Method of making a stator connection assembly

Abstract

Dynamoelectric stator assemblies and methods of fabricating stator assemblies with new and improved winding interconnection arrangements are disclosed. In one disclosed method, windings are generated and disposed in slots of a magnetic core with end turn portions thereof being disposed adjacent a core face. At a tap insulating station, selected winding tap wires are insulated and routed to a common connecting region. The core with winding turns therein is then moved to an end turn pressing station to compress and shape the winding end turns and to condition the end turns to subsequently receive and support a connection insulator. At a connection station, a tap support and aligning means is interfitted with the core for receiving the tap wires and lead wires therein. After interconnections between respective tap wires and lead wires have been made by a connection apparatus, a connection insulator comprising a plurality of holsters is placed over connection points resulting from the interconnections thereby supporting and electrically isolating the connection points. The core and tap support and aligning means are removed from the interfitting relationship. The connection insulator is then positioned within a deformed section at the outer peripheral surface of the winding end turns established during the pressing operation. The connection insulator is retained in position by a retention means and then subsequently secured to the winding end turns by disposing lacing material about the end turns and connection insulator at a lacing station.