Apparatus for winding wire coils on a toothed stack

A wire feed winding needle mounting support and a stack mounting support permit movement of the winding needle and a stack in at least three coordinate axis directions relative to each other. The supports may be formed on separate modules for variable angular orientation relative to each other. A number of motors control relative movement of the winding needle and stack along the three directions for winding selected teeth in the desired distribution. The invention provides as a basic component pliant bearing surface clamp members on either side of the row of teeth of a stack to be wound. A clamp mounting yoke and further motor means alternately move the pliant bearing surfaces toward and away from the row of teeth on either side between a clamp position and an open position. The winding wire filament is alternately clamped against one side of the row of teeth and then the other while the winding needle moves up and down and back and forth "dancing" over the row of teeth seating the wire in slots between teeth of the stack without itself passing between adjacent teeth through the slots. The winding wire is unclamped by releasing the pliant bearing surfaces on both sides of the row of teeth while shifting the stack and row of teeth relative to the winding needle to different slot and tooth locations.

TECHNICAL FIELD 
This invention relates to a new winding apparatus and method for winding 
wire around selected teeth of a toothed or slotted iron core or stack. The 
invention is applicable to a variety of complex windings. 
BACKGROUND ART 
Complex stack or core windings are required for certain motor and sensor 
applications. For example, the stator and rotor windings used in angle 
sensitive transformer resolvers require a complex distribution of annular 
turns for measuring angles. Typically, a tapered distribution of copper 
turns on iron teeth is utilized. 
For high resolution angle resolvers, the teeth of the stack are formed 
correspondingly closer together. At sufficiently high resolutions the high 
density of the teeth and narrowness of the slots prevent a wire feed 
winding needle from passing through the slots between teeth to form the 
turns of wire. Yet turns of wire must be wound at different controlled 
depths on the teeth and with spans extending around different numbers of 
teeth. Furthermore, the turns may have to be formed within the small space 
defined by an annular stack with inwardly projecting teeth. 
Conventional flying head core winding machines do not lend themselves to 
achieving such distributions. In particular, they are inapplicable to 
annular stack configurations having teeth extending radially inwardly. The 
typical single and double flier type core winding machines such as, for 
example, described in U.S. Pat. Nos. 3,973,738; 3,857,172; 3,705,459; and 
2,949,554 are adapted for winding around radially outwardly projecting 
teeth only. Even with radially outwardly projecting teeth flying head 
machines generally wind only large spans of teeth and cannot wind turns of 
wire around single teeth or small spans. 
OBJECTS OF THE INVENTION 
It is therefore an object of the present invention to provide a stack 
winding method and apparatus for automatically winding selected teeth of a 
toothed or slotted stack with windings of tapered or other irregular 
distributions of copper. In particular, the invention is adapted for 
accurate placement of wire turns at selected specified depths on teeth of 
a stack, for winding single teeth or small spans of teeth, and for winding 
turns of wire at high density in small spaces. 
Another object of the invention is to provide an inexpensive method and 
apparatus for automating the winding of complex distributions of copper on 
slotted and toothed stacks having high density teeth and narrow slots, 
particularly where a wire feed winding needle cannot pass through the 
slots between teeth. 
A further object of the invention is to provide an automated method and 
apparatus for stack winding of slotted and toothed stacks of varied 
configuration including both linear and annular stack configurations and 
annular stacks having either radially inwardly projecting or radially 
outwardly projecting teeth, or teeth arranged on axes skewed or angled 
relative to the stack axis. 
DISCLOSURE OF THE INVENTION 
In order to accomplish these results the present invention provides a stack 
winding apparatus using a wire feed winding needle of the hollow type for 
feeding and winding wire around selected teeth of the stack or core. 
According to the invention, the winding needle and stack are mounted on 
supports for movement relative to each other in three coordinate axis 
directions. 
According to the invention the needle, rather than passing through the 
slots between teeth, "dances" over the teeth in alignment with a slot, 
moving up from the base or other selected depth of the teeth, across the 
teeth and down on the other side thereby laying wire in a slot. During 
this movement, the wire is held in place at the base or other selected 
depth of a slot on the side of the teeth by novel pushers or clamps of 
pliant material. 
