Claims
- 1. Apparatus for producing an undulating coil of wire for application to a core of a stator for a dynamo-electric machine comprising:
a gripper configured to hold an initial lead of the wire; receiver structure configured to receive the wire extending from the gripper and to form a coil of the wire having successive turns that are substantially disposed in respective planes that are substantially perpendicular to a central longitudinal axis of the coil and laterally spaced from one another along that axis; forming structure configured to produce undulations in the turns of wire in their respective planes while the turns are on the receiver structure, the undulations giving the turns portions that are substantially radial of the axis; and gripper positioning structure configured to position the gripper relative to the receiver structure so that the initial lead is placed substantially in the plane in which a final turn of the coil is disposed and is substantially aligned with one of the portions of the turns that are substantially radial of the axis.
- 2. The apparatus defined in claim 1 wherein the receiver structure includes a first coil forming structure configured to receive the wire extending from the gripper in order to coil the wire around the axis, and wherein the forming structure includes a second coil forming structure which is initially outside the first coil forming structure, the first and second coil forming structures being movable relative to one another radially inward toward the axis, with the second coil forming structure moving to a final position which is radially inside the first coil forming structure in order to produce the undulations in the turns on the first coil forming structure.
- 3. The apparatus defined in claim 2 wherein the gripper is further configured to direct the initial lead outwardly of the coil.
- 4. The apparatus defined in claim 3 wherein the gripper is rotatable about a gripper axis which is substantially parallel to but laterally offset from the axis.
- 5. The apparatus defined in claim 4 wherein the gripper is further configured to receive the initial lead extending substantially radially inwardly toward the axis and to subsequently rotate so that the initial lead extends substantially radially outwardly from the axis.
- 6. The apparatus defined in claim 4 wherein the gripper is additionally configured to receive the initial lead extending substantially radially inwardly toward the/axis and to subsequently rotate so that the initial lead extends substantially tangent to the coil.
- 7. The apparatus defined in claim 4 wherein the gripper is rotatable in response to tension in the wire gripped by the gripper.
- 8. The apparatus defined in claim 4 further comprising:
a releasable lock structure configured to selectively prevent rotation of the gripper.
- 9. The apparatus defined in claim 8 wherein the releasable lock structure is further configured to lock the gripper in only certain predetermined rotational positions of the gripper.
- 10. The apparatus defined in claim 9 wherein the predetermined rotational positions include a position in which the gripper is aligned to receive the initial lead.
- 11. The apparatus defined in claim 4 wherein the gripper includes two gripper sites on respective opposite sides of the gripper axis.
- 12. The apparatus defined in claim 2 wherein the gripper is part of the first coil forming structure.
- 13. The apparatus defined in claim 1 wherein the gripper comprises:
a shaft having a central longitudinal axis and an outer peripheral surface portion having nonuniform spacing from the central longitudinal axis in a direction annularly around the central longitudinal axis; an anvil structure adjacent to the outer peripheral surface portion; and gripper operating structure configured to produce relative motion between the shaft and the anvil structure about the central longitudinal axis whereby the initial lead of the wire can be releasably gripped between the outer peripheral surface and the anvil structure.
- 14. The apparatus defined in claim 13 wherein the gripper operating structure is further configured to resiliently produce relative motion between the shaft and the anvil structure about the central longitudinal axis in a direction which reduces clearance between the outer peripheral surface and the anvil in order to exert a resilient gripping force on the initial lead.
- 15. The apparatus defined in claim 14 wherein the gripper operating structure comprises actuator structure which is selectively operable to relative motion between the shaft and the anvil structure about the central longitudinal axis in a direction opposite to the direction which reduces clearance between the outer peripheral surface and the anvil in order to release the gripping force on the initial lead.
- 16. The apparatus defined in claim 13 further comprising:
mounting structure configured to mount the shaft, the anvil structure, and the gripper operating structure for selective rotation as a unit about the central longitudinal axis.
- 17. The apparatus defined in claim 16 wherein the mounting structure includes holding structure which is selectively operable to prevent rotation of the shaft, the anvil structure, and the gripper operating structure as a unit about the central longitudinal axis.
