Electrical coil forming apparatus and methods of assembling electrical coils

A coil forming apparatus for forming an electrical coil from an electrical wire. The apparatus includes a frame and a spindle assembly coupled to the frame. The spindle assembly includes: a first arm coupled to the frame, wherein the first arm includes a first moveable bracket and a plurality of first moveable spindles coupled to the first moveable bracket and to the electrical wire in a first position. The spindle assembly further includes a second arm coupled to the frame, wherein the second arm has a second moveable bracket that includes a plurality of second moveable spindles coupled to the second moveable bracket and coupled to the electrical wire in the first position. The coil forming apparatus includes a drive system coupled to the first moveable bracket and the second moveable bracket. The drive system is configured to move the first moveable bracket and the second moveable bracket.

BACKGROUND OF THE INVENTION

The embodiments described herein relate generally to electrical coils, and more particularly, to an electrical coil forming apparatus used in forming electrical coils for electrical machines.

Some electrical machines, such as a motor, typically include a stator having a plurality of electrical coils wound around a stator core. The stator core is generally formed by laminating a plurality of ring plates, and includes an inner circumference having a plurality of slots that extend along an axis of rotation of the electrical machine. In some stator designs, the electrical coils are coated with an electrically insulating enamel, and are wound around the stator core by inserting a portion of each stator coil into, and through, pairs of the slots.

Prior to insertion into the stator slots, the electrical coil is formed by winding a plurality of electrical wires within a winding tool. Some winding tools guide the electrical wires from a spool and around spindles. The spindles segregate the electrical wires into discrete bundles of electrical wires. The tool may continue to wrap the bundle of electrical wires around other circumferentially spaced spindles to form the electrical coil, which has a pair of opposing straight sections and a pair of opposing end turns.

Conventional electrical coils may include four bends within the straight sections and the end turns. This configuration, however, may lead to increased lengths of the straight portions and the end turns which may result in excess material needed for a particular application within the electrical machine. Further, the increased lengths at the end turns may interfere with motor components such as brackets and baffles. Moreover, the excess length and material may increase losses, such as resistive losses and thermal losses, during operation of the electrical coils. Further, during some insertion procedures, conventional coil configurations may increase the labor involved in pushing the electrical coils into the stator slots which may lead to negative ergonomic effects applied to the installer's hands and/or arms. After insertion of conventional electrical coils, the end turns may need to be further pushed and/or bent to make room for insertion of an adjacent electrical coil which may lead to cracking or other damage to the insulating coating and to further stress applied to the installer's hands and/or arms.

BRIEF DESCRIPTION OF THE INVENTION

In one aspect, a coil forming apparatus for forming an electrical coil from an electrical wire is provided. The apparatus includes a frame and a spindle assembly coupled to the frame. The spindle assembly includes a first arm coupled to the frame, wherein the first arm includes a first moveable bracket and a plurality of first moveable spindles coupled to the first moveable bracket and to the electrical wire in a first position. The spindle assembly further includes a second arm coupled to the frame, wherein the second arm has a second moveable bracket that includes a plurality of second moveable spindles coupled to the second moveable bracket and coupled to the electrical wire in the first position. The coil forming apparatus includes a drive system coupled to the first moveable bracket and the second moveable bracket. The drive system is configured to: move the second moveable bracket toward the frame to a second position, wherein the plurality of second moveable spindles of the second arm are configured to form a bend in the electrical wire; and move the first moveable bracket away from the frame to a third position, wherein the plurality of first moveable spindles of the first arm are configured to form another bend in the electrical wire.

In another aspect, an electrical coil for insertion into an electrical machine is provided. The electrical coil includes a first end turn extending in a first plane and includes a first bend; a second end turn extending parallel to the first end turn in the first plane and includes a second bend; a first straight segment coupled to the first end turn and the second end turn and extending in a second plane that is different than the first plane; and a second straight segment coupled to the first end turn and the second end turn and extending in a third plane that is different than the first plane and the second plane.

In a further aspect, a method of manufacturing an electrical coil from an electrical wire is provided. The method includes coupling the electrical wire to a first moveable bracket of a spindle assembly, the first moveable bracket positioned in a first position with respect to a frame of the spindle assembly; coupling the electrical wire to a second moveable bracket of the spindle assembly, the second moveable bracket positioned in the first position with respect to the frame; and moving the second moveable bracket toward the frame to a second position. The method further includes coupling a plurality of second moveable spindles of the second moveable bracket to the electrical wire and forming a first bend in the electrical wire; moving the first moveable bracket away from the frame to a third position; and coupling a plurality of first moveable spindles of the first moveable bracket to the electrical wire and forming another bend in the electrical wire.

