Emerson Electric Company

Vernon E Kieffer

Andrew J Kliethermes

Paul G Michaels

Barry Monroe Newberg

Marshall J Huggins

Billy L Damon

Alexander A MacCormack

Daniel E Ackermann

This invention relates in general to dynamoelectric machines, and in particular to a method of fabricating a low cost salient pole stator assembly for a salient pole motor. Low cost salient pole motors are constructed by minimizing stator core stack height or core stack material and maximizing winding slot fill in the motor design process. Thereafter, the windings for the motor design are formed externally of the motor on high speed winding machines and transferred to axial insertion devices. Transfer to the axial insertion devices may be either accomplished automatically or manually. Thereafter, the windings are axially inserted into the stator core. After insertion, the salient pole stator assembly generally is processed like a conventional distributed winding induction motor.

Method of constructing a salient pole motor

A substantial saving of material cost and weight is obtained in an induction motor by a rotor including two sets of differently punched laminations. The laminations in one of the two groups each weigh less than 95% of the laminations in the other one of the two groups. Such laminations can be automatically produced on a computer-controlled die press by providing a separate punch pattern that is capable of being programmed for selected laminations. The lighter laminations can be used to counterbalance a crank without requiring additional counterbalancing weight to be added outside the motor.

Weight optimized rotors

A reluctance machine system is provided that comprises a reluctance machine having a stator defining a plurality of stator poles, a plurality of phase windings wound around the stator poles, and a rotor defining rotor poles and inter-pole gaps. Contoured topsticks, a dust cover and an endshields are used to reduce the amount of noise in the reluctance system. A winged terminal housing is also used to allow manipulation of the terminal housing and enhance alignment while protecting critical wires.

Reduced noise reluctance machine

An inner diameter block for blocking the inner diameter of windings of an electric motor includes a plurality of first segments and a plurality of second segments arranged in an alternating manner. The segments are movable radially outwardly to block the inner diameter of the windings. One of the segments is generally pie shaped, having an arcuate outer surface and ears extending circumferentially to define part of the outer surface. These first segments define gaps which receive second segments. The first and second segments have sloping inner surfaces which define a core in which an expanding cone is received. The cone, when moved axially in the core, urges the second segments radially outwardly. The second segments then force the first segments radially outwardly. The interaction of the second segments with the ears of the first segments provide a substantially continuous, gap-free outer surface to the inner diameter block at all stages of expansion.

Gapless inner diameter stator winding blocking mechanism

A coil assembly machine for automatic loading of stator cores for dynamoelectric machines, automatic winding insertion, high speed wedge manufacture, automatic wedge insertion, and automatic core removal from the machine is provided in a construction of relatively low cost and high productivity. The machine is designed to operate in conjunction with conventional coil winding devices and improves manufacturing efficiency at relatively low cost. In the preferred embodiment, a four position arrangement is employed. Each position includes an upper tooling assembly of an axial insertion machine. An operator places wound coils on the upper axial insertion tooling. The upper insertion tooling then rotates to a stator core placement position, where the core is placed on the tooling and wedges are positioned for placement in the core. Thereafter, the core and winding move to an insertion position where the coils are inserted axially and wedges are placed in slots of the stator core. The now winding loaded core rotates to a removal position, where the winding/core combination is removed from the machine. Operations are controlled so the various processes occur in a predetermined timed relationship.

Coil assembly machine

A motor test board is provided which permits automatic testing of an electrical motor under load, in addition to permitting other conventional motor tests. In the preferred embodiment, the motor load is a simulated fan load imposed by a windbat which is calibrated to an intended actual load for the motor. A strobe disc is attached the windbat and is designed to permit determination of RPM and direction of rotation for the motor under test. The windbat and associated structure is automatically attached to the motor undergoing test, and the attaching mechanism is disassociated from the motor and load during test so that the test results closely parallel applicational use of the motor.

Fan load simulated automatic motor test board

Method and apparatus for forming a multi-pole winding for a dynamo-electric machine wherein a skein of magnet wire is wound and mounted on spaced retaining jaws biased outwardly to keep the wire under light tension during a subsequent forming process. Forming tools are moved inwardly against the wire between the retaining jaws to produce a petalled, serpentine form with a series of apices between the retaining jaws. Holding pins are inserted between the wire and the forming tools at the apices, and the forming tools are retracted. While the wire is held between the retaining jaws and holding pins, it is loaded onto a fingered transfer tool.

Method and apparatus for forming multi-pole windings

A winding insertion device for axially inserting the windings of a dynamoelectric machine is provided with a pair of blade holders axially aligned with respect to one another. A first set of blades is attached to one of the blade holders, and a second set of blades is attached to the second blade holder. Individual ones of the first and second blade sets are arranged alternately with respect to one another, and the blades define an annular array when viewed in plan. Means are provided for moving the first and second blade holders relative to each other in a reciprocal movement pattern during winding insertion, with consequent movement of the respective blade sets. Because of the relative blade holder movement, the actual distance of movement required for individual ones of the first and second blade sets is small. Consequently, the insertion device is compatible with a wide range of stator assembly stack heights constructed from laminations having a variety of slot configurations.

Oscillating blade winding insertion device

A molded thermstat strap is provided having a central thermostat receiving well. The strap is intended for insertion between the windings of a dynamoelectric machine, for example, an electric motor, during manufacture of the motor so that a thermostat element can be positioned between the windings after motor construction is completed. The strap includes a central well having wing members extending outwardly from opposite sides of the well. Means for removably locking a thermostat within the well is formed integrally with the strap. Means also is provided for holding the strap positionally secured in relation to the motor windings so that the strap does not move during motor constructional steps accomplished after placement of the strap between the motor windings.

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St. Louis, MO, United States of America

Vernon E Kieffer