- 18. The apparatus defined in claim 17 wherein the holding structure is configured to hold the shaft, the anvil structure, and the gripper operating structure as a unit in only certain predetermined angular positions about the central longitudinal axis.
- 19. The apparatus defined in claim 13 wherein the outer peripheral surface is substantially symmetrical about the central longitudinal axis, wherein the anvil structure is one of two substantially similar anvil structures disposed on respective opposite sides of the shaft, and wherein the gripper operating structure is further configured to produce relative between (1) the shaft and (2) the two anvil structure about the central longitudinal axis whereby the initial lead of the wire can be releasably gripped between the outer peripheral surface and either of the anvil structures.
- 20. A method for producing an undulating coil of wire for application to a core of a stator for a dynamo-electric machine comprising:
gripping an initial lead of the wire in a gripper; coiling the wire extending from the gripper on a receiver structure to form a coil of wire having successive turns that are substantially disposed in respective planes that are substantially perpendicular to a central longitudinal axis of the coil and that are laterally spaced from one another along that axis; undulating the turns of wire in their respective planes while the turns are on the receiver structure, the undulations giving the turns portions that are substantially radial of the axis; and positioning the gripper relative to the receiver structure so that the initial lead is placed substantially in the plane in which a final turn of the coil is disposed and is substantially aligned with one of the portions of the turns that are substantially radial of the axis.
- 21. The method defined in claim 20 further comprising:
forming a final lead of the wire substantially in the plane in which the final turn of the coil is disposed.
- 22. The method defined in claim 20 wherein the gripping comprises:
receiving the initial lead in the gripper substantially radially of the axis.
- 23. The method defined in claim 22 wherein the gripping further comprises:
rotating the gripped initial lead so that it is substantially tangent to the turns of wire during the coiling.
- 24. The method defined in claim 23 wherein the gripping still further comprises:
further rotating the gripped initial lead so that it extends substantially radially out from the axis after the coiling.
- 25. The method defined in claim 20 wherein the positioning comprises:
moving the gripper relative to the receiver structure.
- 26. Apparatus for producing an undulating coil of wire for application to a core of a stator for a dynamo-electric machine comprising:
a gripper configured to hold an initial lead of the wire; receiver structure configured to receive the wire extending from the gripper and to form a coil of the wire having successive turns that are substantially disposed in respective planes that are substantially perpendicular to a central longitudinal axis of the coil and laterally spaced from one another along that axis; forming structure configured to produce undulations in the turns of wire in their respective planes while the turns are on the receiver structure, the undulations giving the turns portions that are substantially radial of the axis; and gripper positioning structure configured to position the gripper relative to the receiver structure so that the final lead is placed substantially in the plane in which an initial turn of the coil is disposed and is substantially aligned with one of the portions of the turns that are substantially radial of the axis.
- 27. A method for providing a stator of a dynamo-electric machine with an undulating wire coil comprising:
forming an undulating coil having a central axis, an initial lead extending from an initial wire turn, a final lead extending from a final wire turn, and a plurality of wire turns, each of said wire turns defining a plane of the coil, wherein said initial and final leads are disposed in substantially the same plane; and inserting the coil into the stator such that said initial and final leads are substantially equidistant from said central axis.
- 28. The method of claim 27 wherein said forming comprises winding wire into a polygonal coil using a polygonal wire support structure and deforming said sides to form undulations.
- 29. The method of claim 27 wherein said forming comprises:
providing wire from a wire source; securing said wire to a wire support structure; accumulating said plurality of wire turns on said support structure by rotating said support structure relative to said source; and winding said final wire turn, said final wire turn defining a final turn plane, onto said support structure, wherein said securing occurs substantially in said final turn plane.
- 30. The method of claim 27 wherein, when said final wire turn is a last deposited wire turn:
said final lead extends from said last deposited wire turn; and said forming comprises:
providing wire from a wire source; securing said wire to a wire support structure; accumulating said plurality of wire turns on said support structure by rotating said support structure relative to said source; and winding said last deposited wire turn, said last deposited wire turn defining a last deposited turn plane, onto said support structure, wherein said accumulating and said securing occur on opposite sides of said last deposited turn plane.