DETAILED DESCRIPTION OF THE INVENTION

The embodiments described herein relate to electrical coils and methods of assembling the electrical coils. More particularly, the embodiments relate to a coil forming apparatus that is configured to form electrical coils for electrical machines. It should be understood that the embodiments described herein for electrical coils and electrical machines are not limited to motors, and further understood that the descriptions and figures that utilize an electrical coil, and motor are exemplary only.

FIG. 1is a side elevational view of an exemplary coil forming apparatus100in a first position102.FIG. 2is an opposite side elevational view of coil forming apparatus100shown inFIG. 1.FIG. 3is a front elevational view of coil forming apparatus100shown inFIG. 1. In the exemplary embodiment, three perpendicular axes X, Y and Z and associated X, Y and Z planes of reference are used to define a three-dimensional Cartesian coordinate system relative to coil forming apparatus100. Coil forming apparatus100includes a frame104, a first plate106and a second plate108. A drive system110couples first plate106and second plate108to frame104, wherein drive system110is configured to move first plate106and second plate108with respect to frame104and along X-axis. In the exemplary embodiment, drive system110includes a screw drive112coupled to first plate106and second plate108. Alternatively, drive system110may include other drive configurations such as, for example, a rack and pinion drive, a pneumatic drive and a hydraulic drive. Drive system110can include any drive configuration to enable separate movement of first plate106and second plate108with respect to frame104. Moreover, drive system110may enable movement of first plate106and second plate108with respect to frame104along Y-axis.

Coil forming apparatus100further includes a spindle assembly114coupled to first plate106and second plate108. Spindle assembly114includes a first arm116and a second arm118coupled to first plate106. First arm116and second arm118are coupled to first plate106and extend from first plate106away from frame104and along Z-axis. Moreover, first arm116and second arm118are parallel to each other in the direction of Y-axis. Spindle assembly114further includes a third arm120and a fourth arm122coupled to second plate108. Third arm120and fourth arm122are coupled to second plate108and extend from second plate108away from frame104and along Z axis. Moreover, third arm120and fourth arm122are parallel to each other in the Y-axis. Still further, first arm116and third arm120are parallel to each other in the direction of X-axis and second arm118and fourth arm122are parallel to each other in the direction of X-axis.

First arm116includes a stationary bracket124coupled to first plate106and a moveable bracket126coupled to stationary bracket124. Stationary bracket124includes a first end128, a second end130and a track132located between first end128and second end130. Track132is configured to couple to and guide moveable bracket126as moveable bracket126moves relative to stationary bracket124as described herein. Stationary bracket124further includes a first side134, a second side136, a third side138and a fourth side140located between first end128and second end130.

A plurality of aligned first stationary spindles200is coupled to and along fourth side140at about a 90 degree angle relative to fourth side140and extend from fourth side140along X-axis. Alternatively, spindles200may couple to fourth side140at any angle to enable coil forming apparatus100to function as described herein. In the exemplary embodiment, the plurality of spindles200includes seven spindles201,202,203,204,205,206and207. Alternatively, the plurality of spindles200may include more than seven spindles200or less than seven spindles200. Spindles200are separated to form a plurality of spaces210between adjacent spindles200. In the exemplary embodiment, spaces211,212,213,214,215and216are formed between respective spindles201,202,203,204,205,206,207.

Moveable bracket126includes a first end220, a second end222and a first side224, a second side225, a third side226and a fourth side228located between first end220and second end222. Sides224,225,226, and228further define an internal cavity230between first end220and second end222. Moveable bracket126includes a plurality of apertures232disposed through first side224and third side226and in communication with internal cavity230. A plurality of aligned first moveable spindles240is coupled to and along first side224at about a 90 degree angle relative to first side224and extend from first side224along Y-axis. Alternatively, spindles240may couple to and extend from first side224at any angle to enable coil forming apparatus100to function as described herein. Spindles240are coupled to first side224and partially within apertures232. In the exemplary embodiment, the plurality of spindles240includes seven spindles241,242,243,244,245,246and247. Alternatively, the plurality of spindles240may include more than seven spindles240and less than seven spindles240. Spindles240are separated to form a plurality of spaces250between adjacent spindles240. More particularly, spaces250are formed by respective spindles241,242,243,244,245and246.

The plurality of spindles200of stationary bracket124is aligned in the same Z-planes and substantially orthogonal to the plurality of spindles240of moveable bracket126. More particularly, spindle201is aligned with spindle241; spindle202is aligned with spindle242; spindle203is aligned with spindle243; spindle204is aligned with spindle244; spindle205is aligned with spindle245; spindle206is aligned with spindle246, and spindle207is aligned with spindle247. Due to spindle alignment, the plurality of spaces210of stationary bracket124is aligned in the same Z-planes as the plurality of spaces250of moveable bracket126. More particularly, space211is aligned with space251; space212is aligned with space252; space213is aligned with space253; space214is aligned with space254; space215is aligned with space255, and space216is aligned with space256.

