Elmotec Statomat Vertriebs Gmbh

Schaeffler Elmotec Statomat Gmbh

Industra Products, Inc.

Advanced Machine and Tool Corporation

Elmotec Statomat Holding Gmbh

Keith Witwer

Sadik Sadiku

Robert G Walker

Keith W Moser

Richard A Sanderson

The invention relates to a method for producing a coil winding () for insertion into radially open slots () in a rotor or stator () of an electrical machine, wherein the coil winding () has a wire pack () consisting of a number of wires (), wherein the wires () of the wire pack () run parallel to one another and are connected to one another in pairs at one end of the wire pack (), and wherein the coil winding () is formed by a flat winding former which can be rotated about an axis of rotation (). According to the method, the wire pack () is fixed on a winding former () and winding heads () are produced by displacing fixations of the wire pack (). The winding shaft () can be rotated so that, after carrying out the method, a coil winding () is present in the form of a wave winding having wires () of the wire pack () preconnected in pairs at one end. Such a method allows a particularly space-saving coil winding () to be produced, which has a particularly high mechanical stability and requires the least amount of installation space in a rotor or stator ().

Method for producing a coil winding for insertion into radially open slots of stators or rotors of electrical machines

A method to produce rotors or stators of electric machines having radial grooves into which webs of flat windings having parallel webs and winding heads connecting said webs being pulled, wherein a winding is produced on a rotating, strip-shaped flat former shorter than the winding such that windings are pulled off the former and transferred into a linear transfer device, which transports the windings to a removal position at which the windings are transferred into radial grooves of a rotor or of the transfer tool for transfer into radial grooves of a stator, wherein the former, the transfer device, and the rotor or the transfer tool being jointly rotated about an axis of rotation of the former when rotated to form windings.

Device for producing rotors or stators of electric machines

A coil winding () that consists of a number of wires () braided with one another and bent multiple times in opposite directions such that mutually parallel legs () of the wires () which are intended to fill the slots () are connected by winding overhangs () which project from the end face of the stators () or rotors. The winding overhangs () each have two oblique winding overhang sections () having a winding overhang tip () in between. The wires () are arranged one behind the other in a longitudinal direction (L) of the coil winding (). The winding overhangs (), which are distributed in the longitudinal direction (L) over the entire length of the coil winding, of at least one wire () protrude transversely to the longitudinal direction (L) beyond the winding overhang ().

Coil winding for stators or rotors

Method for producing rotors or stators of electric machines

The method according to the invention is used to produce a coil winding () which can be inserted into the grooves of a stator or rotor of an electric machine. While using a winding template () and a wire handling device (), the invention proposes carrying out a displacement process between a first and a second holding region () even before the wires () are initially wound onto the winding template () in order to produce an inclined wire section () which is subsequently shaped into winding heads () by means of a rotating/winding process. The novel method offers the advantage that all of the wires () of a coil winding () can be processed simultaneously using a comparably simple winding device (). The projection of the winding heads () over the stator can also be minimized.

Method for producing a coil winding for inserting into radially open grooves of stators or rotors of electric machines

The disclosed stator or rotor has a distributed wave winding, in which the wires are associated in pairs lying with straight segments in the same slots. Head portions of two successive straight segments of each wire of a pair protrude from opposite ends of slots. For forming two wire groups, a plurality of coil windings are simultaneously created by winding up n parallel wires with intermediate spacing onto a striplike former that is rotatable about its longitudinal axis. From each of the parallel wires one straight segment and one end turn are doubled by being bent over with the wire length of a head portion, and then head portions are formed and the wires interlaced. Finally, the two wire groups are wound onto one another and thereby intertwined with one another, and then introduced as an entire intertwined wave winding strand into the stator or rotor slots.

Stator or rotor with interlaced wire groups forming an intertwined wave winding

The disclosed method produces a stator or rotor having a distributed wave winding, in which the wires are associated in pairs lying with straight segments in the same slots. Head portions of two successive straight segments of each wire of a pair protrude from opposite ends of slots. For forming two wire groups, a plurality of coil windings are simultaneously created by winding up n parallel wires with intermediate spacing onto a striplike former that is rotatable about its longitudinal axis. From each of the parallel wires one straight segment and one end turn are doubled by being bent over with the wire length of a head portion, and then head portions are formed and the wires interlaced. Finally, the two wire groups are wound onto one another and thereby intertwined with one another, and then introduced as an entire intertwined wave winding strand into the stator or rotor slots.

Method for producing stator or rotor with interlaced wire groups forming an intertwined wave winding

An apparatus for producing a coil winding for stators is described, in which each coil turn rests, with one fillet () each, in two stator slots, and the two fillets () are joined by a head portion (). A plurality of coil turns are made simultaneously by winding up n parallel wires () with intermediate spacing onto a rotatable former (). To obtain small winding heads, alternatingly in a work step A, one fillet () and the wire length of one head portion () are made from each of the n parallel wires () on the former (). Then in a work step B, the resultant fillets () together with the adjoining first end of the respective associated head portions (), and the wire guide together with the second end of these head portions (), are displaced relative to one another along the former () by n times the intermediate spacing of the wires ().

