Claims
- 1. Apparatus for forming a dynamo-electric machine component from a plurality of separate portions of such a component, comprising:
at least one winder that dispenses wire for winding onto the separate portions as wire coils; and a plurality of holding members that each hold a respective one of the separate portions while the wire coils are wound.
- 2. The apparatus defined in claim 1 wherein the holding members are configured to press the separate portions together to form the dynamo-electric machine component.
- 3. The apparatus defined in claim 1 wherein the holding members include a plurality of grippers each configured to hold a separate one of the portions during wire winding.
- 4. The apparatus defined in claim 1 wherein the plurality of the holding members are arranged in a circle and wherein each of the holding members rotates inwardly towards the center of the circle after the wire coils have been wound.
- 5. The apparatus defined in claim 1 wherein the plurality of the holding members are arranged in a circle and wherein each of the holding members rotates inwardly towards the center of the circle after the wire coils have been wound and converges toward the center of the circle to gather the portions together to form the dynamo-electric motor component.
- 6. The apparatus defined in claim 1 wherein the plurality of the holding members are arranged in a circle and wherein each of the holding members rotates inwardly towards the center of the circle after the wire coils have been wound and converges toward the center of the circle to press fit the portions together to form the dynamo-electric motor component.
- 7. The apparatus defined in claim 1 further comprising a single holster into which the separate portions are placed before the wire is wound.
- 8. The apparatus defined in claim 1 further comprising a linear holster into which the portions are placed before the wire is wound.
- 9. The apparatus defined in claim 1 further comprising an insulating holster into which the portions are placed before the wire is wound.
- 10. The apparatus defined in claim 1 further comprising an insulating holster into which the portions are placed before the wire is wound, wherein the holster is subjected to a shearing operation to separate the portions in the holster from each other.
- 11. The apparatus defined in claim 1 further comprising a plurality of winders that simultaneously wind wire onto at least some of the separate portions as wire coils.
- 12. The apparatus defined in claim 1 wherein the holding members each have a shelf on which a respective one of the portions rests during winding.
- 13. The apparatus defined in claim 1 wherein the holding members each have a shelf on which a respective one of the portions rests during winding and grippers for holding the portions during winding.
- 14. The apparatus defined in claim 1 further comprising a rotating table having multiple stations at which the portions are assembled into the dynamo-electric motor component.
- 15. The apparatus defined in claim 1 further comprising a rotating table having multiple stations at which the portions are assembled into the dynamo-electric motor component, wherein the wire coils are wound at a first of the stations and wherein the portions are turned towards each other at another of the stations.
- 16. The apparatus defined in claim 1 further comprising a pusher for press-fitting the portions into a binding ring after the wire coils have been wound.
- 17. The apparatus defined in claim 1 further comprising:
a gripper configured to hold a binding ring; and a pusher for press-fitting the portions into the binding ring after the wire coils have been wound.
- 18. The apparatus defined in claim 1 wherein the holding members each have a shelf on which a respective one of the portions rests during winding, further comprising:
a gripper configured to hold a binding ring; and a pusher for press-fitting the portions into the binding ring after the wire coils have been wound, wherein at least a portion of the pusher passes through a recess in each shelf.
- 19. The apparatus defined in claim 1 further comprising:
a rotating table having multiple stations at which the portions are assembled to form the dynamo-electric motor component; a conveyor; and a gripper for moving the components between the rotating table and the conveyor.
- 20. The apparatus defined in claim 1 wherein the winder is a rotating flyer, further comprising structures for moving the rotating flyer so that it follows a non-circular path when winding wire.
- 21. The apparatus defined in claim 1 wherein the winder is a rotating flyer, further comprising a carriage for translating the rotating flyer so that the trajectory of the rotating flyer is nearly elliptical during winding.
- 22. The apparatus defined in claim 1 wherein the winder is a rotating flyer, further comprising a rotating shaft and a translating carriage for moving the flyer in a nearly elliptical path when winding the wire coils.
