Other

Airex Corporation

Richard D Sedgewick

David J Carroll

James Sedgewick

Michael Drew

A coil winding system and process is provided that includes a coil winding fixture and a coil press fixture. The coil winding fixture includes a pair of winding arms each having a set of in-line winding pins. The sets of in-line pins are arranged parallel to one another in one axis, and form an angle to another axis. Magnetic wire is machine wound into the slots between the pins to form coil phases, and, advantageously the individual coils can be wound together to minimize spatial tolerance build-up between phases. Likewise the slots are arranged parallel and adjacent one another to ensure that each winding is parallel to the next to maximize efficiency of the coils. The press fixture includes a forming press and a saddle to form the wound coils into a predetermined shape using heat and pressure applied to the press fixture.

Method and apparatus for winding and forming motor coil assemblies

A linear motor comprising a DC magnetic field of alternating polarity arranged in a longitudinal axis, a coil assembly located substantially in a plane parallel to and immersed in the alternating magnetic field, said coil assembly containing individual coil loops of essentially rectangular shape and having end turn areas arranged parallel to said longitudinal axis of the magnet field and coil side areas being perpendicular to said longitudinal axis of the magnetic field with each coil side having a coil side width (CSW) and each coil loop having a coil outside width (COW) and coil inside width (CIW) such that COW=CIW+(2.times.CSW) wherein the coils have a coil outside length (COL), forming a coil assembly area (CAA) approximately equal to COW.times.COL and said coil assembly has a coil assembly thickness (CAT) in a direction creating acoil assembly volume (CAV) approximately equal to the coil assembly area (CAA) times the coil assembly thickness (CAT) pursuant to the following equation: CAV.apprxeq.CAT.times.COW.times.COL. wherein said assembly is formed with a plurality of phases each formed in the manner of the first phase, each phase uniformly and sequentially offset from adjacent phases and means for switching current successively between the phases thereby alternating the magnetic fields within the coil assembly sequentially, said plurality of offset phases substantially filling the coil inside width (CIW) of the first phase, such that CIW=CSW.times.(#.phi.-1). The above coil assembly optimally includes a longitudinal opening along the end turn areas within the coil assembly volume allowing non-magnetic metallic members for heat dissipation and structural strength, including a mounting bracket on one end turn area, and a heat sink cap enclosing the opposite end turn area.

Linear motor with improved coil design and heat removal

A linear motor comprising a DC magnetic field of alternating polarity arranged in a longitudinal axis, a coil assembly located substantially in a plane parallel to and immersed in the alternating magnetic field, said coil assembly containing individual coil loops of essentially rectangular shape and having end turn areas arranged parallel to said longitudinal axis of the magnet field and coil side areas being perpendicular to said longitudinal axis of the magnetic field with each coil side having a coil side width CSW) and each coil loop having a coil outside width (COW) and coil inside width (CIW) such that COW=CIW+(2.times.CSW) wherein the coils have a coil outside length (COL), forming a coil assembly area (CAA) approximately equal to COW.times.COL and said coil assembly has a coil assembly thickness (CAT) in a direction creating a coil assembly volume (CAV) approximately equal to the coil assembly area (CAA) times the coil assembly thickness (CAT) pursuant to the following equation: CAV.apprxeq.CAT.times.COW.times.COL, wherein said assembly is formed with a plurality of phases each formed in the manner of the first phase, each phase uniformly and sequentially offset from adjacent phases and means for switching current successively between the phases thereby alternating the magnetic fields within the coil assembly sequentially, said plurality of offset phases substantially filling the coil inside width (CIW) of the first phase, such that CIW=CSW.times.(#.phi.-1). The above coil assembly optimally includes a longitudinal opening along the end turn areas within the coil assembly volume allowing non-magnetic metallic members for heat dissipation and structural strength, including a mounting bracket on one end turn area, and a heat sink cap enclosing the opposite end turn area.

A coil form bobbin (20) for winding coil winding wire is a flat disk (22) formed with a plurality of peripheral radial slots (24,25,26) comprising at least one set of n slots spaced around the periphery of the flat disk dividing the bobbin into a respective set of n segments. The slots extend from the outside perimeter part way the flat disk. A method for winding flat coil windings on the coil form bobbin is described. The coil winding is in flat configuration for rotor and stator applications. Each winding phase (44,45,46) of multiple turns of coil winding wire is wound in the configuration of a flat substantially regular polygon. The multiple turns of coil winding wire turn in the same direction for conducting electrical current in the same rotational direction around the phase. The multiple turns of coil winding wire lie substantially next to each other side-by-side in the flat array along the sides of the polygon and are formed with well defined similar, radially aligned angles stacked one outside the other at each of the apexes or nodes of the polygon.

