CA1152300A - Field winding for dynamoelectric machine and method - Google Patents
Field winding for dynamoelectric machine and methodInfo
- Publication number
- CA1152300A CA1152300A CA000397548A CA397548A CA1152300A CA 1152300 A CA1152300 A CA 1152300A CA 000397548 A CA000397548 A CA 000397548A CA 397548 A CA397548 A CA 397548A CA 1152300 A CA1152300 A CA 1152300A
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- Canada
- Prior art keywords
- mandrel
- strapping
- coils
- core pieces
- winding
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Abstract
ABSTRACT OF THE DISCLOSURE A starter motor field winding comprises an uninterruptedly continuous conductor wound to encircle a plurality of core elements. The conductor comprises strapping edge wound about cores to form coils. The strapping between coils is edge bent to form connections from one coil to the next. The cores about which the coils are formed may be affixed to an arbor or may be removably mounted on the arbor and thereafter assembled to a stator ring to form a completed stator assembly.
Description
3~)~
The pres~nt ~lic~ti~n is a d3yisional o~ appli~ation ~e~ial No. Z88,~12 f~led Octobe~ 13, ~77O
The p~esent ~nVention xelates to dynamoelectric field mem~erS such as ma~ be produced by windinyr to a field winding ~nd to m~th~ds and apparatus for producing field windings and field assel~lies.
The pres~nt ~lic~ti~n is a d3yisional o~ appli~ation ~e~ial No. Z88,~12 f~led Octobe~ 13, ~77O
The p~esent ~nVention xelates to dynamoelectric field mem~erS such as ma~ be produced by windinyr to a field winding ~nd to m~th~ds and apparatus for producing field windings and field assel~lies.
2. Prior ~rt It is ~nown in the prior art to wind portions such as individual coils of a field member by the edge winding of strapping ~hile such edge wo~md coils have been suggested for use in numerous applications, it has not heretofore been the practice to produce complete field members having plural coils by a continuous winding produced from an uninterruptedly contin-uous length of conductive strapping, portions of which may be edge wound.
Summary of *he Invention In the present invention, field members of the type used, for example, in the production of automobile starter motors, are wound from start to finish with an uninterruptedly continuous length of conductive wire or strapping which preferably has an insulating coating. In one embodiment disclosed, the winding comprises interconnected coils, and the apparatus for accom-plishing the winding includes a mandrel having core pieces, on for each coil, the strapping being edge wound successively about each of the core pieces. The portions of the strapping con-necting between adjacent coils are edge bent and each extends from the radially outermost convolution of one coil to the radially innermost convolution of the next adjacent coil. In a modification, the cores upon which the strapping is wound are detachable from the mandrel and transferable with the strapping to provide pole pieces for a dynamoelectric field member. In both embodiments, the mandrel is constructed so that the strap-ping may be supported in position to be guided upon the core -- 1 -- .
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pieces and the man~rel moved rotationally abollt an axis perpen-~ dicular to its major axis for ca-lsing coils to be formed thereon and rotationally about its major axis for forming co~necting portions between coil5.
When using a n~andrel having detachable core pieces, removable supports are provided for temporarily holding the core pieces ~hile the winding is being made. After the winding is completed, the supports are removed, the coil shapes are formed as desired, and the mandrel with the removable core pieces is inserted into a stator housing or ring, The core pieces are then connected to the ring by threaded bolts or the li]ce and the man-drel removed from the ring and the winding and pole pieces are thereby assembled to the ring.
Brief Doscri~tion of the Drawings Figure l is a perspective view illustrating a starter motor field winding known in the prior art.
Figure 2 is a perspective view illustrating a starter motor field winding accomplished in accordance with the present in-vention and having electrical characteristics comparable to th0 winding of Figure lo Figure 3 is a perspective view illustrating a mandrel upon which the winding of ~igure Z has been ~ormed by edge l~inding.
~ igure 4 is a section view taken diametrically across the stator for an automotive starter motor utili~ing the field member illustrated in Figure ~
Figure 5 is an exploded perspective view illustrating a mandrel with detachable core pieces and apparatus used during the winding of a field winding on the detachable core pieces.
Figure 6 is a section view taken diametrically across the mandrel and associated parts of Figure 5 after the field winding has been wound.
Figure 7 is a section view taken diametrically across a stator for an automotive starter motor and a mandrel of the t~-pe shown in ~igures 5 and 6 and lllustrates one step in the ass~mbly of the field winding wherein the core piece~ are used as the field pole pieces. ~ ~
Figure 8 is a perspective view illustrating in simplified form apparatus for use with a mandrel for windi~g the field winding of this invention. In Figure 8 the maIldrel illustrated is the mandrel sho~7n in ~i~lres 5 and 6.
Figure 9 is an illustration of a forming step subsequent to the winding of the coils.
LO Fi~lre 10 is a perspective ~ie~ illustrating steps in the assembly of the coils to the stator housing or ring.
Figure 11 is a perspective view similar to ~igure 10 and illustrating a further step.
Detailed Description of the Preferred Embodiments Referring to the drawings~ reference numeral 10 in Figure 1 designates a stato~ winding of the type commonly used in starter motors for automobiles. The conductive wire 11 used to fabri-cate the ~inding is commonly referred to as strapping. To simplify this prior art illustration, insulation interleaved ~0 with the strapping has been omitted. Such strapping comprises a thin~ generally continuous wire strap having a thickness substantially less than the width of its major sides. When such strapping is wound by bending the strapping about an axis parallel to the major sides thereof 9 the resultant bend or winding is described as flat bent or flat wound. When the strap-ping is wound by bending about an axis perpendicular to the major sides of the strapping, the resultant winding is referred to as edge bent or edge wound~ The winding of Figure 1~ having been accomplished generaLly by bending the strapping about axes ~0 parallel to the major sides of the strappingt is therefore in the nature of a flat wound winding.
The winding 10 has 2 first terminal 12 and a second terminal 14 which are adapted for connection to a battery or
Summary of *he Invention In the present invention, field members of the type used, for example, in the production of automobile starter motors, are wound from start to finish with an uninterruptedly continuous length of conductive wire or strapping which preferably has an insulating coating. In one embodiment disclosed, the winding comprises interconnected coils, and the apparatus for accom-plishing the winding includes a mandrel having core pieces, on for each coil, the strapping being edge wound successively about each of the core pieces. The portions of the strapping con-necting between adjacent coils are edge bent and each extends from the radially outermost convolution of one coil to the radially innermost convolution of the next adjacent coil. In a modification, the cores upon which the strapping is wound are detachable from the mandrel and transferable with the strapping to provide pole pieces for a dynamoelectric field member. In both embodiments, the mandrel is constructed so that the strap-ping may be supported in position to be guided upon the core -- 1 -- .
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pieces and the man~rel moved rotationally abollt an axis perpen-~ dicular to its major axis for ca-lsing coils to be formed thereon and rotationally about its major axis for forming co~necting portions between coil5.
When using a n~andrel having detachable core pieces, removable supports are provided for temporarily holding the core pieces ~hile the winding is being made. After the winding is completed, the supports are removed, the coil shapes are formed as desired, and the mandrel with the removable core pieces is inserted into a stator housing or ring, The core pieces are then connected to the ring by threaded bolts or the li]ce and the man-drel removed from the ring and the winding and pole pieces are thereby assembled to the ring.
Brief Doscri~tion of the Drawings Figure l is a perspective view illustrating a starter motor field winding known in the prior art.
Figure 2 is a perspective view illustrating a starter motor field winding accomplished in accordance with the present in-vention and having electrical characteristics comparable to th0 winding of Figure lo Figure 3 is a perspective view illustrating a mandrel upon which the winding of ~igure Z has been ~ormed by edge l~inding.
~ igure 4 is a section view taken diametrically across the stator for an automotive starter motor utili~ing the field member illustrated in Figure ~
Figure 5 is an exploded perspective view illustrating a mandrel with detachable core pieces and apparatus used during the winding of a field winding on the detachable core pieces.
