Axis USA, Inc.

Axis Corporation

Sabatino Luciani

Massimo Lombardi

Antonio Lumini

Massimo Ponzio

Luciano Santandrea

Federico Sbalchiero

Maurizio Mugelli

Rossano Galassi

Giuseppe Cardini

Graziano Quirini

Romano Lozzi

Alessandro Rossi

Antonio Lunini

A wire guide for winding wire onto the ferromagnetic core of a dynamo-electric machine part to form wire coils in the slots of the core. The wire guide has guide surfaces that allow wire to be wound deeply into the slots of the core. The wire guide also has a pair of coil retention notches. The notches have back walls that prevent wire from climbing along the sides of the slots toward the slot openings during the process of coil winding.

Wire winding guide with coil retention notches

Wire winding guide

A resin coating system includes a coating station for applying resin to dynamo-electric machine components such as electric motor armatures, one or more other stations adjacent to the coating station, a conveyor for transporting components through the coating station where the components are carried by holders holding at least one end of the components without touching the body portion of the components, another conveyor for transporting components through the other stations where the components are carried by holders supporting the body portion of the components, and a transfer device for transferring uncoated and coated components between the two conveyors. The holders attached to the conveyor in the coating station are capable of rotating the components about the longitudinal axis of each component during the coating operation for an even application of the resin to the component. The holders attached to the conveyor for transporting armatures through the other stations are of simpler and less expensive construction. Prior to resin application, the components may be heated by electrical resistance heating of their coils and by electromagnetic induction heating of their ferromagnetic cores.

Conveyance and processing of dynamo-electric machine components in resin

A transfer mechanism is operatively disposed between a conveyor for dynamo-electric machine parts (such as electric motor armatures) and apparatus for simultaneously processing a plurality of those parts (e.g., by winding coils of wire on those parts). The transfer mechanism delivers processed parts to the conveyor and receives unprocessed dynamo-electric machine parts from the conveyor, one at a time in a single alignment position, at least partly concurrent with the processing of other parts. Loss in production time due to wire breakage at the processing apparatus is reduced by substantially instantaneously controlling the broken wire (e.g., by retracting that wire relative to the associated wire dispenser) while continuing to move the wire dispensers.

Multiple dynamo-electric machine parts handling and winding methods and

A resin coating system includes a coating station for applying resin to dynamo-electric machine components such as electric motor armatures, one or more other stations adjacent to the coating station, a conveyor for transporting components through the coating station where the components are carried by holders holding at least one end of the components without touching the body portion of the components, another conveyor for transporting components through the other stations where the components are carried by holders supporting the body portion of the components, and a transfer device for transferring uncoated and coated components between the two conveyors. The holders attached to the conveyor in the coating station are capable of rotating the components about the longitudinal axis of each component during the coating operation for an even application of the resin to the component. The holders attached to the conveyor for transporting armatures through the other stations are of simpler and less expensive construction.

Conveyance of dynamo-electric machine components in resin application

Armatures for dynamo-electric machines are balanced during manufacture by measuring the unbalance of the armature assembly prior to winding the coils on the armature. The numbers of turns of wire in at least some of the coils subsequently wound on the armature are then adjusted so that the unbalance of the resulting coils compensates for the unbalance of the armature prior to coil winding. Alternatively, one or more extra turns of wire that are short-circuited at the commutator may be added to help balance the armature. In addition, masses may be added to the armature to ensure that it is balanced dynamically as well as statically.

Methods and apparatus for producing dynamo-electric machine armatures

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.

Methods for winding armatures having slot commutators

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.

Methods and apparatus for identifying hooks of electric motors

In the performance of fusing operations which involve the application of force and heat to a workpiece, the heat being generated at least in part by electrical resistance heating resulting from passage of an electrical current through an electrical circuit which includes the workpiece and typically also a fusing electrode, the fusing cycle is controlled at least in part on the basis of measurements of the resistance of the above-mentioned circuit during the fusing operation. If desired, the resistance measurements may be corrected to eliminate or at least substantially reduce the contribution of electrode resistance so that the fusing operation is controlled on the basis of the resistance of the workpiece.

Fusing methods and apparatus for use in making dynamo-electric machines

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.

Methods for connecting stator coil leads

Apparatus for winding armatures having slot commutators

Methods and apparatus are provided for generating and connecting an intermediate lead wire extending between multiple portions of a coil wound on a pole of a stator core to a slotted terminal mounted on the stator core. Such stator cores, wound by coil winding shuttles, are used in electric motors, generators and similar devices. An intermediate lead wire extending between multiple portions of a coil is first captured by a hook mechanism, aligned with a slotted terminal, and then inserted in the terminal by a wire insertion device. The wire is then held in engagement with the terminal while the next portion of the coil is begun, producing an intermediate lead wire connection wherein a first portion of the lead wire is engaged within a slot in the terminal and the portion extending from the terminal to the next coil portion is wrapped tightly against the exterior of the terminal. In accordance with the principles of this invention, no cutting of the intermediate lead wire is required.

Methods for connecting intermediate stator coil leads

Methods and apparatus for winding the stator of an electric motor with two wires simultaneously are provided. The apparatus includes a stator winding needle having two separate wire delivery channels. The leads of the two wire to be wound are passed through the winding needle and are held by start lead holders. When winding is complete, the wires are identified by a lead pulling apparatus which rotates in a predetermined direction to grip an appropriate wire. The lead pulling apparatus draws each of the wires to a termination lead holder. Each wire is gripped and cut by a gripping assembly, which holds the cut leads in a predetermined position to facilitate winding of a subsequent stator.

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Florence, Italy

Sabatino Luciani