- 23. A method for forming components for dynamo-electric machines comprising:
winding wire on a plurality of separate portions of a dynamo-electric machine component to form wire coils on each separate portion; and joining the separate dynamo-electric machine component portions together after winding the wire coils to form the dynamo-electric machine component.
- 24. The method defined in claim 23 further comprising pressing the separate portions together after coil winding to form the dynamo-electric machine component.
- 25. The method defined in claim 23 further comprising holding each separate one of the portions during winding using a respective one of a plurality of grippers.
- 26. The method defined in claim 23 further comprising:
using a plurality of holding members to arrange the plurality of portions in a circle; and rotating the holding members and portions inwardly towards the center of the circle after the wire coils have been wound.
- 27. The method defined in claim 23 further comprising:
using a plurality of holding members to arrange the plurality of portions in a circle; rotating the holding members and portions inwardly towards the center of the circle after the wire coils have been wound; and causing the holding members and portions to converge toward the center of the circle after the portions have been rotated inwardly to gather the portions together to form the dynamo-electric motor component.
- 28. The method defined in claim 23 further comprising:
using a plurality of holding members to arrange the plurality of portions in a circle; rotating the holding members and portions inwardly towards the center of the circle after the wire coils have been wound; and causing the holding members and portions to converge toward the center of the circle to press fit the portions together to form the dynamo-electric motor component.
- 29. The method defined in claim 23 further comprising placing the separate portions into a single holster before the wire is wound.
- 30. The method defined in claim 23 further comprising placing the separate portions into a linear holster before the wire is wound.
- 31. The method defined in claim 23 further comprising placing the separate portions into an insulating holster before the wire is wound.
- 32. The method defined in claim 23 further comprising:
placing the separate portions into an insulating holster before the wire is wound; and using a shearing operation to separate the portions in the holster from each other.
- 33. The method defined in claim 23 further comprising using a plurality of winders to simultaneously wind wire onto at least some of the separate portions as wire coils.
- 34. The method defined in claim 23 further comprising holding the portions during winding using holding members that each have a shelf on which a respective one of the portions rests.
- 35. The method defined in claim 23 further comprising holding the portions during winding using holding members that each have grippers and a shelf on which a respective one of the portions rests.
- 36. The method defined in claim 23 further comprising using a rotating table having multiple stations to assemble the portions into the dynamo-electric motor component.
- 37. The method defined in claim 23 wherein a rotating table having multiple stations is used to assemble the portions into the dynamo-electric motor component, the method further comprising:
winding the wire coils at a first of the stations; and turning the portions towards each other at another of the stations.
- 38. The method defined in claim 23 further comprising using a pusher to press-fit the portions into a binding ring after the wire coils have been wound.
- 39. The method defined in claim 22 further comprising:
holding a binding ring relative to the joined dynamo-electric machine portions; and using a pusher to press-fit the joined dynamo-electric machine portions into the binding ring.
- 40. The method defined in claim 23 further comprising:
holding the portions during winding using holding members that each have a shelf on which a respective one of the portions rests; holding a binding ring relative to the joined dynamo-electric machine portions; and using a pusher to press-fit the joined dynamo-electric machine portions into the binding ring, wherein at least a portion of the pusher passes through a recess in each shelf.
- 41. The method defined in claim 23 further comprising:
using a rotating table having multiple stations to assemble the portions into the dynamo-electric motor component; using a gripper to move the component between the rotating table and a conveyor.
- 42. The method defined in claim 23 further comprising:
using a rotating flyer nozzle to wind the wire; and moving the nozzle so that it follows a non-circular path when winding the wire.
- 43. The method defined in claim 23 further comprising:
using a rotating flyer to wind the wire; and using a carriage to translate the rotating flyer during winding so that the trajectory of the rotating flyer is nearly elliptical during winding.
- 44. The method defined in claim 23 further comprising using a rotating shaft and a translating carriage to move a rotating flyer in a nearly elliptical path to wind the wire coils.
- 45. Apparatus for forming a dynamo-electric machine component from a plurality of separate portions, comprising:
a plurality of wire dispensing structures; a plurality of holding members each of which holds a respective one of the separate portions while wire coils are wound onto that separate portion from a respective one of the wire dispensing structures; and a plurality of movable support structures on which the holding members are mounted, wherein the movable support structures are moved to join each of the portions together to form the component while each portion is being held by the same holding member that was used during winding of the wire coils onto that portion.