Figure 6 is a section view taken diametrically across the mandrel and associated parts of Figure 5 after the field winding has been wound.
Figure 7 is a section view taken diametrically across a stator for an automotive starter motor and a mandrel of the t~-pe shown in ~igures 5 and 6 and lllustrates one step in the ass~mbly of the field winding wherein the core piece~ are used as the field pole pieces. ~ ~
Figure 8 is a perspective view illustrating in simplified form apparatus for use with a mandrel for windi~g the field winding of this invention. In Figure 8 the maIldrel illustrated is the mandrel sho~7n in ~i~lres 5 and 6.
Figure 9 is an illustration of a forming step subsequent to the winding of the coils.
LO Fi~lre 10 is a perspective ~ie~ illustrating steps in the assembly of the coils to the stator housing or ring.
Figure 11 is a perspective view similar to ~igure 10 and illustrating a further step.
Detailed Description of the Preferred Embodiments Referring to the drawings~ reference numeral 10 in Figure 1 designates a stato~ winding of the type commonly used in starter motors for automobiles. The conductive wire 11 used to fabri-cate the ~inding is commonly referred to as strapping. To simplify this prior art illustration, insulation interleaved ~0 with the strapping has been omitted. Such strapping comprises a thin~ generally continuous wire strap having a thickness substantially less than the width of its major sides. When such strapping is wound by bending the strapping about an axis parallel to the major sides thereof 9 the resultant bend or winding is described as flat bent or flat wound. When the strap-ping is wound by bending about an axis perpendicular to the major sides of the strapping, the resultant winding is referred to as edge bent or edge wound~ The winding of Figure 1~ having been accomplished generaLly by bending the strapping about axes ~0 parallel to the major sides of the strappingt is therefore in the nature of a flat wound winding.
The winding 10 has 2 first terminal 12 and a second terminal 14 which are adapted for connection to a battery or
3~0 other source (not shown) ~hen mounted into the housing or yolce of an electric motor. The first terminal 12 is at the end of a start end or leg 16 of a first coil 18. Coil lg is flat wound and convoluted out~ardly from the innermost convolution thereof to the outermost convolution thereof, At the comme~cement of the ~inding of the coil 18, its start end 16 is first flat bent and then edge bent. At the end of the ~inding the finish end or leg is rotated or twisted approximately 90 about its central a.~is to form an up~ardly extending twisted termination 20 to which is soldered a start end or leg 22 of a second coil 24.
The leg 22 is edge bent downwardly and by combined edge and flat bends rotated approximately 90 about its own axis to commence the second coil 24, which is flat wou~d outwardly from the inner-most to the outermost convolution. Its outermost convolution is twisted to form a termination 26 that is brazed or soldered at 28 to a termination 30 of a third coil 32. Commencing with a start end or leg 34 which is bent downwardly and then both edge and flat bent to accomplish a 90 rotation about its own axis, the third coil 32 is flat wound outwardly from the innermost to the outermost convolution. The outermost convolution is both bent and twisted to form the termination 30~ The start leg of the third coil 32 is soldered or brazed to the start end or leg 36 of a fourth coil 38. The coil 38 is also flat wound and con-voluted outwardly from the innermost convolution thereof to the outerlnost convolution thereof. At the commencement of the wind-ing of the fourth coil 38, its start end 36 is first flat bent and then edge bent and at the end of the winding the final con volution includes an upwardly extending leg 40 which is twisted approximately 90 about it~ center axis to form the termination 14.
As previously indicated~ the winding 10 i5 representative of prior art. The winding is accomplished by individually winding the coils 18, 24, 32 and 38 Usillg four separ~te ~inding machines and then soldering or brazing the terminal ends of the coils in the manner illustr~ted in Figure 1 Col;sidering current flow throu~h the coils and assuming a positi~e potential applied to the first terminal 12 and ground applied to the second terrninal 14, a positive current will flow counterclockwise about the first coil 18, clockwise about the second coil 24, counter-clockwise about the third coil 32, and clocl~ise about the four~h !.
coil 38 if the observer is located outside the periphery of the winding. It is noteworthy that the sections of strapping which are used for the winding form four separate coils wherein each coil required at least one and sollletimes two 90 twists of the strapping about its own axis for completion of the coil, edge bending as well as flat bending of the strapping, and brazed or soldered connections were required to interconnect the coils. ~ ;
Figure 2 illustrates a winding 48 rhich is co~lparable in terms of electrical characteristics to the prior winding of Figure 1 but which~ in accordance ~ith the present invention~
has been accomplished with an uninterruptedly continuous length of insulated strapping 11. The winding is accomplished without soldering or brazing and t~Yisting or rotation of the strapping about its own axis as is required on numerous occasions to accomplish the prior art winding~ A particularly notable feature is that the winding of Figure 2 is an edge wound winding as opposed to the flat wound winding of Figure 1.
Progressing through the generally circular winding of Figure 2~ the winding commences with a start end or terminal 50 ; From the terminal 50 the strapping proceeds horizontally to a flat bend~ from which the strapping proceeds downwardly along a straight section of a convolution 52~ ~hich is edge wound to form a coil 54. It can be noted that the successive convolutions of the coil 54 proceed axially outwardly as they are wound one adjacent the other. Thus the coi7 54 increases in axial ~23~
thickness as successive convolutions are added to the coil.
Comparing this feature to the flat wound coils of~Figure 1~ it should be noted that the coils of ~igure 1 each have a sub-stantially constant axial thickness with respect to an axis surrounded by the coil~ but each of the coils of the winding 10 has an increasing radial thickness as the number of convolutions in each such coil increases.
After winding ~f the coil 54~ the finishing portion of the wire is edge turned to form a starting portion or leg 56 which continues uninterruptedly into the first con~olution 58 of an edge wound coil 60 which is ~ound axially outwardly by edge wind-ing until a final convolution or finishing portion 62 i5 wound.
After completion of the convolution 62, the strapping i9 continued without interruption along a starting portion by a leg 64 which continues without interruption to the commencement of the first convolut'ion 66 of an edge wound coil 68. It will be noted that the leg 64 i5 bent do~nwardly so that it does not span over the third coil 68,- whereas the afore~entioned leg 56 spans from the first coil 54 over the second coil 60. The coil 68 again increases outwardly in axial thic~ness as successive convolutions thereof are wound.
After winding of the coil 68, its finishing portion continueC ~ithout interruption along an arm 70 and without interruption to form the radially innermost starting portion or con~olution 72 of an edge ~ound coil 74 where~ again~ the coil progresses axially outwardly in thickness to the final con-volutlon thereof rhich is edge turned to form a finish portion or terminal 76. The resultant winding 48 is characterized by a generally cylindrical shape in which the coils 54~ 60~ 68 and 74 are laterally spaced apart and the ~tart and finish portions which interconnect the coils are disposed at the upper axial extreme of the winding as appears in Figure 2.
In ~ddition to the use of edge ~iinding as opposed to the ~Z3~V
flat winding in Fi~lre l and the use of a continuous strapping in the winding of Fi~lre 2, another notable feature of the windin~ of Figure 2 is that all coils are wound outwardly from an axially innermost convolution to an axially outermost convo-lution. Further~ the winding of Figure 2 is gener~lly circular whcn viewed fron1 either end thereof and the major surfaces of the strapping are parallel to the longitudinal axis of the wind-ing throughout all of the coils and the col~ection~ therebet~.een.
Accordingly~ the entire length of strapping used to form the winding 48 has its ~ajor surfaces lying essentially along the periphery of the imaginary cylinder which the coils form. After completion of the winding 48~ the flat bent part of the start portion or terminal 50 could be either straightened or cut off.