The stack and winding needle then translate relative to each other along 
the row of teeth to another slot location. There, the winding needle 
"dances" back over to complete a turn. While laying the wire in the second 
slot by movement up, across the teeth and down, the wire is again retained 
in place at the base or other selected depth of the teeth by a pliant 
pusher or clamp on the other side. Thus, according to the invention the 
winding needle forms the turns of copper wire not by passing through the 
slots but by "dancing" back and forth over the row of teeth in alignment 
with slots. 
This action is achieved by motion of the winding needle and stack relative 
to each other in three mutually perpendicular coordinate axis direction. A 
first direction is back and forth across the row of teeth from one side to 
the other. A second direction is up and down parallel to the teeth, and a 
third direction is along the row of teeth. 
For example, in one embodiment the winding needle mounting support 
comprises a swing plate mounted on an axle for rotational motion through a 
prescribed and limited arc. A translating needle carrier is further 
mounted on the swing plate for imparting translational motion to the 
winding needle relative to the swing plate. The needle carrier operates by 
extending and retracting a needle mounting arm which extends beyond the 
side of the swing plate. 
The wire feed winding needle is mounted at the end of the needle mounting 
arm and therefore translates back and forth across a row of teeth in the 
first coordinate axis direction upon rotational motion of the swing plate 
through the prescribed arc. In addition, extension and retraction of the 
needle arm by the needle carrier imparts translational motion up and down 
parallel with the slots to the winding needle in the second substantially 
orthogonal coordinate axis direction. 
The iron stack or core to be wound is supported in a stack mounting plate 
constructed and arranged for imparting independent movement to the toothed 
stack relative to the winding needle and needle mounting arm in yet a 
third coordinate axis direction generally along the row of teeth of the 
stack. Thus, the row of teeth may be shifted left and right relative to 
the winding needle. Where the slotted stack is of annular configuration 
movement of the stack and row of teeth relative to the winding needle is 
accomplished by rotating the stack in opposite clockwise and 
counterclockwise rotational directions. The stack mounting plate positions 
the row of teeth of the stack or core at a location beneath or adjacent to 
the winding needle with the winding needle in alignment with a slot. 
A number of motors may provide the relative movement between the stack and 
winding needle. For example, a first motor drives the needle mounting 
support for motion of the needle back and forth in the first direction 
across the stack to either side of the row of teeth. In one embodiment 
this is accomplished by engaging the swing plate to move the swing plate 
back and forth through a prescribed arc. A second motor drives the needle 
carrier and needle mounting arm for extension and retraction for moving 
the winding needle up and down along the second direction parallel with 
the slots and teeth of the stack. 
A third motor is coupled to the stack mounting plate for moving the stack 
itself and row of teeth right and left relative to the winding needle in a 
third substantially orthogonal axial direction along the row of teeth of 
the stack. For example, the third motor drives a worm gear which engages 
the geared periphery of a circular frame in the stack mounting plate for 
rotational motion of annual configuration stacks and cores. 
However, a variety of arrangements and configurations may be constructed 
for imparting relative motion between the winding needle and stack along 
three perpendicular coordinate axis directions. In a preferred form of the 
winding apparatus the winding needle and needle arm are mounted on a first 
winding apparatus module which imparts motion to the winding needle in the 
first and second orthogonal coordinate axis directions. The toothed stack 
is mounted on a second winding apparatus module for movement of the row of 
teeth relative to the winding needle in a third coordinate axis direction. 
The modules are juxtaposed so that the winding needle "dances" over the 
row of teeth without passing through the slots laying turns of wire 
according to the method of the invention around desired spans of teeth. 
The invention further provides as a basic element wire clamps or pushers 
made of pliant material such as rubber positioned on either side of the 
row of teeth of the stack. A clamp mounting support mounts the clamps for 
movement toward and away from the row of teeth between a clamp position 
and an open position. In the clamp position the pliant bearing surface of 
the clamp or pusher bears against a portion of one side of the row of 
teeth of the stack, conforming to the surface of any winding already 
formed around selected teeth. As a result, the winding wire filament and 
windings of wire already formed are held in place near the base of a slot 
or at a desired depth while the winding needle "dances" over the row of 
teeth, moving relative to the stack back and forth or up and down seating 
windings of wire filament in selected slots. In the open position when the 
pliant bearing surfaces of the clamps or pushers are withdrawn and 
released the stack and row of teeth or the winding needle are moved in the 
third direction along the row of teeth relative to each other for 
subsequently winding wire filament around teeth and through slots at 
further locations. 