Flat windings and coil forms

Flat windings, coil forms, and winding method

A stack winding apparatus and method is described for winding wire filament around selected teeth of a slotted stack. The apparatus and method are applicable for stacks of annular configuration with radially inwardly and outwardly directed teeth; for winding tapered or other complex distributions of copper turns on iron; and for winding stacks with high density teeth and narrow slots where a winding needle cannot pass between adjacent teeth. A wire feed winding needle mounting support and a stack mounting support permit movement of the winding needle and a stack in at least three coordinate axis directions relative to each other. The supports may be formed on separate modules for variable angular orientation relative to each other. A number of motors control relative movement of the winding needle and stack along the three directions for winding selected teeth in the desired distribution. The invention provides as a basic component pliant bearing surface clamp members on either side of the row of teeth of a stack to be wound. A clamp mounting yoke and further motor means alternately move the pliant bearing surfaces toward and away from the row of teeth on either side between a clamp position and an open position. According to the method of the invention the winding wire filament is alternately clamped against one side of the row of teeth and then the other while the winding needle moves up and down and back and forth 'dancing' over the row of teeth seating the wire in slots between teeth of the stack without itself passing between adjacent teeth through the slots. The winding wire is unclamped by releasing the pliant bearing surfaces on both sides of the row of teeth while shifting the stack and row of teeth relative to the winding needle to different slot and tooth locations.

Method for winding wire coils on a toothed stack

Apparatus is described for precise placement of an object or sensing or measurement of a parameter using a plurality of tilt plates in substantially parallel spaced apart relationship forming a stack. Adjacent pairs of tilt plates in the stack are joined by unitary hinge plates secured to respective edges of each adjacent pair of tilt plates on one side. Each hinge plate is constructed and arranged of rigid elastic material for controlled elastic bending and recovery under applied bending moment stress. A plurality of spreader elements are provided operatively coupled to each pair of adjacent tilt plates at the side opposite the respective hinge plate. A spreader actuator actuates the spreaders for imparting tilting motion to the respective pair of tilt plates by varying the spacing of the pair of adjacent tilt plates relative to each other at one side imparting bending moment stress to the hinge plate on the other side. An object or sensor coupled to the top or end of the stack may be precisely placed, positioned or moved by controlled actuation of the spreaders. Parameters accurately measured by using, for example, temperature sensitive, pressure sensitive or weight sensitive motional response spreader elements. Passive motion sensors or transducers may be substituted for the spreaders for sensing motin or deflection. Strain gauges may be applied to the hinge plates for the same purpose. The apparatus is applied, by way of example, in retrofitting a conventional grinder for fine adjustment and precise placement of a workpiece relative to a working tool. Other applications include work holders, manipulators, robots, measuring instruments, scales, springs, bellows and deflection devices.

Apparatus for precision placement and parameter measurement

A wire feed winding needle mounting support and a stack mounting support permit movement of the winding needle and a stack in at least three coordinate axis directions relative to each other. The supports may be formed on separate modules for variable angular orientation relative to each other. A number of motors control relative movement of the winding needle and stack along the three directions for winding selected teeth in the desired distribution. The invention provides as a basic component pliant bearing surface clamp members on either side of the row of teeth of a stack to be wound. A clamp mounting yoke and further motor means alternately move the pliant bearing surfaces toward and away from the row of teeth on either side between a clamp position and an open position. The winding wire filament is alternately clamped against one side of the row of teeth and then the other while the winding needle moves up and down and back and forth 'dancing' over the row of teeth seating the wire in slots between teeth of the stack without itself passing between adjacent teeth through the slots. The winding wire is unclamped by releasing the pliant bearing surfaces on both sides of the row of teeth while shifting the stack and row of teeth relative to the winding needle to different slot and tooth locations.

Apparatus for winding wire coils on a toothed stack

Single and multi-phase, multi-pole arrays of adjacent equivalent current loops are formed in a self-supporting structure as wound. The multi-pole windings are formed by zig-zag winding elements having peaks and troughs. The peaks and troughs of each winding element form alternate halves of adjacent effective or equivalent current loops. When the peaks of one winding element are aligned with the troughs of another, the two elements provide a single phase ring of adjacent coupled current loops equivalent to the conventional separately wound coils. However, the current loops are already in a correctly positioned and oriented array as wound. The filaments of one winding element cross over the filaments of another intermediate the peaks and troughs and current passes in one direction through the first element returning in the opposite direction through the second. Multi-phase windings in a variety of configurations are described. The annular windings are wound on an arbor by a new winding apparatus and simplified method according to the disclosure. Windings are removed from the arbor and are particularly applicable for use in sensing and torque producing devices.

Growing community of inventors

Dover, NH, United States of America

Richard D Sedgewick