- 46. The apparatus defined in claim 45 further comprising a plurality of hooks, each of which is associated with a respective one of the holding members for positioning the wire before and after that holding member is wound.
- 47. The apparatus defined in claim 45 further comprising a rotating member for rotating each movable support member as wire is dispensed during winding.
- 48. The apparatus defined in claim 45 wherein the movable support member comprises a linear translation stage for moving the portions together when forming the component.
- 49. The apparatus defined in claim 45 wherein the wire dispensing structures comprise nozzles that translate during winding to evenly distribute the wire.
- 50. The apparatus defined in claim 45 wherein the holding structures include anchoring structures for anchoring wire.
- 51. The apparatus defined in claim 45 wherein the moveable support structures include brakes for arresting rotational motion of the moveable support structures.
- 52. The apparatus defined in claim 45 wherein the holding members each have a shelf on which a respective one of the portions rests during winding.
- 53. A method for forming a component for a dynamo-electric machine from separate portions of such a component comprising:
winding wire coils onto each separate portion from a plurality of respective wire dispensing structures; holding the separate portions using a plurality of respective holding members while the wire coils are wound; and using a plurality of movable support structures on which the holding members are mounted to join each of the portions together to form the component while each portion is being held by the same holding member that was used during winding of the wire coils onto that portion.
- 54. The method defined in claim 53 further comprising positioning the wire before and after each portion is wound using a plurality of hooks each of which is associated with a respective one of the holding members.
- 55. The method defined in claim 53 further comprising rotating each movable support member as wire is dispensed during winding.
- 56. The method defined in claim 53 further comprising using a linear translation stage to move the portions together when forming the component.
- 57. The method defined in claim 53 wherein the wire dispensing structures comprise nozzles, the method further comprising translating the nozzles during winding to evenly distribute the wire on the portions.
- 58. The method defined in claim 53 further comprising using anchoring structures on the holding members to anchor the wire.
- 59. The method defined in claim 53 further comprising arresting rotational motion of the moveable support structures using brakes.
- 60. The method defined in claim 53 wherein the holding members each have a shelf, the method further comprising resting the portions on the shelves during winding. trajectory of the nozzle with respect to the pole during winding is non-circular.
- 62. (New) The apparatus defined in claim 61 wherein the pole is elongated in one dimension, wherein one end of the elongation is a first end and the other end of the elongation is a second end, wherein the arm is configured to rotate the nozzle when the nozzle is near the first and the second ends of the arm during winding, and wherein the carriage is configured to provide relative motion between the arm and the pole when the nozzle is between the first and the second ends of the arm.
- 63. (New) The apparatus defined in claim 61 wherein the trajectory of the nozzle with respect to the pole during winding is nearly elliptical.
- 64. (New) The apparatus defined in claim 61 further comprising a rotatable shaft configured to translate the carriage.
- 65. (New) The apparatus defined in claim 64 wherein the rotatable shaft is provided with an external thread for engaging a female thread present in the carriage and wherein when the rotatable shaft is rotated, the carriage is translated due to the engagement of the external thread and the female thread.
- 66. (New) The apparatus defined in claim 61 wherein the carriage is configured to translate the arm to provide the relative motion between the arm and the pole during winding.
- 67. (New) The apparatus defined in claim 66 further comprising:
a hollow rotatable shaft that is coupled to the arm, wherein an end of the hollow shaft opposite of the arm is provided with key portions; a first gear wheel that is configured to receive the key portions on the end of the hollow shaft so that the first gear wheel and the hollow rotatable shaft rotate together; a second rotatable shaft that is provided with key portions; and a second gear wheel that is configured to receive the key portions on the second rotatable shaft so that the second gear wheel and the second rotatable shaft rotate together, wherein:
the first and the second gear wheels are provided with external teeth; the external teeth of the first and the second gear wheels are configured to engage when the first gear wheel is substantially perpendicular to the second gear wheel; and the second gear wheel is configured to translate with respect to the second rotatable shaft while remaining engaged with the first gear wheel when the carriage translates.