A feature and advantage of the winding wire pusher or clamp according to 
the invention is that turns of wire can be held in place at any selected 
depth along the height of a tooth. The winding needle lays the wire at the 
desired depth in a slot and the pusher holds it in place against a tooth 
while the winding needle moves up and over the row of teeth to the correct 
depth on the other side of the row. 
In the swing plate form of the invention a clamp yoke is formed coaxially 
around the axle for independent rotational movement relative to the axle. 
The clamp yoke is formed with first and second yoke arms extending on 
either side of the axle and swing plate. A clamp or pusher mounting arm 
extends from each of the respective first and second yoke arms in a 
direction parallel with the needle mounting arm. Each clamp or pusher 
comprises a member of pliable material such as rubber mounted respectively 
on the clamp mounting arms. A fourth motor drives the clamp yoke for 
imparting reciprocal rotational motion so that the pliant surface of the 
clamps or pushers alternately extend back and forth between the clamp 
position and the open position. The stack mounting plate positions the 
stack and row of teeth at a location below or adjacent the winding needle 
and between the clamps or pushers supported by the clamp yoke. 
In a preferred form of the invention using first and second stack winding 
apparatus modules, the pliant clamps or pushers and clamp arms extend from 
a rotatable shaft mounted from the second module for pushing and 
retracting the clamps between the clamp position and release position. A 
feature and advantage of the two module winding apparatus is that the 
first and second modules can be oriented at an angle relative to each 
other for winding angled or skewed teeth as well as right angle teeth. 
Thus, the axes of the teeth and slots may be offset at an angle to the 
stack axis. 
According to the stack winding method the present invention contemplates 
positioning relative to each other at a first location the wire feeding 
winding needle and a toothed stack to be wound. The wire is placed at a 
desired depth relative to the teeth and slots. The invention then provides 
for clamping the winding wire or filament from the winding needle against 
one side of the row of teeth of the stack using the pliant surface of the 
clamp or pusher thereby holding the wire at the first location. At each 
such location, the winding needle is generally aligned with a slot. 
The invention then contemplates the steps of raising the winding needle 
from a position adjacent to the base of the row of teeth of the stack or 
other desired depth to a position above the row of teeth, moving the 
winding needle from a position on one side of the row of teeth to a 
position on the other side, and then lowering the winding needle to a 
position adjacent to the base of the row of teeth or other desired depth 
so that wire is seated in the slot between teeth of the row. These steps 
of raising the winding needle, moving it across the row, and then lowering 
it on the other side all take place while clamping the winding wire 
against the row of teeth on the initial side at the desired wire turn 
location. Furthermore, the characterization used herein that the winding 
needle "dances" over the row of teeth in laying turns of copper wire 
refers to these steps. 
Further steps follow according to the invention of unclamping the wire on 
the one side by releasing the pliant surface of the clamp and moving the 
stack and row of teeth relative to the winding needle to a second location 
at which the winding needle is aligned with a slot. 
A series of similar steps then follows on the other side by clamping the 
wire at a desired depth against the other side of the row of teeth with 
the pliant surface of a clamp or pusher according to the invention and 
then in sequence raising the winding needle from a position at the desired 
depth to a position above the row of teeth, moving the winding needle from 
the position on the other side of the row of teeth back to a position on 
the initial side, and then lowering the winding needle to the desired 
depth so that the wire is seated in another slot between teeth of the row, 
thereby completing a turn or partial turn of wire. 
Finally the method provides for unclamping the wire on the other side by 
releasing the pliant surface of the clamp or pusher and again moving the 
stack and row of teeth relative to the winding needle to another location. 
The foregoing steps by which the winding needle dances over the row of 
teeth laying turns of wire are of course repeated according to a 
programmed sequence either manually or by the use of automated machinery 
and controls to complete windings around selected teeth in the desired 
distribution pattern and configuration. 