A drive system260is coupled to moveable bracket126. In the exemplary embodiment, drive system260is a pneumatic drive and includes an inlet port262and an outlet port264, which are coupled to a piston264. Piston264is coupled to moveable bracket126. Inlet port262and outlet port264are coupled to a pressure source (not shown) via pneumatic tubes. Alternatively, drive system260may include other drive configurations such as, for example, a hydraulic drive system and a motorized gear system. Drive system260can include any configuration to enable coil forming apparatus100to function as described herein. Drive system260is configured to reciprocally slide moveable bracket126longitudinally within track132and along Z-axis.

Second arm118includes a stationary bracket268coupled to first plate106and a moveable bracket270coupled to stationary bracket268. Stationary bracket268includes a first end272, a second end274and a track276located between first end272and second end274. Track276is configured to couple to and guide moveable bracket270as moveable bracket270moves relative to stationary bracket268as described herein. Stationary bracket268further includes a first side278, a second side280, a third side282and a fourth side284located between first end272and second end274.

A plurality of aligned second stationary spindles300are coupled to third side282at about a 90 degree angle relative to third side282and extend from third side282along Y-axis. Alternatively, spindles300may couple to third side282at any angle to enable coil forming apparatus100to function as described herein. In the exemplary embodiment, the plurality of spindles300includes seven spindles301,302,303,304,305,306and307. Alternatively, the plurality of spindles300may include more than seven spindles300or less than seven spindles300. Spindles300are separated to form a plurality of spaces320between adjacent spindles300. In the exemplary embodiment, spaces321,322,323,324,325and326are formed between respective spindles301,302,303,304,305,306and307. Stationary bracket268includes a plurality of grooves329disposed within third side282, wherein grooves329are positioned substantially orthogonal to the plurality of spindles300. Spindles300are coupled to a handle331which is configured to rotate spindles300into grooves329as described herein.

Moveable bracket270includes a first end330, a second end332and first side334, a second side336, a third side338and a fourth side340located between first end330and second end332. A plurality of aligned second moveable spindles350are coupled to fourth side340at about a 90 degree angle relative to fourth side340and extend from fourth side340along X-axis. Alternatively, spindles350may couple to and extend from fourth side340at any angle to enable coil forming apparatus100to function as described herein. In the exemplary embodiment, the plurality of spindles350includes seven spindles351,352,353,354,355,356and357. Alternatively, the plurality of spindles350may include more than seven spindles350and less than seven spindles350. Spindles350are separated to form a plurality of spaces360between adjacent spindles350. More particularly, spaces361,362,363,364,365and366are formed by respective spindles351,352,353,354,355,356and357.

The plurality of spindles300of stationary bracket268is aligned in the same Z-planes and substantially orthogonal to the plurality of spindles350of moveable bracket270. More particularly, spindle301is aligned with spindle351; spindle302is aligned with spindle352; spindle303is aligned with spindle353; spindle304is aligned with spindle354; spindle305is aligned with spindle355; spindle306is aligned with spindle356, and spindle307is aligned with spindle357. Due to spindle alignment, the plurality of spaces320of stationary bracket268is aligned in the same Z-planes as the plurality of spaces360of moveable bracket270. More particularly, space321is aligned with space361; space322is aligned with space362; space323is aligned with space363; space324is aligned with space364; space325is aligned with space365, and space326is aligned with space366.

A drive system370is coupled to moveable bracket270. In the exemplary embodiment, drive system370is a pneumatic drive and includes an inlet port372and an outlet port374, which are coupled to a piston376. Piston376is coupled to moveable bracket270. Inlet port372and outlet port374are coupled to a pressure source (not shown) via pneumatic tubes. Alternatively, drive system370may include other drive configurations such as, for example, a hydraulic drive system370and a motorized gear system. Drive system370can include any configuration to enable coil forming apparatus100to function. Drive system370is configured to reciprocally slide moveable bracket270longitudinally within track276and along Z-axis.

Third arm120includes a stationary bracket380coupled to second plate108and a moveable bracket382coupled to stationary bracket380. Stationary bracket380includes a first end384, a second end386and a track388located between first end384and second end386. Track388is configured to couple to and guide moveable bracket382as moveable bracket382moves relative to stationary bracket380as described herein. Stationary bracket380further includes a first side390, a second side392, a third side394and a fourth side396located between first end384and second end386.

A plurality of aligned third stationary spindles400are coupled to second side392at about a 90 degree angle relative to second side392and extend from second side392along X-axis. Alternatively, spindles400may couple to second side392at any angle to enable coil forming apparatus100to function as described herein. In the exemplary embodiment, the plurality of spindles400includes seven spindles401,402,403,404,405,406and407. Alternatively, the plurality of spindles400may include more than seven spindles400or less than seven spindles400. Spindles401,402,403,404,405,406and407are separated to form a plurality of spaces410between adjacent spindles400. In the exemplary embodiment, spaces411,412,413,414,415and416are formed between respective spindles401,402,403,404,405,406and407.