As an alternative, the winding may be accomplished ~Yithout the flat bend in the start portion 50. In either event, the winding 48 can be inserted directly into a stator housing or ring and suitable terminal connections made for electrical connection to the terminals 50 and 76. No solder or brazed connections are required in the winding 48, and all connected coils are inter-connected by edge bent strapping portions having major faceslying substantiall~ in the same imaginary cylinder as the major faces of the coils.
Considering the electrical characteristics of the winding 48, one can consider that the starting terminal 50 is connected to a source of positive ~oltage~ and that the finishing ter~inal 76 is connected to ground. ~ith such connections~ a positive current as ~seen" by an observsr outside the winding will flow counterclockwise in the coil 54, clockwise in the coil 60, count~rclockwise in the coil 68 and clockwise in the coil 74 to ground at the terminal 76. The electrical result will be basically the sam~ as for the prior art coil illustrated in Figure l.
Figure 3 illustrates the general manner in which a winding o such as dcscribed in reference to Fi.gure 2 can be accomplished on a malldrel~ generally designated 80. The mandrel 80 com-prises a generally cylindrical body or arbor having four ou-t-.ardly projecting and generally rectang~llar cores 82~ 84~ 86 and 88 bounded by respective side walls or shoulders 82a, 84a, 86a and 88a. Only the cores 82 and 88 and their side ~alls 82a and 88a appear in the drawings~
A piece of strapping 11 is secured at one end thereof~
forming the start end 50 of the winding 48, to one end of the ~andrel 80 by means of a clamp 90 secured by a fastener 92 The strapping is so secured to the mandrel 80 that, ~ith a single 90 degree bend~ the strapping can be flat bent to commence the innermost convolution 52 of the coil 54 which is ~ound edgewise about the shoulder 82a to produce cou~ter-clockwise wollnd coil 54. It may be noted that other means~
not shown~ could ~e pro~ided to grip the start end S such that the flat bend would be unnecessaryO
The strapping which forms the outermost convolution of the coil 54 is then turned edgewise, extended circumferentially adjacent the upper shoulder, not appearing in Figure 3, of the mandrel core 84, a-lso not appearing in Figure 3, edge bent do~nwardly and then wound edgewise in the clockwise direction about shoulder 84a to produce the coil 60 appearing in Figure 2.
Because of the edgewise turning of the strapping after the winding of the coil 54, it will be noted that the edge of the strapping engaging the shoulder 82a is the opposite edge of the strapping which engages the shoulder of the core piece 84. A
study Df Figures 2 and 3 will reveal that the coils wound in a clockwise direction have the same strapping edges confronting and engaging the core pieces and those wound in a counter-clockwise direction have opposite edges confronting and engaging the core pieces.
The strapping is then continued from the coil 60 peripher-_ g~
ally about the mandrel 80, cdge bent do~mwardly adjacent theleft hand side of the core 86, not appearing in ~figure 3~ and then edge wound about such core to accomplish the counter-clock~ise ~inding of the coil 68 which appears in Figure 2.
The strapping is then continued from the coil 68 and along the upper shoulder 88a, as appears in Figure 3, and edge wound clockwise about the core 88 to accomplish the coil 74. The last convolution of the coil 74 is permitted to extend vertically up~ardly as appears in ~igure 3 to form the terminal 76 ~hich also appears in Figure 2.
Figure 4 schematically illustrates a starter motor field assembly using the winding of ~igure 3. After release of the cl~mp 90 illustrated in Figure 3, the ~inding is pulled outwardly and away from the mandrel 80~ returned and formed as needed to a generally circular shape~ and inserted into a hollow~ cylin-drical stator housing or ring 94. Four indiYidual pole pieces identified by the reference numeral 96, and each preferably surrsunded by insulating sleeves 97~ are then fastened in a circular array to the stator ring at 90 degree circumferential angles by means of suitable fasteners 98 threaded into the pole pieces 96 so that the pole pieces 96 project inwardly of the ring 94. In such assembly, both the axially and circumferentially extending side walls of the pole pieces 96 are confronted by the radially irlnermost edge surfaces of the strapping but insulated from the strapping by the sleeves 97. Only the axially extending side walls~ designated 99~ are illustrated in the section of ~igure 4 As is conventional, these are out~Tardly flanged or flared to retain the coils thereon. In the illustra-tion of Figure 4~ there is a substantial spacing between the curved inside surface of the ring 94 and the radially outermost surfaces of the coils 549 60, 68 and 74. In practice~ the radial dimensions of the coils 54, 60~ 68 and 74 relative to the radial length of the pole pieces 96 is preferably s~ch that _ g _ 3~(~
the flared side walls 99 compress the several coils 549 Go, G8 and 74 ag~inst the incide surface of the stator ri~n~ so that the coils are snugly retained on the ring. Suitable terminal connections~ not sho-~ because well ]~lo~ to those skilled in the art~ are then provided for connection of the start and finish portions 50 and 76 appearing in Figure 2 to an electrical source.
The field assembly is thus seen to include a one-piece wind-ing comprising a single lengtll of conductive strapping edge wo~d into the laterally spaced ~nd connected coils 54, 60, 68 and 74 9 one coil surrounding each of the pole pieces 96. Since the strapping forming the coils is coated with insulating material~
there is electrically insulating means between adjacent convo-lutions of each coil. As possible alternati~es, insulation could be formed between the coil convolutions after the winding is completed, or insulating strips could be wowld with the strapping. When assembled in the ring 94, the adjacently located colls are connected by ed~e bent portions of strapping integral with the coils and extending from a finishing~
radially outermost portion of one coil to a starting, radially innermost portion of the adjacently located coil. As is obvious from an inspection of the drawings~ the ~ajor sides of the coils ard al~o the connecting strapping portions between them are substantially concentric with the inside surface of the ring 94. The same would be true of the connection between coils 54 and 74 if either one or both of their adjacent termina_ tion legs 50 and 76 are edge bent to produce the connectionO
Figures 5, 6 and 7 illustrate a modification wherein a - mandrel, generally designated 300) comprises an assembly of parts including core or pole pieces about which coils are edge wound. Upon completion of the winding, the core or pole pieces are separated from the assembly along with the winding for inser- j tion into a stator yoke wherein the core pieces are fastened to the stator yoke so as to function as stator pole pieces.
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The mandrel 300 can be seen to comprise a generally cylin~
drical body or arbor 301 having radially outwardly e~tending ~e~s 302 along the length thereof. The radially extending surfaces of the keys 302 are identified by the reference characters 304 and 306~ respectively. The keys 302 are flanked by recessed~ axial-ly extending, arcuate surfaces 308, there being four such arcuate surfaces 308, each bounded by a pair of radial surfaces 304 and 306. The keys 302 are designed to slidably receive bet~een them core pieces 310, there being one core or pole piece 310 for each arcuate surface 3080 Thus for a .inding having four coils~ there are four core pieces 310 as illustrated.
Each core or pole piece 310 comprises a generally rectangu-lar body member 312 having arcuate flanges 314 projecting from each axially extending side walt and having a convexly curved outer surface 316 and a concavely curved inner surface 318. The core pieces 310 are shaped to become the pole pieces for the field assembly as will be described belo~t and may be shaped identically to pole pieces presently in use. _ As best sho~.~ in Eigure 6, the keys 302 a~d the arcuate surfaces 308 are so constructed that the flanged portion of the core pieces 310 can be slidable in either axial or radial directions relative to the axis of the arbor 301 to be snugly received thereby. The core pieces 310 can then be assembled in abutting relation with the arcuate surfaces 308, whereupon the core pieces 3I0 provide the same function as the core pieces 82f 84, 86 and 88 illustrated in Fi~lre 3~ Since the pieces 310 will become the pole pieces of the completed field assembly, an insulating sleeve 320 is placed on each of the pieces 310 prior to the winding of coils thereon.
The pieces 310 are clamped to the arbor 301 by means of a pair of sliding clamp members 322 and 324 which may be of identical construction. Each has an end platc designated 326 apertured at 328 to receive a shaft part 330 or 332 projecting 3~
from the opposite ends of the mandrel 300 and four cl<~nping fingers 334 projecting from the corners of the en~ plate 326.