According to the preferred form of the invention the method is applicable 
to stacks of annular configuration and the step of moving the stack and 
row of teeth relative to the winding needle is accomplished by reciprocal 
rotation of the stack in clockwise and counterclockwise directions 
relative to the winding needle. In this respect the method and apparatus 
of the invention are applicable to annular stacks or cores which are 
slotted or toothed around either the inner periphery or circumference or 
the outer periphery or circumference, or on both sides. Furthermore, the 
invention is applicable to linear cores having rows of teeth in linear or 
other noncircular configuration. The method permits winding coils of 
different densities and numbers of turns, around different spans of teeth 
including a single tooth, and with accurate placement along the depth of 
the teeth and slots. 
Throughout the winding method specified tension is maintained on the 
winding wire passing through the winding needle for achieving neat, well 
placed and taught turns of wire filament in each winding. Such a wire 
tensioning device or arrangements may be mounted on the stack mounting 
plate or other portion of the apparatus to achieve the desired tension as 
the wire feeds to the winding needle. Other objects, features and 
advantages of the present invention will become apparent in the following 
specification and accompanying drawings.

DESCRIPTION OF PREFERRED EXAMPLE EMBODIMENTS AND BEST MODE OF THE INVENTION 
A stack winding machine or apparatus 10 according to the invention is 
illustrated in FIGS. 1-3. As there shown, winding wire or filament 11 is 
fed through a hollow wire feed winding needle 12 for winding in a selected 
pattern around the teeth 14 of slotted stack or core 15. In the embodiment 
of FIGS. 1-3 a stack or core 15 of annular configuration is shown. 
Furthermore, the annular stack 15 is slotted or toothed around its inner 
periphery or circumference. As is hereafter apparent, the invention is 
applicable also to annular stacks slotted or toothed around the outer 
periphery or circumference and to linear stacks having at least a row of 
teeth. 
The winding needle 12 is of the hollow type for feeding and winding wire 
held under selected tension by a standard tensioning means or device, not 
shown, which may be mounted on the apparatus. The winding wire is 
delivered through the tensioning device from a source not shown. 
Winding needle 12 is mounted on the needle mounting arm 18 which extends 
from the needle carrier 19 which in turn is mounted on and connected to a 
swing plate or needle mounting plate 20. The needle swing plate 20 is 
mounted for rotational movement on an axle 22. The swing plate 20 
undergoes reciprocal rotation through a prescribed arc and is driven in 
this swinging or rotational movement by a first drive motor 24 which 
rotates a gear element 25. The rotating gear 25 engages a rack 26 mounted 
at the free end of swing plate 20 for rotational motion or swinging motion 
of swing plate 20 through a prescribed arc. As a result of the swinging 
motion of plate 20 the winding needle 12 undergoes translation back and 
forth across the row of teeth 12 from one side of the teeth to the other 
side in a first coordinate axis direction. 
The needle carrier 19 from which extends the needle mounting arm 18 
includes a winding needle motor 19a which extends and retracts the needle 
arm 18 by, for example, driving a conventional lead screw which lifts 
needle arm 18 up and down on a threaded sleeve or nut for imparting up and 
down motion of the winding needle 12 in a second coordinate axis direction 
parallel to the slots between the selected teeth 14 around which the wire 
is being wound. 
The annular stack or core 15 is mounted for rotational movement in a 
circular frame or insert 28 in turn supported in a stack mounting plate 30 
positioned adjacent to the swing plate 20. The stack mounting plate 30 is 
fixed in stationary postion while the circular frame or insert 28 may 
rotate relative to the stack plate 30. In order to effect the rotation of 
the stack 15 within the stack mounting plate 20 the circular frame or 
insert 28 is formed around its outer periphery with a geared surface 32. 