Moveable bracket382includes a first end420, a second end422and a first side424, a second side426, a third side428and a fourth side430located between first end420and second end422. Sides424,426,428, and430further define an internal cavity230between first end420and second end422. Moveable bracket382includes a plurality of apertures232disposed through first side424and third side428and in communication with internal cavity230. A plurality of aligned third moveable spindles440is coupled to and along first side424at about a 90 degree angle relative to first side424and extend from first side424along Y-axis. Alternatively, spindles440may couple to and extend from first side424at any angle to enable coil forming apparatus100to function as described herein. Spindles440are coupled to first side424and partially within apertures232. In the exemplary embodiment, the plurality of spindles440includes seven spindles441,442,443,444,445,446and447. Alternatively, the plurality of spindles440may include more than seven spindles440and less than seven spindles440. Spindles441,442,443,444,445,446and447are separated to form a plurality of spaces450between adjacent spindles440. More particularly, spaces451,452,453,454,455and456are formed by respective spindles441,442,443,444,445,446and447.

The plurality of spindles400of stationary bracket380is aligned in the same Z-planes and substantially orthogonal to the plurality of spindles440of moveable bracket382. More particularly, spindle401is aligned with spindle441; spindle402is aligned with spindle442; spindle403is aligned with spindle443; spindle404is aligned with spindle444; spindle405is aligned with spindle445; spindle406is aligned with spindle446, and spindle407is aligned with spindle447. Due to spindle alignment, the plurality of spaces410of stationary bracket380is aligned in the same Z-planes as the plurality of spaces450of moveable bracket382. More particularly, space411is aligned with space451; space412is aligned with space452; space413is aligned with space453; space414is aligned with space454; space415is aligned with space455, and space416is aligned with space456.

A drive system460is coupled to moveable bracket382. In the exemplary embodiment, drive system460is a pneumatic drive and includes an inlet port462and an outlet port464, which are coupled to a piston466. Piston466is coupled to moveable bracket382. Inlet port462and outlet port464are coupled to a pressure source (not shown) via pneumatic tubes. Alternatively, drive system460may include other drive configurations such as, for example, a hydraulic drive system460and a motorized gear system. Drive system460can include any configuration to enable coil forming apparatus100to function. Drive system460is configured to reciprocally slide moveable bracket382longitudinally within track388and along Z-axis.

Fourth arm122includes a stationary bracket468coupled to second plate108and a moveable bracket470coupled to stationary bracket468. Stationary bracket468includes a first end472, a second end474and a track476located between first end472and second end474. Track476is configured to couple to and guide moveable bracket470as moveable bracket470moves relative to stationary bracket468as described herein. Stationary bracket468further includes a first side478, a second side480, a third side482and a fourth side484located between first end472and second end474.

A plurality of aligned fourth stationary spindles490are coupled to third side482at about a 90 degree angle relative to third side482and extend from third side482along Y-axis. Alternatively, spindles490may couple to third side482at any angle to enable coil forming apparatus100to function as described herein. In the exemplary embodiment, the plurality of spindles490includes seven spindles491,492,493,494,495,496and497. Alternatively, the plurality of spindles490may include more than seven spindles490or less than seven spindles490. Spindles491,492,493,494,495,496and497are separated to form a plurality of spaces500between adjacent spindles490. In the exemplary embodiment, spaces501,502,503,504,505and506are formed between respective spindles490. Stationary bracket468includes a plurality of grooves329disposed within third side482, wherein grooves329are positioned substantially orthogonal to the plurality of spindles490. Spindles490are coupled to a handle331which is configured to rotate spindles490into grooves329as described herein.

Moveable bracket470includes a first end510, a second end512and first side514, a second side516, a third side518and a fourth side520located between first end510and second end512. A plurality of aligned fourth moveable spindles530are coupled to second side516at about a 90 degree angle relative to second side516and extend from second side516along X-axis. Alternatively, spindles530may couple to and extend from third side518at any angle to enable coil forming apparatus100to function as described herein. In the exemplary embodiment, the plurality of spindles530includes seven spindles531,532,533,534,535,536and537. Alternatively, the plurality of spindles530may include more than seven spindles530and less than seven spindles530. Spindles531,532,533,534,535,536and537are separated to form a plurality of spaces540between adjacent spindles530. More particularly, spaces541,542,543,544,545and546are formed by respective spindles531,532,533,534,535,536and537.