- 31. The method of claim 27 wherein said forming comprises:
providing wire from a wire source; securing said wire to a wire support structure having a plurality of forming members, at least one of said forming members having an initial lead aperture; accumulating wire turns on said support structure by rotating said support structure relative to said source; and winding a final wire turn onto said support structure, wherein said securing comprises passing a portion of said wire through said initial lead aperture.
- 32. The method of claim 31, wherein:
said accumulating further comprises forming a plurality of polygonal turns; and said method further comprises aligning said initial lead substantially parallel to a portion of said final wire turn.
- 33. The method of claim 32 wherein said aligning comprises:
rotating said initial lead about an axis substantially parallel to said central axis; and passing said initial lead out of said initial lead aperture in a plane substantially perpendicular to said central axis.
- 34. The method of claim 31 wherein said final wire turn defines a final turn plane, and said accumulating further comprises:
gripping said initial lead; depositing a first wire turn on said support structure; adding additional turns to said support structure; allowing said additional turns to urge said first turn plane away from said final turn plane along said forming members; and forming a transitional wire portion of said wire, said transitional wire portion extending between said initial lead and said initial turn, wherein said transitional wire portion spans the coil from said initial turn plane to said final turn plane.
- 35. Apparatus for forming an undulating wire coil for insertion in a stator of a dynamo-electric machine, said apparatus comprising:
a support structure configured to support wire from a source to gradually form the coil, the coil having a central axis, an initial lead, a final lead, and a plurality of wire turns, each of said wire turns defining a plane of the coil, wherein said initial and final leads are arranged in the same plane.
- 36. The apparatus of claim 35 further comprising;
a plurality of forming members; a gripper mounted on one of said plurality of forming members; a plurality of slanted sides, wherein:
each one of said plurality of slanted sides is disposed on one of said plurality of forming members; each of said slanted sides has a first end portion and a second end portion, said second end portion extending to a greater radial distance from said central axis than said first end portion; and wherein said plurality of slanted sides can support said plurality of wire turns.
- 37. The apparatus of claim 36 wherein said wire gripper is configured to rotatably grip said initial lead.
- 38. The apparatus of claim 37, wherein:
said support structure further comprises a forming member having an initial lead aperture, said initial lead aperture having an open side and being configured to receive said initial lead while said gripper grips said initial lead; and said open side permits said lead to rotate, in a plane perpendicular to said central axis, out of said initial lead aperture as said structure rotates to form said coil.
- 39. The apparatus of claim 36 further comprising a plurality of curved seats, wherein:
each one of said plurality of curved seats extends from one of said plurality of slanted sides; and said plurality of curved seats receives wire from said source for forming a wire turn.
- 40. The apparatus of claim 39 further comprising a plurality of apicies, wherein:
each one of said curved seats includes one of said apicies; said plurality of apicies defines a plane perpendicular to said central axis; and said gripper is mounted on a first side of said plane and said plurality of slanted sides is disposed on a second side of said plane.
- 41. The apparatus of claim 36 wherein said plurality of forming members substantially defines a polygon about which said wire can be wound into a polygonal coil and said support structure further comprises a second plurality of forming members, wherein said second plurality can be positioned external to said polygonal coil and can be moved inward against the coil to form undulations in the coil after said wire is wound on first of said pluralities of forming members.
- 42. A winding for a dynamo-electric machine comprising:
an undulated coil of wire having a plurality of turns, each of said turns defining a plane of said coil, wherein:
said coil further includes an initial lead and a final lead; and said initial lead and said final lead are arranged in the same plane.
- 43. The winding of claim 42, wherein:
said coil further comprises a final turn, said final turn defining a final turn plane, and an initial turn, said initial turn defining an initial turn plane and being joined to said initial lead by a transitional portion; and said transitional portion spans said coil between said initial turn plane and said final turn plane.
Parent Case Info
[0001] This application claims the benefit of provisional application No. 60/129,094, filed Apr. 13, 1999, which is hereby incorporated by reference herein in its entirety.
Provisional Applications (1)
|
Number |
Date |
Country |
|
60129094 |
Apr 1999 |
US |
Continuations (1)
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Number |
Date |
Country |
Parent |
09546195 |
Apr 2000 |
US |
Child |
10105006 |
Mar 2002 |
US |