The clamp ~nembers 322 and 324 are adapted to be extended over opposite ends of the arbor 301 with each of the clamp fingers 334 centered over one of the keys 302 and with the a~ially ex-tending side edges of the clamp fingers 334 overlying the flange portions 314 of the core pieces 310 and the parts of the insu-lating slee~e 320 lying against the flanged portions 31~. As clearly illustrated in Figure 6~ each clamping finger 334 spans across adjacent flanges 314 of adjacent core pieces 310 when the parts are assembled. The arbor 301 is substantially the same length as the pieces 310 and the clamp fingers are sliglltly less ; than one-half said length. Accordingly~ the end plates 326 of the clamp members 322 and 324, upon assembly of the mandrel 300 centrally locate the pieces 310 on the arbor 301. ~rhen -~
assembled to the arbor 301, the fingers 334 of the clamp member 322 are aligned with and confront the corresponding fingers of the clamp member 324. This assembly is sho~ in Figure 8. The inside surfaces of the side edges of the clamp fingers 334 can engage the core or pole piece flange portions 314 with a suffi-ciently close friction fit that the assembled mandrel 300 will remain assembled unless forcibly disassembled. Alternatively~
or in addition, separate means (not shown) could be provided for holding the clamp members 322 and 324 in assembled relation to the arbor 301.
The assembled mandrel comprising the arbor 301 t the core pieces 310, and the clamp member~ 322 and 324 has essentially the same configuration as the mandrel 80 illustrated in Figure ~herefore, strapping can be edge bent or wound around the 30 side walls or shoulders of the core pieces 310 to form coils and edge bent to duplicate the connecting portions 56, 64 and 70 shown in Figure 2D Fig~re 6 shows the mandrel 300 with com-pleted coils designated 336~ 338~ 340 and 342 wound thereon.
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o ~ 'ith reference to Figures 6 alid 7, the core or pole pieces 31Q ha~e centrally located threaded apertures 344 extending therethrough so that they may be used as the pole pieces of a completed starter motor field assembly 345 sho~ in Figure 7 The field assembly 345 includes a stator housing or ring 346 which has an insulating liner 348 and which also has apertures for recei~ring scre~s 350 for attachment of the pole pieces thereto, ~ igures 8-10 illustrate in simplified form the steps followed in the manufacture of the starter motor field assembly 345. The winding of the coils on the mandrel 300 can b0 accom-plished as illustrated in Figure 8 wherein the shaft parts 330 and 332 of the arbor 301 are Journalled for rotation in opposed parts of a yoke 352 rotatably driven by a yoke drive assembly 354 about an axis extending centrally through the mandrel 300 per-pendicular to its longitudinal axis. The mandrel 300 may be rotated about its longitudinal axis by a rack 356 mounted on the yoke 352 and ~ri~ren by a dri~e cylinder 35O or the like and which engages a pinion 360 mounted on the shaft part 332, One end of the strapping 11 can be clamped to the cla~p member 322 and guided from a suitable strapping source (not sho~.~) by a strap guide member 362. As conventional in other winding procedures, the strapping is placed under tension at its source. Thererore, the coils may be edge bent or wound about the core piece 310 by rotation of the yoke 352 and the connecting strapping parts between coils edge bent by rotation of the mandrel 300 upon energization of the cylinder 358 whereupon the racX 356 rotat-ably drives the pinion 360. The yoke 352 is rotated in either clockwise or counterclockwise directions to cdge wind +he -oi ~ -in the desired directions about the pieces 310. Suitable tooling may be pro~ided to assist in edge bending the strapping as necessary to wind the coils and rorm the connections between coils.
It will be noted in Figure 6 that the coils are edge wound around the pole pieces with their radially innermost major 3~
surfaces lying flat against and suppcrted by flat surface por-tions of the clamp fingers 334. Accordingly the l~ajor surface of each convolution thereof is substantially perpendicular to radial lines extending centrally through the apertures 344~
After the windin~ of the coils in the m~lner described above in connection .ith Figure 8 the strapping is se~ered from its source and the mandrel 300 is remo~Ted from the yoke 352 and the clamp members 322 and 324 then removed from the arbor 301~ The strapping 11 forming the winding is typically quite stiff so that the completed winding itself will retain the core or pole pieces 310 on the arbor 301. After removal of the clamp members 322 and 324 the arbor 301 carrying the pole pieces 310 with the winding thereon is moved to a coil forming machine which modifies the shape of each of the coils so that they have an arcuate outer periphery concentric with the arbor 301 and are suitably shaped for insertion into the stator ring 346. Forming machines are conventional in the industry and may include as shown in Figure 9 one or more forming dies or press members 364. As apparent from an inspection of Figure 9~ advancement of the member 364 to~Yard the longitudinal axis of the arbor 301 will cause the coil 342 to be bent or formed into a circular arc for insertion into the stator ring 346. All coils wound on the pieces 310 are either simultaneously or sequentially formed to the desired a.c.
The arcuate or circular configuration of all of the coils is clearly shown in Figure 7.
After forming of the coils the insulating liner 348 is preferably ~rapped around the core or pole pieces 310. As illustrated in Figure 10 the liner 348 may conveniently comprise an insulating paper or the like sheet having plural apertures 366 which are provided to permit contact between the core or pole pieces 310 and the inside surface of the stator ring 346. The liner 348 is wrapped around the assembled arbor and pole pieces.
After wrapping~ its ends can be connected as by a piece of tape 3~) (not sho~n~. This assembly is then inserte~ into the stator ring 346 ~nd the scre~s 350 ~re then inserted through~the apertures in the stator ring and thre~dedly engaged with the pole pieces ~10 to affix them along with the winding and the insulating liner 348 to the ring 346. At such time the parts have the appearance illustrated in Figure 7. Thereafter~ the arbor 301 is removed from the assembled fleld assembly 345 as sho~n in ~igure 11, read~
for reuse in the manufacture of another field assembly. As believed apparent J the winding and assembly method illustrated in Figures 8-11 can be accomplished manually with the use of simple tools~ or the entire assembly process could be carried out by automatically operating machines with the potential for sub-stant.ial savings in the cost of Manufacture of the conventional starter motor field assemblies ~tili~ing the separately wound coils illustrated in Figure 1.
Referring to ~igures 3 and 8~ the winding apparatus shown in Figure 8 could be used for the winding of coils on the man~
drel 80 ~.~hich would be used instead of the mandrel 300. In such event, the coils would be wound and the connections between coils formed by repeated rotations of the mandrel 80 ab~ut the axis of rotation of the yoke 352~ i.e., perpendicular to the longitudi-nal axis of the mandrel 80, and about~ the longitudinal axis of the mandrel ~0 in the same manner in which the coils are formed on the mandrel 300. After the coils are wound on the mandrel 80, the coil terminal portion 50 is released from the clamp 90 ~-here-upon the winding can be removed by hand. The coils can then be formed to the desired arcuate configuration and inserted into the stator ring 94. Prior to such insertion of the coils~ they would either be wrapped by an insulating sleeve (not shown) ~hich may be identical to the insulator 348 or such insulating sleeve may be positioned within the ring ~4L Thereafter the pole pieces 96 with the insulating sleeves 97 thereon would be inserted in-side the winding located in the ring 94 and mo~ed radially out-- ~5'~3~
.ardly through the coils and then attached to the stator ring by the screws or bolts 98 to form the completed fieldtillustrated in Fi~ure 4.
While the present application describes the m~nner in ~hicl-a prior art ~inding might be substantially duplicated~ it will occur to those skilled in the art that numerous variations are possible.