The plurality of spindles490of stationary bracket468is aligned in the same Z-planes and substantially orthogonal to the plurality of spindles530of moveable bracket470. More particularly, spindle491is aligned with spindle531; spindle492is aligned with spindle532; spindle493is aligned with spindle533; spindle494is aligned with spindle534; spindle495is aligned with spindle535; spindle496is aligned with spindle536, and spindle497is aligned with spindle537. Due to spindle alignment, the plurality of spaces500of stationary bracket468is aligned in the same Z-planes as the plurality of spaces540of moveable bracket470. More particularly, space501is aligned with space541; space502is aligned with space542; space503is aligned with space543; space504is aligned with space544; space505is aligned with space545, and space506is aligned with space546.

A drive system550is coupled to moveable bracket470. In the exemplary embodiment, drive system550is a pneumatic drive and includes an inlet port552and an outlet port554, which are coupled to a piston556. Piston556is coupled to moveable bracket470. Inlet port552and outlet port554are coupled to a pressure source (not shown) via pneumatic tubes. Alternatively, drive system550may include other drive configurations such as, for example, a hydraulic drive system550and a motorized gear system. Drive system550can include any configuration to enable coil forming apparatus100to function. Drive system550is configured to reciprocally slide moveable bracket470longitudinally within track476and along Z-axis.

In first position102(shown inFIGS. 1-3), the pluralities of spindles200,240,300,350,400,440,490and530are aligned in respective Z-planes. More particularly, spindles201,241,301,351,401,441,491and531are aligned in a Z-plane. Spindles202,242,302,352,402,442,492and532are aligned in a Z-plane. Spindles203,243,303,353,403,443,493and533are aligned in a Z-plane. Moreover, spindles204,244,304,354,404,444,494and534are aligned in a Z-plane. Spindles205,245,305,355,405,445,495and535are aligned in a Z-plane. Spindles206,246,306,356,406,446,496and536are aligned in a Z-plane. Still further, spindles207,247,307,357,407,447,497and537are aligned in a Z-plane.

A plurality of electrical wires558(shown inFIGS. 1-3) is coupled to and around coil forming apparatus100. In particular, electrical wires558are coupled, under tension, to first arm116and second arm118and to third arm120and fourth arm122. Each electrical wire558includes an insulating coating560. Electrical wires558are positioned within spaces wherein the pluralities of spindles200,240,300,350,400,440,490and530couple to and segregate electrical wires558into separate bundles562along Z-axis. Since bundles562are coupled to first arm116, second arm118and to third arm120and fourth arm122, each bundle562includes a first corner bend564at first arm116, a second corner bend566at second arm118and includes a third corner bend568at third arm120and a fourth corner bend570at fourth arm122. In the exemplary embodiment, bends564,566,568and570include about a 90 degree angle relative to Z-axis. Alternatively, bends564,566,568and570may include any angle to enable electrical wire to function as described herein. Electrical wire558includes a conductive material such as copper and is rectangular in cross section. Alternatively, electrical wire558may include other conductive materials such as, for example, aluminum, gold, silver and can include other cross sectional shapes such as round and square.

FIG. 4is a side elevational view of coil forming apparatus100in a second position572.FIG. 5illustrates an opposite side elevational view of coil forming apparatus100shown inFIG. 4.FIG. 6illustrates a front elevational view of coil forming apparatus100shown inFIG. 4. In second position572, drive system370slides moveable bracket270longitudinally within track276. More particularly, drive system370moves moveable bracket270along Z-axis and toward first plate106. The plurality of first moveable spindles350moves with moveable bracket270and toward first plate106. In second position572, the plurality of spindles350is shifted along Z-axis. During movement of the plurality of spindles350, spindles350couple to bundles562and preform bundles562. In the exemplary embodiment, spindles350preform bundles562by pushing bundles562toward first plate106. More particularly, spindles350facilitate forming a first bend574within each bundle562. In the exemplary embodiment, bend574includes about a 45 degree angle relative to Z-axis. Alternatively, moveable bracket270may move toward first plate106to facilitate spindles350preforming bends574in bundles562at angles less than 45 degrees and at angles greater than 45 degrees.

Moreover, in second position572, drive system550slides moveable bracket470longitudinally within track476. More particularly, drive system550moves moveable bracket470along Z-axis and toward second plate108. The plurality of fourth moveable spindles530moves with moveable bracket470and toward second plate108. In second position572, the plurality of spindles530is shifted along Z-axis. During movement of the plurality of spindles530, spindles530couple to bundles562and preform bundles562. In the exemplary embodiment, spindles530preform bundles562by pushing bundles562toward second plate108. More particularly, spindles530facilitate forming second bend576within each bundle562. In the exemplary embodiment, bend576includes about a 45 degree angle relative to Z-axis. Alternatively, moveable bracket470may move toward second plate108to facilitate spindles530performing bends576in bundles562at angles less than 45 degrees and at angles greater than 45 degrees. In second position572, the pluralities of spindles350and spindles530are moved toward frame104and are unaligned in different Z-planes with the pluralities of spindles200,240,300,350,400,440and490as compared to first position102(shown inFIG. 1).