A worm gear 34 external to the mounting plate 30 engages the complimentary 
surface 32 formed around the periphery of insert 28. The worm gear may be 
formed on the axle 22 below the stack 15 and insert 28 or on a separate 
axle 35 positioned at the top of stack mounting plate 30 above the stack 
15 and insert 28 as shown in FIG. 1. The worm gear 34 which engages the 
complementary gears 32 of the insert 28 is driven by a third motor 38 
which upon rotation translates or moves the row of teeth 14 back and forth 
in the vicinity of winding needle 12 in a third coordinate axis direction 
orthogonal to the first and second directions. A feature and advantage of 
this arrangement is that the stack may be shifted left or right as many 
teeth as desired for winding turns around different numbers of teeth, e.g. 
1, 2, 3 teeth at a time, etc. After each stack shift the winding needle is 
aligned with a slot when the stack stops. 
Another basic element of the stack winding apparatus according to the 
invention is a clamp yoke 40 fitted and mounted around axle 22 for free 
rotation relative to the axle. The clamp yoke 40 includes elongate yoke 
arms 42 and 43 which extend on either side of the axle 22 and swing plate 
20. A clamp or pusher block support arm 44 extends from each yoke arm 42 
and 43. A clamp, pusher, or block 45 made of resilient material such as 
rubber is mounted at the end of the each of the clamp arms 44 extending 
from the respective yoke arms 42 and 43. As shown in FIG. 3 and also in 
more detail in FIG. 4, each clamp block 45 includes spaced apart clamping 
elements 45a and 45b spaced from each other a distance corresponding to 
the spacing of the teeth 14 of the stack or core 15 to be wound. 
The fixed elements of the stack winding apparatus including stack mounting 
plate 30, motors 24, 48 and 38 and axle 22 are fixed and mounted to a side 
frame 60 shown in FIG. 3. 
As is apparent in FIGS. 1-3 the stack mounting plate 30 positions the stack 
or core 15 to be wound at a location adjacent to swing plate 20 so that 
the selected teeth at the row of teeth 14 to be wound are positioned 
beneath or adjacent to winding needle 12 and between the clamp blocks 45. 
The clamp yoke 40 is driven for reciprocal rotational motion relative to 
the axle 22 by means of a fourth motor 48. By rotational motion of clamp 
yoke 40 the clamp blocks or pushers 45 are alternately applied to and fro 
against a portion of the row of teeth 14 of stack 15 between a clamp 
position and an open position. In the clamp position the resilient face 46 
of clamp block 45 is applied against a portion of the side of the row of 
teeth and the resilient surface 46 yields and conforms to the irregular 
surface on the side where previous windings may have already been formed. 
In this manner, the winding wire is held securely against the side of the 
teeth for further winding operations as hereafter described without injury 
or damage to the wire. 
The clamping blocks or pushers 45 positioned on either side of the stack to 
be wound are shown in further detail in FIG. 4. It is noted that each 
clamp block or pusher 45 of pliant material such as rubber includes two 
clamp elements 45a and 45b which generally coincide with adjacent portions 
of the row of teeth 14 of the stack 15. During the winding operation as 
hereafter described only one of the elements 45a or 45b on either side is 
actually operative to secure the winding wire at the desired location. 
Thus, only the diagonally opposite elements 45a and 45b are operative 
according to the direction of translation and direction of winding as 
shown in FIGS. 4A and 4B. The detailed sequence of steps for stack winding 
according to the method of the present invention and the corresponding 
operation of the winding wire clamps or blocks are further elucidated with 
reference to FIGS. 5A through 5I. 
At the outset of the winding operation the wire feed winding needle 12 and 
toothed stack to be wound 15 are positioned relative to each other to 
initiate the winding operation. In particular, the winding needle 12 and 
toothed stack 15 are positioned relative to each other at a first location 
as illustrated in FIG. 5B. At this location the winding wire is clamped 
against one side of the row of teeth 14 by the pliant bearing surface 46 
of clamp block or pliant member 45b which is moved into the clamping 
position as shown in FIG. 5C. 
In the illustrated steps of FIG. 5 the stack 15 may represent either a 
linear stack or annular stack having a row of teeth 14 in a generally 
linear sequence either as the straight row of a linear stack or as the 
portion of a row of teeth from the inner or outer periphery of an annular 
stack. While clamp block element 45b is in the clamp position, clamp 
element 45a on the opposite side of the row of teeth 14 is in the open 
position. Furthermore, throughout the initial steps illustrated in FIGS. 