The particular winding described as illustrative of the present invention has the first wou3ld and third ~Yo~ld coils wound counterclockwise~ for example, and the second wound and fourth ~ound coils wound clock~ise. The ~inding techniques described in the present application~ of course~ include tec}~iques for shi~ting the direction of wind as from clockwise to counter-cloc~wise or vice versa, i.e., winding one side of the strapping against a core when Yinding clockwise and the opposite side of the strapping against a core when winding counterclockwise; and the particular sequence of respectively clockwise and counter-clockwise windings is thus variable to suit the desires of the customer. Of course, windings having other than four coils could be made in accordance with the principles of this inven-tion. Four coils are illustrated since this is the common con-figuration for auto~7otive starter motor field windings. This invention is presently believed most suitable for such windings because of the need for the coils thereo~ to be formed from strapping.
In addition to a substantial savings in the number Or operations required to produce a completed field winding~ it is expected that this invention can be practiced to produce a savings in the length of strapping used to form a completed .inding~ Since strapping is normally made from copper which is relatively expensive~ and since field windings are normally ~ass-produced in very large quantities, a savings of even a small length of strapping for each ~inding can result in a ;Z3~0 savings of many thousands of dollars a year, It is also con~
templated that new coil confi~urations may be made~possible by ; the practice of this invention and in particular that it may be possible to obtain field strength characteristics comparable to the characteristics obtained in the prior art using windings which occupy a smaller space and, thus~ this invention could lead to a reduction in the size and weight of automotive starter motors.
Although the presently preferred embodiments of this invention have been described, it will be understood that within the purview of this invention various changes may be : made within the scope of the appended claims.
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The leg 22 is edge bent downwardly and by combined edge and flat bends rotated approximately 90 about its own axis to commence the second coil 24, which is flat wou~d outwardly from the inner-most to the outermost convolution. Its outermost convolution is twisted to form a termination 26 that is brazed or soldered at 28 to a termination 30 of a third coil 32. Commencing with a start end or leg 34 which is bent downwardly and then both edge and flat bent to accomplish a 90 rotation about its own axis, the third coil 32 is flat wound outwardly from the innermost to the outermost convolution. The outermost convolution is both bent and twisted to form the termination 30~ The start leg of the third coil 32 is soldered or brazed to the start end or leg 36 of a fourth coil 38. The coil 38 is also flat wound and con-voluted outwardly from the innermost convolution thereof to the outerlnost convolution thereof. At the commencement of the wind-ing of the fourth coil 38, its start end 36 is first flat bent and then edge bent and at the end of the winding the final con volution includes an upwardly extending leg 40 which is twisted approximately 90 about it~ center axis to form the termination 14.
As previously indicated~ the winding 10 i5 representative of prior art. The winding is accomplished by individually winding the coils 18, 24, 32 and 38 Usillg four separ~te ~inding machines and then soldering or brazing the terminal ends of the coils in the manner illustr~ted in Figure 1 Col;sidering current flow throu~h the coils and assuming a positi~e potential applied to the first terminal 12 and ground applied to the second terrninal 14, a positive current will flow counterclockwise about the first coil 18, clockwise about the second coil 24, counter-clockwise about the third coil 32, and clocl~ise about the four~h !.
coil 38 if the observer is located outside the periphery of the winding. It is noteworthy that the sections of strapping which are used for the winding form four separate coils wherein each coil required at least one and sollletimes two 90 twists of the strapping about its own axis for completion of the coil, edge bending as well as flat bending of the strapping, and brazed or soldered connections were required to interconnect the coils. ~ ;
Figure 2 illustrates a winding 48 rhich is co~lparable in terms of electrical characteristics to the prior winding of Figure 1 but which~ in accordance ~ith the present invention~
has been accomplished with an uninterruptedly continuous length of insulated strapping 11. The winding is accomplished without soldering or brazing and t~Yisting or rotation of the strapping about its own axis as is required on numerous occasions to accomplish the prior art winding~ A particularly notable feature is that the winding of Figure 2 is an edge wound winding as opposed to the flat wound winding of Figure 1.
Progressing through the generally circular winding of Figure 2~ the winding commences with a start end or terminal 50 ; From the terminal 50 the strapping proceeds horizontally to a flat bend~ from which the strapping proceeds downwardly along a straight section of a convolution 52~ ~hich is edge wound to form a coil 54. It can be noted that the successive convolutions of the coil 54 proceed axially outwardly as they are wound one adjacent the other. Thus the coi7 54 increases in axial ~23~
thickness as successive convolutions are added to the coil.
Comparing this feature to the flat wound coils of~Figure 1~ it should be noted that the coils of ~igure 1 each have a sub-stantially constant axial thickness with respect to an axis surrounded by the coil~ but each of the coils of the winding 10 has an increasing radial thickness as the number of convolutions in each such coil increases.
After winding ~f the coil 54~ the finishing portion of the wire is edge turned to form a starting portion or leg 56 which continues uninterruptedly into the first con~olution 58 of an edge wound coil 60 which is ~ound axially outwardly by edge wind-ing until a final convolution or finishing portion 62 i5 wound.
After completion of the convolution 62, the strapping i9 continued without interruption along a starting portion by a leg 64 which continues without interruption to the commencement of the first convolut'ion 66 of an edge wound coil 68. It will be noted that the leg 64 i5 bent do~nwardly so that it does not span over the third coil 68,- whereas the afore~entioned leg 56 spans from the first coil 54 over the second coil 60. The coil 68 again increases outwardly in axial thic~ness as successive convolutions thereof are wound.
After winding of the coil 68, its finishing portion continueC ~ithout interruption along an arm 70 and without interruption to form the radially innermost starting portion or con~olution 72 of an edge ~ound coil 74 where~ again~ the coil progresses axially outwardly in thickness to the final con-volutlon thereof rhich is edge turned to form a finish portion or terminal 76. The resultant winding 48 is characterized by a generally cylindrical shape in which the coils 54~ 60~ 68 and 74 are laterally spaced apart and the ~tart and finish portions which interconnect the coils are disposed at the upper axial extreme of the winding as appears in Figure 2.
In ~ddition to the use of edge ~iinding as opposed to the ~Z3~V
flat winding in Fi~lre l and the use of a continuous strapping in the winding of Fi~lre 2, another notable feature of the windin~ of Figure 2 is that all coils are wound outwardly from an axially innermost convolution to an axially outermost convo-lution. Further~ the winding of Figure 2 is gener~lly circular whcn viewed fron1 either end thereof and the major surfaces of the strapping are parallel to the longitudinal axis of the wind-ing throughout all of the coils and the col~ection~ therebet~.een.
Accordingly~ the entire length of strapping used to form the winding 48 has its ~ajor surfaces lying essentially along the periphery of the imaginary cylinder which the coils form. After completion of the winding 48~ the flat bent part of the start portion or terminal 50 could be either straightened or cut off.
As an alternative, the winding may be accomplished ~Yithout the flat bend in the start portion 50. In either event, the winding 48 can be inserted directly into a stator housing or ring and suitable terminal connections made for electrical connection to the terminals 50 and 76. No solder or brazed connections are required in the winding 48, and all connected coils are inter-connected by edge bent strapping portions having major faceslying substantiall~ in the same imaginary cylinder as the major faces of the coils.
Considering the electrical characteristics of the winding 48, one can consider that the starting terminal 50 is connected to a source of positive ~oltage~ and that the finishing ter~inal 76 is connected to ground. ~ith such connections~ a positive current as ~seen" by an observsr outside the winding will flow counterclockwise in the coil 54, clockwise in the coil 60, count~rclockwise in the coil 68 and clockwise in the coil 74 to ground at the terminal 76. The electrical result will be basically the sam~ as for the prior art coil illustrated in Figure l.