- 68. (New) The apparatus defined in claim 67 wherein the second rotatable shaft is powered to provide rotation to the second gear wheel, which is configured to provide rotation to the first gear wheel, which is configured to provide rotation to the hollow rotatable shaft and the arm.
- 69. (New) The apparatus defined in claim 61 wherein the nozzle comprises a pulley wheel having a groove through which wire being dispensed runs to reach the surface of the pole and wherein the groove of the pulley wheel maintains a substantially constant orientation in relation to the surface of the pole during winding.
- 70. (New) A method for winding coils of wire around poles of dynamo-electric machine components, comprising:
using a rotating flyer to move a nozzle that dispenses wire onto a pole of a dynamo-electric machine component during winding; and using a carriage to provide relative motion between the rotating flyer and the pole during winding, wherein the trajectory of the nozzle with respect to the pole during winding is non-circular.
- 71. (New) The method defined in claim 70 wherein the pole is elongated in one dimension and wherein one end of the elongation is a first end and the other end of the elongation is a second end, the method further comprising:
rotating the flyer to move the nozzle when the nozzle is near the first and the second ends of the arm during winding; and using the carriage to provide relative motion between the rotating flyer and the pole when the nozzle is between the first and the second ends of the arm.
- 72. (New) The method defined in claim 70 wherein the trajectory of the nozzle with respect to the pole during winding is nearly elliptical.
- 73. (New) The method defined in claim 70 further comprising using a rotatable shaft to translate the carriage.
- 74. (New) The method defined in claim 73 wherein the rotatable shaft is provided with an external thread for engaging a female thread present in the carriage, the method further comprising providing translation of the carriage by rotating the rotatable shaft, wherein when the rotatable shaft is rotated, the carriage is translated due to the engagement of the external thread and the female thread.
- 75. (New) The method defined in claim 70 wherein the carriage is used to translate the rotating flyer to provide the relative motion between the rotating flyer and the pole during winding.
- 76. (New) The method defined in claim 75 wherein:
a hollow rotatable shaft is coupled to the nozzle; an end of the hollow shaft opposite of the nozzle is provided with key portions; a first gear wheel is configured to receive the key portions on the end of the hollow shaft so that the first gear wheel and the hollow rotatable shaft rotate together; a second rotatable shaft is provided with key portions; a second gear wheel is configured to receive the key portions on the second rotatable shaft so that the second gear wheel and the second rotatable shaft rotate together; the first and the second gear wheels are provided with external teeth; and the external teeth of the first and the second gear wheels are configured to engage when the first gear wheel is substantially perpendicular to the second gear wheel, the method further comprising:
translating the second gear wheel with respect to the second rotatable shaft while the second gear wheel remains engaged with the first gear wheel when the carriage translates.
- 77. (New) The method defined in claim 76 further comprising powering the second rotatable shaft to provide rotation to the second gear wheel, which is configured to provide rotation to the first gear wheel, which is configured to provide rotation to the hollow rotatable shaft and the nozzle.
- 78. (New) The method defined in claim 70 wherein the nozzle comprises a pulley wheel having a groove through which wire being dispensed runs to reach the surface of the pole, the method further comprising maintaining a substantially constant orientation of the groove of the pulley wheel in relation to the surface of the pole during winding.
Parent Case Info
[0001] This application claims the benefit of U.S. provisional application No. 60/163,363, filed Nov. 3, 1999, No. 60/186,963, filed Mar. 6, 2000, and No. 60/203,756, filed May 12, 2000, which are hereby incorporated by reference herein in their entireties.
Provisional Applications (3)
|
Number |
Date |
Country |
|
60163363 |
Nov 1999 |
US |
|
60186963 |
Mar 2000 |
US |
|
60203756 |
May 2000 |
US |
Continuations (1)
|
Number |
Date |
Country |
Parent |
09697675 |
Oct 2000 |
US |
Child |
10382077 |
Mar 2003 |
US |