5B and 5C the winding needle 12 is at a location on one side of the row of 
teeth adjacent to the base of the slots between the teeth 14 for seating 
the winding wire 11 at the base of a slot. 
After clamping as shown in FIG. 5C, the winding needle 12 is raised upward 
in the second coordinate axis direction parallel to the direction of teeth 
as shown in FIG. 5D. While FIG. 5D has the same appearance as FIG. 5C 
because it is a plan view from above, it should be kept in mind that the 
winding needle 12 is in a lower position adjacent to the base of the slots 
between teeth 14 in FIG. 5C and in raised position above the teeth 14 in 
FIG. 5D. 
In the next step according to the stack winding method the winding needle 
12 traverses across and over the row of teeth 14 from one side of the 
stack to the other side in the first coordinate axis direction while the 
winding wire 11 is clamped against the initial side of the row of teeth 
14. The needle then drops from the raised position above the row of teeth 
14 to a lower position adjacent the base of the slots and respective teeth 
14 as shown in FIG. 5F. While FIG. 5F appears similar to FIG. 5E because 
it is a plan view it should be kept in mind that the winding needle 12 is 
in raised position in FIG. 5E and in lowered position in FIG. 5F. 
The back and forth motion of winding needle 12 from one side of the row of 
teeth 12 to the other is effected by the first motor 24 swinging or 
rotating the swing plate 20 through a prescribed arc. The motion of 
winding needle 12 up and down in the second axial direction is implemented 
by needle carrier motor 19a extending and retracting the needle mounting 
arm 18 and therefore raising and lowering the winding needle 12 relative 
to the row of teeth 14. Throughout such steps, the winding needle is 
always in alignment with a slot for laying wire in the slot but without 
passing through the slot. 
The clamp block 45b is then released and clamp block elements 45a and 45b 
on opposite sides of stack 15 are temporarily both in the open position as 
shown in FIG. 5G. With,the clamp blocks both in open position the row of 
teeth 14 is then translated back to the left relative to the winding 
needle and clamp blocks which in the case of the annular configuration 
stack is effected by clockwise rotation of stack 15 within the rotating 
frame or insert 28 of stack mounting block 30. In the event a linear stack 
is wound the row of teeth is simply translated in the desired direction. 
Movement of the stack 15 and row of teeth 14 to the left relative to 
winding needle 12 and clamp blocks 45a and 45b is illustrated in FIG. 5H. 
The opposite clamp block element 45a is then actuated to the clamping 
position by fourth motor 48 and clamp yoke 40 pushing and clamping the 
winding wire 11 against the other side of the row of teeth 14. A sequence 
of steps then follows with clamp block element 45b in clamping position 
comprising raising the winding needle 12 from a position adjacent the base 
of the row of teeth to a position above the row of teeth; moving the 
winding needle from the position on the other side of the row of teeth to 
a position on the initial side of the row of teeth: and lowering the 
winding needle once again to a position adjacent to the base of the row of 
teeth so that the winding wire is again seated in a slot between teeth 14 
of the row. However, at no time does the winding needle pass through a 
slot. 
Clamp block element 45b is then released and while the clamping members 45a 
and 45b on opposite sides of the row of teeth are both in open position 
the step follows of again moving the stack 15 and row of teeth 14 this 
time to the right relative to the winding needle 12 to another location 
for further winding operations. 
It is apparent from the sequence of steps set forth above that in the 
method of stack winding according to the present invention the winding 
needle "dances" up and down and back and forth over the row of teeth in 
alignment with a slot seating the winding wire in slots between respective 
teeth of the stack. During the "dance" of the winding needle, the clamping 
blocks or elements alternately clamp the winding wire against one side of 
the row of teeth and then the other side by means of the pliant surface 
while the winding needle moves up and down and back and forth over the row 
of teeth. Of equal importance, the clamping blocks or elements on opposite 
sides of the stack release the pliant surfaces from either side of the row 
of teeth and both remain in open position while the stack and row of teeth 
move relative to the winding needle and clamp blocks or elements to 
different slot and teeth locations of the stack. A diagrammatic and 
perspective representation of the "dance" of the winding needle according 
to the method of the present invention is illustrated in FIG. 6. 