Figure 3 illustrates the general manner in which a winding o such as dcscribed in reference to Fi.gure 2 can be accomplished on a malldrel~ generally designated 80. The mandrel 80 com-prises a generally cylindrical body or arbor having four ou-t-.ardly projecting and generally rectang~llar cores 82~ 84~ 86 and 88 bounded by respective side walls or shoulders 82a, 84a, 86a and 88a. Only the cores 82 and 88 and their side ~alls 82a and 88a appear in the drawings~
A piece of strapping 11 is secured at one end thereof~
forming the start end 50 of the winding 48, to one end of the ~andrel 80 by means of a clamp 90 secured by a fastener 92 The strapping is so secured to the mandrel 80 that, ~ith a single 90 degree bend~ the strapping can be flat bent to commence the innermost convolution 52 of the coil 54 which is ~ound edgewise about the shoulder 82a to produce cou~ter-clockwise wollnd coil 54. It may be noted that other means~
not shown~ could ~e pro~ided to grip the start end S such that the flat bend would be unnecessaryO
The strapping which forms the outermost convolution of the coil 54 is then turned edgewise, extended circumferentially adjacent the upper shoulder, not appearing in Figure 3, of the mandrel core 84, a-lso not appearing in Figure 3, edge bent do~nwardly and then wound edgewise in the clockwise direction about shoulder 84a to produce the coil 60 appearing in Figure 2.
Because of the edgewise turning of the strapping after the winding of the coil 54, it will be noted that the edge of the strapping engaging the shoulder 82a is the opposite edge of the strapping which engages the shoulder of the core piece 84. A
study Df Figures 2 and 3 will reveal that the coils wound in a clockwise direction have the same strapping edges confronting and engaging the core pieces and those wound in a counter-clockwise direction have opposite edges confronting and engaging the core pieces.
The strapping is then continued from the coil 60 peripher-_ g~
ally about the mandrel 80, cdge bent do~mwardly adjacent theleft hand side of the core 86, not appearing in ~figure 3~ and then edge wound about such core to accomplish the counter-clock~ise ~inding of the coil 68 which appears in Figure 2.
The strapping is then continued from the coil 68 and along the upper shoulder 88a, as appears in Figure 3, and edge wound clockwise about the core 88 to accomplish the coil 74. The last convolution of the coil 74 is permitted to extend vertically up~ardly as appears in ~igure 3 to form the terminal 76 ~hich also appears in Figure 2.
Figure 4 schematically illustrates a starter motor field assembly using the winding of ~igure 3. After release of the cl~mp 90 illustrated in Figure 3, the ~inding is pulled outwardly and away from the mandrel 80~ returned and formed as needed to a generally circular shape~ and inserted into a hollow~ cylin-drical stator housing or ring 94. Four indiYidual pole pieces identified by the reference numeral 96, and each preferably surrsunded by insulating sleeves 97~ are then fastened in a circular array to the stator ring at 90 degree circumferential angles by means of suitable fasteners 98 threaded into the pole pieces 96 so that the pole pieces 96 project inwardly of the ring 94. In such assembly, both the axially and circumferentially extending side walls of the pole pieces 96 are confronted by the radially irlnermost edge surfaces of the strapping but insulated from the strapping by the sleeves 97. Only the axially extending side walls~ designated 99~ are illustrated in the section of ~igure 4 As is conventional, these are out~Tardly flanged or flared to retain the coils thereon. In the illustra-tion of Figure 4~ there is a substantial spacing between the curved inside surface of the ring 94 and the radially outermost surfaces of the coils 549 60, 68 and 74. In practice~ the radial dimensions of the coils 54, 60~ 68 and 74 relative to the radial length of the pole pieces 96 is preferably s~ch that _ g _ 3~(~
the flared side walls 99 compress the several coils 549 Go, G8 and 74 ag~inst the incide surface of the stator ri~n~ so that the coils are snugly retained on the ring. Suitable terminal connections~ not sho-~ because well ]~lo~ to those skilled in the art~ are then provided for connection of the start and finish portions 50 and 76 appearing in Figure 2 to an electrical source.
The field assembly is thus seen to include a one-piece wind-ing comprising a single lengtll of conductive strapping edge wo~d into the laterally spaced ~nd connected coils 54, 60, 68 and 74 9 one coil surrounding each of the pole pieces 96. Since the strapping forming the coils is coated with insulating material~
there is electrically insulating means between adjacent convo-lutions of each coil. As possible alternati~es, insulation could be formed between the coil convolutions after the winding is completed, or insulating strips could be wowld with the strapping. When assembled in the ring 94, the adjacently located colls are connected by ed~e bent portions of strapping integral with the coils and extending from a finishing~
radially outermost portion of one coil to a starting, radially innermost portion of the adjacently located coil. As is obvious from an inspection of the drawings~ the ~ajor sides of the coils ard al~o the connecting strapping portions between them are substantially concentric with the inside surface of the ring 94. The same would be true of the connection between coils 54 and 74 if either one or both of their adjacent termina_ tion legs 50 and 76 are edge bent to produce the connectionO
Figures 5, 6 and 7 illustrate a modification wherein a - mandrel, generally designated 300) comprises an assembly of parts including core or pole pieces about which coils are edge wound. Upon completion of the winding, the core or pole pieces are separated from the assembly along with the winding for inser- j tion into a stator yoke wherein the core pieces are fastened to the stator yoke so as to function as stator pole pieces.
' .
v~
The mandrel 300 can be seen to comprise a generally cylin~
drical body or arbor 301 having radially outwardly e~tending ~e~s 302 along the length thereof. The radially extending surfaces of the keys 302 are identified by the reference characters 304 and 306~ respectively. The keys 302 are flanked by recessed~ axial-ly extending, arcuate surfaces 308, there being four such arcuate surfaces 308, each bounded by a pair of radial surfaces 304 and 306. The keys 302 are designed to slidably receive bet~een them core pieces 310, there being one core or pole piece 310 for each arcuate surface 3080 Thus for a .inding having four coils~ there are four core pieces 310 as illustrated.
Each core or pole piece 310 comprises a generally rectangu-lar body member 312 having arcuate flanges 314 projecting from each axially extending side walt and having a convexly curved outer surface 316 and a concavely curved inner surface 318. The core pieces 310 are shaped to become the pole pieces for the field assembly as will be described belo~t and may be shaped identically to pole pieces presently in use. _ As best sho~.~ in Eigure 6, the keys 302 a~d the arcuate surfaces 308 are so constructed that the flanged portion of the core pieces 310 can be slidable in either axial or radial directions relative to the axis of the arbor 301 to be snugly received thereby. The core pieces 310 can then be assembled in abutting relation with the arcuate surfaces 308, whereupon the core pieces 3I0 provide the same function as the core pieces 82f 84, 86 and 88 illustrated in Fi~lre 3~ Since the pieces 310 will become the pole pieces of the completed field assembly, an insulating sleeve 320 is placed on each of the pieces 310 prior to the winding of coils thereon.
The pieces 310 are clamped to the arbor 301 by means of a pair of sliding clamp members 322 and 324 which may be of identical construction. Each has an end platc designated 326 apertured at 328 to receive a shaft part 330 or 332 projecting 3~
from the opposite ends of the mandrel 300 and four cl<~nping fingers 334 projecting from the corners of the en~ plate 326.
The clamp ~nembers 322 and 324 are adapted to be extended over opposite ends of the arbor 301 with each of the clamp fingers 334 centered over one of the keys 302 and with the a~ially ex-tending side edges of the clamp fingers 334 overlying the flange portions 314 of the core pieces 310 and the parts of the insu-lating slee~e 320 lying against the flanged portions 31~. As clearly illustrated in Figure 6~ each clamping finger 334 spans across adjacent flanges 314 of adjacent core pieces 310 when the parts are assembled. The arbor 301 is substantially the same length as the pieces 310 and the clamp fingers are sliglltly less ; than one-half said length. Accordingly~ the end plates 326 of the clamp members 322 and 324, upon assembly of the mandrel 300 centrally locate the pieces 310 on the arbor 301. ~rhen -~
assembled to the arbor 301, the fingers 334 of the clamp member 322 are aligned with and confront the corresponding fingers of the clamp member 324. This assembly is sho~ in Figure 8. The inside surfaces of the side edges of the clamp fingers 334 can engage the core or pole piece flange portions 314 with a suffi-ciently close friction fit that the assembled mandrel 300 will remain assembled unless forcibly disassembled. Alternatively~
or in addition, separate means (not shown) could be provided for holding the clamp members 322 and 324 in assembled relation to the arbor 301.
