according to claim 32 wherein said main body includes a pair of cutouts formed therein, each of said cutouts accommodating a respective clamp assembly, said main body presenting a generally arcuate outer surface bridging said cutouts.
37. A method of winding stator teeth, comprising:
mounting a first stator tooth and a second stator tooth at spaced locations on a tool;
presenting said first stator tooth to a winding device and winding a coil having a first orientation thereon;
biasing said tool to present said second stator tooth to said winding device; and
winding a coil on said second stator tooth having an orientation opposite that of the coil wound on said first stator tooth, wherein the relative locations of said first stator tooth and said second stator tooth on said tool are such that the span of wire extending from said first stator tooth to said second stator tooth includes substantially no excess length when said first stator tooth and second stator tooth are positioned side-by-side.
US10/888,564 2003-07-07 2004-07-07 Apparatus and method for winding stator teeth Abandoned US20050051661A1 (en)

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US10530200B2 (en) 2009-07-22 2020-01-07 Control Techniques Dynamics Limited Electric device stator and methods for winding
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