FIG. 7is a side elevational view of coil forming apparatus100in a third position578.FIG. 8is an opposite side view of coil forming apparatus100shown inFIG. 7.FIG. 9illustrates a front elevational view of coil forming apparatus100shown inFIG. 7. In third position578, drive system110moves first plate106along X-axis and toward but spaced from second plate108. Alternatively, drive system110may move second plate108along X-axis and toward but spaced from first plate106. In third position578, drive system110moves first plate106and or second plate108along X-axis to reduce or minimize tension within bundles562.

In third position578, drive system260slides moveable bracket126longitudinally within track132. More particularly, drive system260moves moveable bracket126along Z-axis and away from first plate106. The plurality of first moveable spindles240moves with moveable bracket126and away from first plate106. In third position578, the plurality of spindles240is shifted along Z-axis. During movement of the plurality of spindles240, spindles240couple to bundles562and preform bundles562. In the exemplary embodiment, spindles240preform bundles562by pushing bundles562away from first plate106. More particularly, spindles240facilitate forming third bend580within each bundle562. In the exemplary embodiment, bend580includes about a 45 degree angle relative to Z-axis. Alternatively, moveable bracket126may move away from first plate106to facilitate spindles240preforming bends580in bundles562at angles less than 45 degrees and at angles greater than 45 degrees.

Moreover, in third position578, drive system460slides moveable bracket382longitudinally within track388. More particularly, drive system460moves moveable bracket382along Z-axis and away from second plate108. The plurality of third moveable spindles440moves with moveable bracket382and away from second plate108. In third position578, the plurality of spindles440is shifted along Z-axis. During movement of the plurality of spindles440, spindles440couple to bundles562and preform bundles562. In the exemplary embodiment, spindles440preform bundles562by pushing bundles562away from second plate108. More particularly, spindles440facilitate forming fourth bend582within each bundle562. In the exemplary embodiment, bend582includes about a 45 degree angle relative to Z-axis. Alternatively, moveable bracket382may move away from second plate108to facilitate spindles440preforming bends582in bundles562at angles less than 45 degrees and at angles greater than 45 degrees. In third position584, the pluralities of spindles240and spindles490are moved away from frame104and unaligned in different Z-planes with the pluralities of spindles200,300,350,400,440and530as compared to first position102(shown inFIG. 1).

In at least one of first position102, second position572and third position578, spindles300which extend beyond third side282of stationary bracket268are configured to form at least one intermediate bend581in each electrical wire558. Further, in at least one of first position102, second position572and third position578, spindles490which extend beyond third side482of stationary bracket468are configured to form at least one intermediate bend587in each electrical wire558.

FIG. 10is a side elevational view of coil forming apparatus100in a fourth position584.FIG. 11is an opposite side elevational view of coil forming apparatus100shown inFIG. 10.FIG. 12illustrates a front elevational view of coil forming apparatus100shown inFIG. 10. In fourth position584, drive assembly110moves first plate106and second plate108along X-axis toward each other to facilitate releasing tension applied to the pluralities of bundles562, wherein bundles562are shown partially released from tool100. In fourth position584, the plurality of spindles240are moved to a retracted position586. More particularly, the plurality of spindles240are moved within cavity230and partially extend beyond third side138of stationary bracket124. Additionally, in fourth position584, the plurality of spindles440are moved to retracted position586. More particularly, the plurality of spindles440are moved within cavity230and partially extend beyond third side394stationary bracket380

In the exemplary embodiment, spindles240and spindles440are moved to retracted position586under force, applied by a user (not shown), to spindles240and spindles440. More particularly, the user pushes spindles240and spindles440downward and into cavity230. Alternatively, spindles240and spindles440may be automatically moved to retracted position586by a powered drive system. Any configuration for applying force may be used to move spindles240and spindles440to retracted position586.

Moreover, in fourth position584, spindles300and spindles490are moved to retracted position586. More particularly, spindles300and spindles490are rotated within the plurality of grooves329which are sized and shaped to receive spindles300and spindles490. In the exemplary embodiment, spindles300and spindles490are rotated to retracted position586under force, applied by the user, to spindle300and spindles490. More particularly, user rotates handles331that are coupled to spindles300and spindles490respectively. Alternatively, spindles300and spindles490may be automatically moved to retracted position586by a powered drive system110. Any configuration for applying force may be used to move spindles300and spindles490to retracted position586. Alternatively, in retracted position586, at least a portion of spindles300may extend beyond third side282of stationary bracket268to form another intermediate bend (not shown) in each electrical wire558. Further, in retracted position586, at least a portion of spindles490extends beyond third side482of stationary bracket468to form another intermediate bend (not shown) in each electrical wire558. Moreover, in retracted position586, spindles240,440and spindles300,490are decoupled from bundles562to facilitate removal of bundles562from coil forming apparatus100to enable unloading of bundles562from coil forming apparatus100. Spindles200,350,400and530remain coupled to bundles562to separate bundles562to facilitate grasping each bundle562while removing each bundle562from coil forming apparatus100.