The assembled mandrel comprising the arbor 301 t the core pieces 310, and the clamp member~ 322 and 324 has essentially the same configuration as the mandrel 80 illustrated in Figure ~herefore, strapping can be edge bent or wound around the 30 side walls or shoulders of the core pieces 310 to form coils and edge bent to duplicate the connecting portions 56, 64 and 70 shown in Figure 2D Fig~re 6 shows the mandrel 300 with com-pleted coils designated 336~ 338~ 340 and 342 wound thereon.
.
o ~ 'ith reference to Figures 6 alid 7, the core or pole pieces 31Q ha~e centrally located threaded apertures 344 extending therethrough so that they may be used as the pole pieces of a completed starter motor field assembly 345 sho~ in Figure 7 The field assembly 345 includes a stator housing or ring 346 which has an insulating liner 348 and which also has apertures for recei~ring scre~s 350 for attachment of the pole pieces thereto, ~ igures 8-10 illustrate in simplified form the steps followed in the manufacture of the starter motor field assembly 345. The winding of the coils on the mandrel 300 can b0 accom-plished as illustrated in Figure 8 wherein the shaft parts 330 and 332 of the arbor 301 are Journalled for rotation in opposed parts of a yoke 352 rotatably driven by a yoke drive assembly 354 about an axis extending centrally through the mandrel 300 per-pendicular to its longitudinal axis. The mandrel 300 may be rotated about its longitudinal axis by a rack 356 mounted on the yoke 352 and ~ri~ren by a dri~e cylinder 35O or the like and which engages a pinion 360 mounted on the shaft part 332, One end of the strapping 11 can be clamped to the cla~p member 322 and guided from a suitable strapping source (not sho~.~) by a strap guide member 362. As conventional in other winding procedures, the strapping is placed under tension at its source. Thererore, the coils may be edge bent or wound about the core piece 310 by rotation of the yoke 352 and the connecting strapping parts between coils edge bent by rotation of the mandrel 300 upon energization of the cylinder 358 whereupon the racX 356 rotat-ably drives the pinion 360. The yoke 352 is rotated in either clockwise or counterclockwise directions to cdge wind +he -oi ~ -in the desired directions about the pieces 310. Suitable tooling may be pro~ided to assist in edge bending the strapping as necessary to wind the coils and rorm the connections between coils.
It will be noted in Figure 6 that the coils are edge wound around the pole pieces with their radially innermost major 3~
surfaces lying flat against and suppcrted by flat surface por-tions of the clamp fingers 334. Accordingly the l~ajor surface of each convolution thereof is substantially perpendicular to radial lines extending centrally through the apertures 344~
After the windin~ of the coils in the m~lner described above in connection .ith Figure 8 the strapping is se~ered from its source and the mandrel 300 is remo~Ted from the yoke 352 and the clamp members 322 and 324 then removed from the arbor 301~ The strapping 11 forming the winding is typically quite stiff so that the completed winding itself will retain the core or pole pieces 310 on the arbor 301. After removal of the clamp members 322 and 324 the arbor 301 carrying the pole pieces 310 with the winding thereon is moved to a coil forming machine which modifies the shape of each of the coils so that they have an arcuate outer periphery concentric with the arbor 301 and are suitably shaped for insertion into the stator ring 346. Forming machines are conventional in the industry and may include as shown in Figure 9 one or more forming dies or press members 364. As apparent from an inspection of Figure 9~ advancement of the member 364 to~Yard the longitudinal axis of the arbor 301 will cause the coil 342 to be bent or formed into a circular arc for insertion into the stator ring 346. All coils wound on the pieces 310 are either simultaneously or sequentially formed to the desired a.c.
The arcuate or circular configuration of all of the coils is clearly shown in Figure 7.
After forming of the coils the insulating liner 348 is preferably ~rapped around the core or pole pieces 310. As illustrated in Figure 10 the liner 348 may conveniently comprise an insulating paper or the like sheet having plural apertures 366 which are provided to permit contact between the core or pole pieces 310 and the inside surface of the stator ring 346. The liner 348 is wrapped around the assembled arbor and pole pieces.
After wrapping~ its ends can be connected as by a piece of tape 3~) (not sho~n~. This assembly is then inserte~ into the stator ring 346 ~nd the scre~s 350 ~re then inserted through~the apertures in the stator ring and thre~dedly engaged with the pole pieces ~10 to affix them along with the winding and the insulating liner 348 to the ring 346. At such time the parts have the appearance illustrated in Figure 7. Thereafter~ the arbor 301 is removed from the assembled fleld assembly 345 as sho~n in ~igure 11, read~
for reuse in the manufacture of another field assembly. As believed apparent J the winding and assembly method illustrated in Figures 8-11 can be accomplished manually with the use of simple tools~ or the entire assembly process could be carried out by automatically operating machines with the potential for sub-stant.ial savings in the cost of Manufacture of the conventional starter motor field assemblies ~tili~ing the separately wound coils illustrated in Figure 1.
Referring to ~igures 3 and 8~ the winding apparatus shown in Figure 8 could be used for the winding of coils on the man~
drel 80 ~.~hich would be used instead of the mandrel 300. In such event, the coils would be wound and the connections between coils formed by repeated rotations of the mandrel 80 ab~ut the axis of rotation of the yoke 352~ i.e., perpendicular to the longitudi-nal axis of the mandrel 80, and about~ the longitudinal axis of the mandrel ~0 in the same manner in which the coils are formed on the mandrel 300. After the coils are wound on the mandrel 80, the coil terminal portion 50 is released from the clamp 90 ~-here-upon the winding can be removed by hand. The coils can then be formed to the desired arcuate configuration and inserted into the stator ring 94. Prior to such insertion of the coils~ they would either be wrapped by an insulating sleeve (not shown) ~hich may be identical to the insulator 348 or such insulating sleeve may be positioned within the ring ~4L Thereafter the pole pieces 96 with the insulating sleeves 97 thereon would be inserted in-side the winding located in the ring 94 and mo~ed radially out-- ~5'~3~
.ardly through the coils and then attached to the stator ring by the screws or bolts 98 to form the completed fieldtillustrated in Fi~ure 4.
While the present application describes the m~nner in ~hicl-a prior art ~inding might be substantially duplicated~ it will occur to those skilled in the art that numerous variations are possible.
The particular winding described as illustrative of the present invention has the first wou3ld and third ~Yo~ld coils wound counterclockwise~ for example, and the second wound and fourth ~ound coils wound clock~ise. The ~inding techniques described in the present application~ of course~ include tec}~iques for shi~ting the direction of wind as from clockwise to counter-cloc~wise or vice versa, i.e., winding one side of the strapping against a core when Yinding clockwise and the opposite side of the strapping against a core when winding counterclockwise; and the particular sequence of respectively clockwise and counter-clockwise windings is thus variable to suit the desires of the customer. Of course, windings having other than four coils could be made in accordance with the principles of this inven-tion. Four coils are illustrated since this is the common con-figuration for auto~7otive starter motor field windings. This invention is presently believed most suitable for such windings because of the need for the coils thereo~ to be formed from strapping.
In addition to a substantial savings in the number Or operations required to produce a completed field winding~ it is expected that this invention can be practiced to produce a savings in the length of strapping used to form a completed .inding~ Since strapping is normally made from copper which is relatively expensive~ and since field windings are normally ~ass-produced in very large quantities, a savings of even a small length of strapping for each ~inding can result in a ;Z3~0 savings of many thousands of dollars a year, It is also con~
templated that new coil confi~urations may be made~possible by ; the practice of this invention and in particular that it may be possible to obtain field strength characteristics comparable to the characteristics obtained in the prior art using windings which occupy a smaller space and, thus~ this invention could lead to a reduction in the size and weight of automotive starter motors.
