Patent ID: 7805825
Filing Date: 2010-10-05
Classification: H02K,Y10T

Abstract:
1. A method of forming motor winding conductors from rectangular conductor wire comprising: providing a forming fixture having a plurality of pockets distributed in equal number in one or more pairs of adjacent circles, each concentric with a center of the forming fixture, at least one member defining each of the pockets in one of each pair of adjacent circles being rotatable, at least through a limited angle, with respect to a member defining the pockets in the other of the respective pair of adjacent circles, the members defining each of the pockets in each pair of first adjacent circles being at a first elevation, and the members defining each of the pockets in each pair of second adjacent circles adjacent to the first adjacent circles being at a second elevation higher than the first elevation, the difference in elevation providing clearance over the hairpin conductors inserted into the members at the first elevation when inserting hairpin conductors into the members at the second elevation; with the pockets of each respective pair of adjacent circles being aligned with a respective radial line from the center, populating at least most of the pockets with hairpin shaped conductors, each having first and second legs integrally joined by a loop at one end thereof, with one leg of each hairpin conductor in a respective one of the pockets in a pair of adjacent circles and aligned with a respective radial line; spacing the loops of hairpin conductors in pockets for each pair of adjacent circles at a predetermined separation from the forming fixture for that pair of adjacent circles, either on populating the pockets or after populating the pockets; and, rotating in a first direction, relative to each other, the members defining the pockets in each pair of circles through a predetermined angle, to permanently separate the two legs of each hairpin conductor without substantial rotation of each leg of the hairpin conductors relative to its respective pocket; wherein longer hairpin conductors are inserted in pockets for each pair of larger adjacent circles than in smaller adjacent circles, and the separation of the loops from the forming fixture, of hairpin conductors in pockets for each pair of larger adjacent circles, is greater than in smaller adjacent circles.