FIG. 13is a perspective view of an electrical coil588formed from bundle562(shown inFIG. 12) now removed from coil forming apparatus100.FIG. 14is a front elevational view of electrical coil588shown inFIG. 13. Electrical coil588includes a first straight segment590and an opposite second straight segment592. Moreover, electrical coil588includes a first end turn594and an opposite second end turn596. Electrical coil588further includes second corner bend566located between second straight segment592and first end turn594, wherein bend566includes a substantially 90 degree angle relative to second straight segment592and first end turn594. First end turn594includes first bend574located between first straight segment590and second straight segment592, wherein bend576includes a substantially 45 degree angle.

Electrical coil588further includes first corner bend564and third bend580between first end turn594and first straight segment590. Bend564includes a substantially 90 degree angle relative to first end turn594and first straight segment590and third bend580includes a substantially 45 degree angle relative to first end turn594and first straight segment590. In the exemplary embodiment, electrical coil588includes third corner bend568and fourth bend582located between first straight segment590and second end turn596. Fourth bend582includes a substantially 45 degree angle relative to first straight segment590and second end turn596and third corner bend568includes a substantially 90 degree angle relative to first straight segment590and second end turn596. Second end turn596includes second bend576which includes a substantially 45 degree angle. Fourth corner bend570is located between second end turn596and second straight segment592, wherein bend570includes a substantially 90 degree angle relative to second end turn596and second straight segment592. Alternatively, bends564,566,568,570,574,576,580, and582may include any angle to enable electrical coil588to function as described herein.

Bends564,566,568,570,574,576,580,582,581and587in electrical coil588facilitate reducing size and weight of electrical coil588. The length of first straight segment590is different than at least one of second straight segment592, first end turn594and second end turn596. More particularly, first straight segment590has a shorter length than at least one of first straight segment590, first end turn594and second end turn596. Moreover, first end turn594and second end turn596have a shorter length than second straight segment592. The reduction of length of at least one of first straight segment590, second straight segment592, first end turn594and second end turn596minimizes losses such as resistive losses and thermal losses, which increases the efficiency of electrical coil588. Further, the reduction of length of at least one of first straight segment590, second straight segment592, first end turn594and second end turn596minimizes needed material such as copper, which reduces the cost of electrical coil588.

Moreover, bends564,566,568,570,574,576,580,582,581and587are configured to position first end turn594and second end turn596in different planes than first straight segment590and second straight segment592. More particularly, first end turn594extends in a first plane A. Second end turn596extends parallel to first end turn594in first plane A. Due to at least third bend580and fourth bend582, first straight segment590extends in a second plane B which is different than first plane A. Further, due to at least first bend574and second bend576, second straight segment592extends in a third plane C that is different than first plane A and second plane B. Alternatively, bends574,576,580and582may be angled to position first straight segment590and second straight segment592in the same plane. Still further, bends564,566,568,570,574,576,580,582,581and587of electrical coil588are sized, shaped and positioned within electrical coil588to facilitate efficient coupling of electrical coil588to other adjacent electrical coils588.

FIG. 15is a perspective view of a plurality of electrical coils588coupled together.FIG. 16is a perspective view of the plurality of electrical coils588shown inFIG. 15coupled to a stator598. Bends564,566,568,570,574,576,580,582,581and587in electrical coil588facilitate coupling together adjacent electrical coils588. In the exemplary embodiment, bends564,566,568,570,574,576,580,582,581and587facilitate coupling together electrical coils588in a sequential arrangement599. More particularly, sequential arrangement599includes a nest arrangement600. First corner bend564and third corner bend568are configured to align with and couple to first corner bend564and third corner bend568of adjacent electrical coil588. Second corner bend566and fourth corner bend570are configured to align with and couple to second corner bend566and fourth corner bend570of adjacent electrical coil588. First bend574is configured to couple and within adjacent first bend574of adjacent electrical coil588. Second bend576is configured to couple and within adjacent second bend576of adjacent electrical coil588. Third bend580is configured to couple to and within adjacent third bend580of adjacent electrical coil588. Fourth bend582is configured to couple to and within adjacent fourth bend582of adjacent electrical coil588.