Although the presently preferred embodiments of this invention have been described, it will be understood that within the purview of this invention various changes may be : made within the scope of the appended claims.
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Claims (23)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A method for manufacturing a field winding from strapping, comprising:
providing a mandrel having plural core pieces arranged about the major axis of said mandrel;
supporting said mandrel for rotation about said major axis;
guiding strapping from a source of strapping to said mandrel;
edge winding said strapping to form coils about each of said core pieces; and forming connecting portions between pairs of said coils by rotating said mandrel about said major axis between the winding of a first coil of each of said pairs and the wind-ing of the next coil of each of said pairs so that said field winding is formed from a continuous and uninterrupted length of strapping having coils edge wound about said core pieces with connecting portions extended from coil to coil.
providing a mandrel having plural core pieces arranged about the major axis of said mandrel;
supporting said mandrel for rotation about said major axis;
guiding strapping from a source of strapping to said mandrel;
edge winding said strapping to form coils about each of said core pieces; and forming connecting portions between pairs of said coils by rotating said mandrel about said major axis between the winding of a first coil of each of said pairs and the wind-ing of the next coil of each of said pairs so that said field winding is formed from a continuous and uninterrupted length of strapping having coils edge wound about said core pieces with connecting portions extended from coil to coil.
2. The method of claim 1, wherein the step of edge winding coils comprises rotating said mandrel about a second axis inclined from said major axis so that said strapping is drawn from said source to said mandrel and is edge bent about said core pieces.
3. The method of claim 2 wherein said second axis is generally perpendicular to said major axis.
4. The method of claim 2 further comprising:
securing the leading end of said strapping to said mandrel prior to edge winding of coils about said core pieces.
securing the leading end of said strapping to said mandrel prior to edge winding of coils about said core pieces.
5. The method of claim l further comprising:
providing means for detachably mounting said core pieces on said mandrel.
providing means for detachably mounting said core pieces on said mandrel.
6. The method of claim l wherein each of said coils is wound with plural convolutions.
7. The method of claim l wherein there are four coils wound about four core pieces.
8. The method of claim l, wherein each coil has plural convolutions and the winding of each coil progresses from a first convolution nearest said major axis axially outwardly along its own axis to a last convolution farthest from said major axis.
9. The method of claim 2, wherein said strapping has parallel major faces and edges extending between said major faces, wherein said core pieces have surrounding side walls, and wherein said strapping is edge wound about said side walls with each side wall confronted by an edge of said strapping.
10. The method of claim 9 wherein one of said core pieces is wound with one edge of said strapping confronting the side walls thereof and an adjacent one of said core pieces is wound with an opposite edge of said strapping confronting the side walls thereof.
11. The method of claim 9 wherein, prior to the wind-ing of coils about said core pieces, insulating sleeves are mounted in surrounding relation to the side walls of said core pieces, and wherein said strapping is wound around said sleeves.
12. The method of claim 11 wherein four of said coils are wound on four of said core pieces.
13. Apparatus for manufacturing dynamoelectric wind-ings having plural coils, comprising:
a mandrel having a major axis and a plurality of core pieces spaced about said major axis;
means supporting said mandrel for rotation about said major axis;
means for guiding strapping from a source of strapping to a position adjacent said mandrel;
means for edge winding said strapping into edge wound coils about each of said core pieces; and means for rotating said mandrel about said major axis for successively presenting each of said core pieces in position to have said strapping guided thereto for winding said coils and for forming continuous and uninterrupted connecting portions be-tween the coils.
a mandrel having a major axis and a plurality of core pieces spaced about said major axis;
means supporting said mandrel for rotation about said major axis;
means for guiding strapping from a source of strapping to a position adjacent said mandrel;
means for edge winding said strapping into edge wound coils about each of said core pieces; and means for rotating said mandrel about said major axis for successively presenting each of said core pieces in position to have said strapping guided thereto for winding said coils and for forming continuous and uninterrupted connecting portions be-tween the coils.
14. The apparatus of claim 13 wherein said core pieces form a permanent part of said mandrel.
15. The apparatus of claim 14 wherein said core pieces are detachably mounted on said mandrel.
16. The apparatus of claim 15 further comprising means for securing the leading end of said strapping to said mandrel, and wherein said means for edge winding includes means for rotat-ing said mandrel about a second axis inclined from said major axis for drawing said strapping from said source to edge bend said strapping into coils about said core pieces.
17. The apparatus of claim 16 wherein said means for rotating said mandrel about a second axis comprises a yoke en-gaging said mandrel and motive means for rotating said yoke, and said means for rotating said mandrel about said major axis includes means supported by said yoke and engaging said mandrel.
18. The apparatus of claim 16, wherein said second axis is generally perpendicular to said major axis.
19. The apparatus of claim 15, 16, or 18, wherein said mandrel comprises an arbor having a longitudinal axis coin-cidental with said major axis, a body member shaped to receive said core pieces, and means for detachably retaining said core pieces on said body member.
20. The apparatus of claim 13, including:
clamp means for detachably mounting the core pieces on said mandrel in equally circumferentially spaced locations thereon, said mandrel being so constructed and said core pieces being so mounted on said mandrel that said mandrel with said core pieces may be inserted into a stator ring of a dynamoelectric device subsequent to the winding of the coils and in a position wherein the core pieces may be connected to said stator ring and then detached from said mandrel by movement of parts of said clamp ring.
clamp means for detachably mounting the core pieces on said mandrel in equally circumferentially spaced locations thereon, said mandrel being so constructed and said core pieces being so mounted on said mandrel that said mandrel with said core pieces may be inserted into a stator ring of a dynamoelectric device subsequent to the winding of the coils and in a position wherein the core pieces may be connected to said stator ring and then detached from said mandrel by movement of parts of said clamp ring.
21. The apparatus of claim 20 further comprising means for securing the leading end of said strapping to said mandrel, and wherein said means for edge winding includes means for rotating said mandrel about a second axis inclined from said major axis for drawing said strapping from said source to edge bend said strapping into coils about said core pieces.
22. The apparatus of claim 21 wherein said means for rotating said mandrel about a second axis comprises a yoke en-gaging said mandrel and motive means for rotating said yoke, and said means for rotating said mandrel about said major axis includes means supported by said yoke and engaging said mandrel.
23. The apparatus of claim 21 or 22 wherein said second axis is generally perpendicular to said major axis.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000397548A CA1152300A (en) | 1976-10-29 | 1982-03-03 | Field winding for dynamoelectric machine and method |
| CA000430090A CA1177870A (en) | 1976-10-29 | 1983-06-09 | Field winding and field assembly for dynamoelectric machine and method |
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US736,880 | 1976-10-29 | ||
| US05/736,880 US4131988A (en) | 1976-10-29 | 1976-10-29 | Method of manufacturing a dynamoelectric field member |
| CA000288612A CA1121580A (en) | 1976-10-29 | 1977-10-13 | Continuous conductor edge-wound field winding for dynamoelectric machine and method |
| CA000397548A CA1152300A (en) | 1976-10-29 | 1982-03-03 | Field winding for dynamoelectric machine and method |
Related Parent Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000288612A Division CA1121580A (en) | 1976-10-29 | 1977-10-13 | Continuous conductor edge-wound field winding for dynamoelectric machine and method |
Related Child Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000430090A Division CA1177870A (en) | 1976-10-29 | 1983-06-09 | Field winding and field assembly for dynamoelectric machine and method |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1152300A true CA1152300A (en) | 1983-08-23 |
Family
ID=27165317
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000397548A Expired CA1152300A (en) | 1976-10-29 | 1982-03-03 | Field winding for dynamoelectric machine and method |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1152300A (en) |
-
1982
- 1982-03-03 CA CA000397548A patent/CA1152300A/en not_active Expired
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry | ||
| MKEX | Expiry |
Effective date: 20000823 |