Apparatus for producing a coil winding for stators or rotors of electrical machines

A method for producing a pattern of coil windings in which each coil turn has one fillet each in two slots, and the two fillets are joined by a head portion. A plurality of coil turns are made simultaneously by winding n parallel wires with intermediate spacing onto a rotatable former. To obtain small winding heads, there is a repeating of: a laying work step where one fillet and the wire length of one head portion are laid on the former; and a displacing work step where the resultant fillets together with the adjoining first end of the respective associated head portions, and the wire guide together with the second end of these head portions, are displaced relative to one another along the former by n times the intermediate spacing of the wires. Next, the winding is removed from the former, and pressed flat.

Method for producing a coil winding for stators or rotors of electrical machines

A method for producing a coil winding for stators is described, in which each coil turn rests, with one fillet () each, in two stator slots, and the two fillets () are joined by a head portion (). A plurality of coil turns are made simultaneously by winding up n parallel wires () with intermediate spacing onto a rotatable former (). To obtain small winding heads, alternatingly in a work step A, one fillet () and the wire length of one head portion () are made from each of the parallel wires () on the former (). Then in a work step B, the resultant fillets () together with the adjoining first end of the respective associated head portions (), and the wire guide together with the second end of these head portions (), are displaced relative to one another along the former () by n times the intermediate spacing of the wires (). After work steps A and B have been repeated multiple times, the fillets () for the last n stator slots are then also made on the former (). Next, the winding is removed from the former, pressed flat, and placed in a striplike coil holder. From there it is transferred into slots of a rotorlike transfer tool that are open radially outward, and from there it is finally positively displaced radially outward into the stator slots.

Method and apparatus for producing a coil winding for stators or rotors of electrical machines, and stator or rotor produced thereby

The stator for electrical machines has stator slots that are open radially inward, at least some of which contain coils made from round wire and have side walls () of equal length that each extend parallel to their center radial plane. To attain an especially high fill factor, the entrances () of the stator slots have a width, measured transversely to their center radial plane, that is slightly greater than the diameter d of the round wire (). A further condition is that the width of the stator slots, measured between the parallel side walls (), amounts to (1+cos 30&#xb0;)d, and the radially outer slot wall () forms angles of 60&#xb0; and 120&#xb0;, respectively, with each of the two side walls ().

Stator for electric machines

A method and apparatus in which wave windings, cut from a continuously formed wave winding band, are brought with a defined number of waves essentially tangentially to a rotor or stator lamination packet or a rotorlike transfer tool having radially outwardly open slots. During a rotary motion of the lamination packet or transfer tool and a substantially tangential relative motion, at a speed corresponding to the circumferential speed of the rotary motion, the straight portions of the bandlike wave windings are pressed into the slots.

Method and apparatus for introducing wave windings into rotor and stator lamination packets of electrical machines

An apparatus for inserting coils and wedges into the stator core of an electric motor. The apparatus includes a plurality of elongated blades arranged in a circular array, a plurality of wedge guides arranged in a circular array, and a stripper. Additionally, a wedge guide support is provided which moves axially together with the blades and which supports the wedge guides when coils are inserted into a long stator core. The wedge guide support prevents deflection of the wedge guides radially inward by pressure of the coil end turns on the wedge guides when the blade pack is axially moved out of the wedge guides.

Blade pack extension and wedge guide support

A coil placing machine having an improved operating sequence for positioning coil separating insulators in certain core slots is disclosed. The insulators are supported about a coil placing machine super structure and stripped therefrom into the respective slots by movement of the stator core into position for receiving coils from the placing machine. In the preferred apparatus a stator gage and blade aligning tool has a first portion for engaging blades of a coil placing apparatus and the second portion for axially and radially aligning a stator core with the coil placing apparatus as well as a portion intermediate the first and second portions for supporting insulators in a position to be transferred to a stator core by relative motion between the core and tool. With this arrangement, the motion normally required to position the stator core preparatory to receiving coils is also effective to locate the intermediate insulators in the stator core.

Method and apparatus for positioning intermediate insulators in cores

A coil placing machine having an improved operating sequence for positioning prewound coils and coil separating insulators in certain core slots is disclosed. A portion of each insulator is supported obliquely to the core axis and then both insulators and coils are moved toward the core, coil movement is interrupted while the insulators continue to move into their ultimate position within the core and thereafter coil movement is resumed to complete the coil and insulator placing operation. In the preferred aparatus a conventional coil stripper and insulation inserting gauge and blade alignment tool are separately actuated to pass into the core so that the axial separation between the stripper and tool is at first constant and then increases and finally decreases as the coil and insulator insertion progresses.

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Fort Wayne, IN, United States of America

Keith Witwer