Stator598includes a stator core602having a plurality of slots604, and the plurality of electrical coils588. The stator core602is preferably formed from a plurality of laminations606, and is preferably cylindrically shaped. It will be appreciated that the stator core602need not be formed from individual laminations606, but could also be formed of a single, cast piece. Stator core602has a first end608, a second end610, an outer circumferential surface612, and an opening614that extends through it along an axis616, thereby forming an inner circumferential surface618. It is noted that stator core602may be formed of any one of numerous known materials known in the art including, but not limited to, electrical-grade steels such as cobalt-iron and silicon-iron.

Each of the plurality of slots604is formed on inner circumferential surface618. Slots604preferably extend longitudinally between the first and second ends608,610of stator core602, and are preferably evenly spaced around the inner circumferential surface618. In addition, each of the slots604is radially sized to receive electrical coils588, one in an inner slot position and one in an outer slot position. Electrical coils588are wound around the stator core602by inserting nest arrangement600into adjacent slots604.

FIG. 17is a partial view ofFIG. 16illustrating the plurality of electrical coils588coupled to stator598. Pre-forming electrical coils588reduces insertion time and effort by reducing effective coil span and coil length582,581and587. Moreover, nest arrangement600reduces and/or eliminates a stacking effect during electrical coil insertion. Still further, nest arrangement600reduces and/or eliminates additional forming to be applied to electrical coil588during insertion into stator598. More particularly, preformed first end turn594and second end turn596minimizes an extension length620from first end608and second end610respectively. More particularly, extension length620is less than conventional extension length of typical end turns. Accordingly, nest arrangement600reduces and/or eliminates interference with motor components (not shown) such as, but not limited to, motor brackets and baffles. Moreover, since nest arrangement600reduces and/or eliminates further forming such a pushing or bending electrical coil588to make room for adjacent electrical coil588, nest arrangement600reduces stress applied to the installer's arms and/or hands. The ergonomics of electrical coil insertion is improved which increases process productivity. Moreover, since nest arrangement600reduces and/or eliminates further forming such a pushing or bending electrical coil588to make room for adjacent electrical coil588, nest arrangement600reduces stress applied insulating coating560.

FIG. 18illustrates an exemplary flowchart illustrating a method1800of assembling electrical coil588. Method1800includes coupling an electrical wire, such as electrical wire588(shown inFIG. 1) to a spindle assembly, for example spindle assembly114(shown inFIG. 1). More particularly, method1800includes coupling1802the electrical wire to a first moveable bracket, such as first moveable bracket126(shown inFIG. 1), of the spindle assembly. The first moveable bracket is positioned in a first position, such as first position102(shown inFIG. 1), with respect to a frame, for example frame104, of the spindle assembly. Method1800includes coupling1804the electrical wire to a second moveable bracket, such as second moveable bracket270(shown inFIG. 1), of the spindle assembly. The second moveable bracket is positioned in the first position with respect to the frame.

In the exemplary embodiment, method1800includes moving1806the second moveable bracket toward the frame to a second position, for example second position572(shown inFIG. 4). A plurality of second moveable spindles, such as second moveable spindles350(shown inFIG. 4), of the second moveable bracket is coupled1808to the electrical coil to form a first bend, such as first bend574(shown inFIG. 4) in the electrical wire. The method1800further includes moving1810the first moveable bracket away from the frame to a third position, for example third position578(shown inFIG. 7). Moreover, in the exemplary embodiment, method includes coupling1812a plurality of first moveable spindles, such as first moveable spindles240(shown inFIG. 7), of the first moveable bracket to the electrical wire and forming another bend, for example bend580(shown inFIG. 7), in the electrical wire.

The exemplary embodiments described herein facilitate forming electrical coils for an electrical machine. More particularly, the exemplary embodiments are configured to facilitate insertion of the electrical coil within the electrical machine. Moreover, the exemplary embodiments reduce stress applied to the installer's arms and/or hands during electrical coil insertion. Still further, the exemplary embodiments reduce stress applied to insulation of the electrical coil during electrical coil insertion. Additionally, the exemplary embodiments reduce the length of the electrical coil which reduces resistive losses during operation of the electrical coil.

Exemplary embodiments of a coil forming apparatus and methods for assembling an electrical coil are described above in detail. The methods and systems are not limited to the specific embodiments described herein, but rather, components of systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the methods may also be used in combination with other manufacturing systems and methods, and are not limited to practice with only the systems and methods as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other electrical component applications. Moreover, the electrical machine can include a forced air device, such as a fan, coupled to housing and/or shaft.

While the embodiments described herein are described with respect to motors in which a stator surrounds a rotor such as, for example, a permanent magnet rotor or an induction rotor, embodiments are contemplated in which an “inside-out” motor incorporates one or more of the improvements described herein. Inside-out motors refer to motors where a stationary stator is surrounded by a rotating rotor. Further, the embodiments are applicable to any permanent magnet rotating machine.