In FIG. 6 the sequence of steps according to the stack winding method are 
renumbered 1 through 12 for convenience. In step 1 the stack is rotated to 
place the row of teeth in positon relative to the stack winding needle at 
a first location. At the end of step 1 the clamping member or block on the 
one side or initial side of the row of teeth is actuated into the clamping 
position against the winding wire and row of teeth represented in the 
diagram by numeral 2. The winding needle then rises above the row of teeth 
represented by line 3, traverses over or across the row of teeth 
represented by line 4, and lowers on the other side to the base of a slot 
of the row of teeth represented by line 5. By this sequence of steps the 
winding wire is seated in the base of a slot at the desired first 
location. The first clamping block or member on the initial side of the 
row of teeth is then released represented by the corner designation 
numeral 6 and while the clamps on both sides of the row of teeth are in 
open position the stack is rotated or translated represented by line 7 to 
a position relative to the winding wire at a second location. After each 
stack shift, a slot in the row of teeth is aligned with the winding 
needle. 
At the second location the clamp or clamping member on the other side of 
the row of teeth, that is the second clamping member, is actuated to the 
clamp position clamping and holding the winding wire against the opposite 
side of the row of teeth which step is represented by the corner 
designation numeral 8. While the second clamping member on the opposite 
side of the row of teeth is in clamp position the winding needle rises 
from a position at the base of the slot and teeth at the second location 
to a raised position above the row of teeth represented by line 9. The 
winding needle then traverses or translates across and over the row of 
teeth represented by line 10, and then lowers on the initial side to a 
position at the base of the slot at the second location represented by 
line 11. 
The second clamp on the opposite side of the row of teeth is then released 
and while both clamps are in open position the stack may be rotated or 
translated placing the row of teeth relative to the winding needle in 
another location for further winding operations. 
A critical feature of the method according to the present invention is the 
interrelationship of the "dance" of the winding needle and the actuation 
of the pliant surface clamps or clamping blocks between the clamp position 
and open position. Referring to FIG. 6, during steps 3, 4, and 5 the 
winding wire is clamped against the initial side of the row of teeth by 
the clamping block on that side. During steps 9, 10, and 11 the winding 
wire is clamped against the opposite side of the row of teeth. During 
steps 1 and 7 both clamping blocks on either side of the row of teeth are 
in open position. 
A sequential listing of each of the steps corresponding to FIG. 6 and the 
corresponding state of the stack winding elements is found in Table I. 
During most of the steps the stack and row of teeth are stopped and in 
fixed position. However, at appropriate steps in the method the stack or 
row of teeth typically alternately shift left and then right or rotate 
clockwise and then counterclockwise. The alternate right and left shifts 
or clockwise and counterclockwise rotational shifts alternately position 
the stack and row of teeth relative to the winding needle for placing 
multiple turns of wire in the desired copper density distributions such as 
the tapered distributions required for angle resolver transformer 
windings. 
It will be readily apparent to one skilled in the art that the four motors 
actuating and driving the moving elements of the stack winding apparatus 
and method may be automatically controlled in desired programmed sequences 
using, for example, a microprocessor. In this way complex winding 
distributions may be achieved and automated in accordance with the 
apparatus and method of the present invention. Furthermore, a variety of 
other hardware arrangements may be used for achieving relative motion 
between the winding needle and stack in three coordinate axis directions. 
While the invention has been described with reference to particular example 
embodiments, it is intended to cover all variations and equivalents within 
the scope of the following claims. 
TABLE I 
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WIRE GUIDE 
NEEDLE CLAMP #1 CLAMP #2 
STEP POSITION POSITION STACK POSITION 
______________________________________ 
1 Down Open Shift Open 
Right 
2 Down Clamp Stop Open 
3 Up Clamp Stop Open 
4 Traverse Clamp Stop Open 
5 Down Clamp Stop Open 
6 Down Open Stop Open 
7 Down Open Shift Left 
Open 
8 Down Open Stop Clamp 
9 Up Open Stop Clamp 
10 Traverse Open Stop Clamp 
11 Down Open Stop Clamp 
12 Down Open Shift Open 
Right 
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