FLAT COIL DYNAMOELECTRIC DEVICE, PREFORM THEREFOR, AND METHOD AND APPARATUS FOR USE IN THEIR MANUFACTURE

Abstract: A discoidal, flat coil armature for a flat disc motor is formed by winding coils of wire on mutually spaced inner and outer ring structures (60, 62). The inner ring structure surrounds a commutator body (44) having segments (50) with tangs (52). Automatic apparatus, including a rotating flier (128), a preform clamp (140) and rotator, and a wire guide assembly (190, 216) winds the coils and makes coil terminal connections to the commutator tangs before, during, and after the winding of the coils. The coils are tightly wound on the ring sutructures so that they form, along with the ring structures and the commutator body, an armature preform having a self-supporting shape. The parts of the finished preform are bonded together and to an armature shaft by a matrix (114) of resinous material. When com­ pleted, the armature includes a thin-walled, active coil section having substantially radially extending active coil sides encapsulated in plastic and located between the inner and the outer ring structures and also includes inner and outer coil end turns that are also encapsulated in plastic and that extend substantially circumferentially along the inner and the outer ring structures, respectively.

Description: Flat Coil Dynamoelectric Device, Preform Therefor, and Method and Apparatus for use in their manufacture This invention relates to a flat coil dynamoelectric device It also relates to a preform, method of manufacture and apparatus for use in the manufacture of such a device. The invention is particularly, but not exclusively, concerned with a discoidal armature of the type comprising plural, flat coils wound from insulated wire, the armature having a thin-walled, flat annular active coil section surrounding a center structure including a commutator to which the several coils are connected. However, the invention is not necessarily so limited. For example, certain aspects of the invention could apply to the manufacture of dynamoelectric devices, such as field members. which do not include a commutator. Many approaches have been used to manufacture flat coil dynamoelectric devices, but the known techniques require the use of time-consuming and expensive manual steps and/or the use of elaborate and extensive equipment for winding and thereafter handling the coils as needed to form the completed devices. The invention aims to simplify and thereby reduce the cost of manufacturing flat coil dynamoelectric devices. Provided in accordance with one aspect of the invention is a preform for a flat coil dynamoelectric device, comprising an outer frame structure having a self-supporting shape and being substantially symmetrical about a center axis, an inner frame structure substantially symmetrical about said center axis located within and substantially coplanar with said outer frame structure and having a self-supporting shape,and plural coils of wire wound on said frame structures, said coils having sides spanning between said frame structures and end turns extending generally along along said frame structures. Preferably, the coils are so wound that their inner and outer end turns substantially overlie the inner and the outer frame structures respectively, and securely engage surfaces thereof, the coil sides extend substantially radially to the common axis of the frame structures; and the coil sides span between the two frame structures. The coils are wound under sufficient tension, and the frame members built to withstand such tension, that the completed preform comprises a self-supporting body which may be handled by automatic materials handling equipment in essentially the same manner it would be handled if it were a solid piece. Upon completion of the preform, it is encapsulated in a matrix of resinous material to form the completed dynamoelectric device. According to another aspect the invention provides a flat coil dynamoelectric device comprising a preform having an outlet frame structure having a self-supporting shape and being substantially symmetrical about a center axis, an inner frame structure substantially symmetrical about said center axis located within and substantially coplanar with said outer frame structure and having a self-supporting shape, plural coils of wire wound on said frame structures, said coils having sides spanning between said frame structures and end turns extending generally along said frame structures, and a matrix of resinous material encapsulating said frame structures and said coils. In a preferred embodiment described in detail hereinafter, the device is a flat coil armature, and the preform frame comprises concentric inner and outer ring structures having surfaces over which the coil end turns are engaged. A commutator body is located within the bore of the inner ring structure and has tangs extending therefrom. Appropriate connections of the coil terminal wire portions to the commutator tangs are made before during, and after the coils are wound. The commutator body is securely mounted within the bore of the inner ring structure and the coils are wound under sufficient tension that the wound assembly (termed an armature preform") of the preform frame and the commutator have a self-supporting shape. The preform may, accordingly, be handled by automatic materials handling equipment, there being no loose coils or wire leads requiring attention. The invention also resides, according to a further aspect, in a method of manufacturing a flat disc armature, comprising the steps of: providing an inner frame structure and an outer frame structure; winding coils of wire having outer end turns adjacent and engaging said outer ring structure, inner end turns adjacent and engaging said inner ring structure, and side turns spanning between said inner and outer structures; and after the winding of all coils has been completed, encapsulating said inner and outer frame structures and said coils in a matrix of resinous material. Conveniently ,either #fore#ortter nepreforin z waind ,the commutator is mounted on an armature shaft and the preform and the shaft located within the cavity of a plastic molding machine, such as an injection molding machine, whereupon the inner and outer ring structures along with the coil wires therebetween are encapsulated in a matrix of resinous material. The matrix of resinous material also encapsulates the commutator tangs and the lead wire connections thereto and surrounds portions of the armature shaft and the commutat*r body. An armature embodying the invention may-have a well defined, thin-walled active coil section with the active coil wires extending along substantially radial paths to maximize the efficiency with which the coils are affected by the magnetic fields within which they operate. The end turns of the coils are coursed over surface portions of the inner and outer rings shaped to retain the inner and outer end turns of each coil separated from one another and from the area of the active coil sections. According to yet another aspect there is provided by the invention an apparatus for use in manufacturing a preform for a dynamoelectric device, the preform having a frame comprising an inner frame structure and an outer frame structure, said frame structures being spaced apart and having a common axis, and a plurality of coils extending around said axis, said coils having outer end turns retained by retaining means provided on said outer frame structure and inner end turns retained by retaining means provided on said inner frame structure. the apparatus comprising: : preform clamp means for holding said inner and said outer frame structures in a predetermined substantially coplanar, relative rotary, and mutually coaxial relation on a predetermined axis; a wire guide flier rotatable about a winding axis parallel to and spaced from said predetermined axis; means for rotating said flier about said winding axis; wire guide shield means for guiding wire exiting from said flier, when said flier is rotating, into engagement with both said inner coil end turns retaining means and said outer coil end turns retaining means and shielding other portions of said preform frame from being engaged by said wire so that a coil of wire is wound on said preform frame having sides spanning between said frame structures; and means for rotating said clamp means about said predetermined axis so that additional coils of wire may be wound on said preform frame at different positions thereon. In accordance with a still further aspect the invention provides a method of winding coils of wire in the manufacture-of a preform for a dynamoelectric device having a preform frame comprising an inner frame structure having inner coil end turns retaining means and an outer frame structure having outer coil end turns retaining means, said frame structures being spaced apart and having a common axis and said preform having a plurality of coils extending around said axis, said coils having outer end turns retained by said outer coil end turns retaining means and inner end turns retained by said inner coil end turns retaining means, said method comprising the steps of: : holding said inner and outer frame structures in a predetermined relative rotary and mutually coaxial relation on an axis parallel to and spaced from a predetermined axis of rotation of a wire guide flier; rotating said flier and, while said flier is rotating. guiding wire exiting from said flier into engagement with both said inner coil end turns retaining means and said outer coil end turns retaining means while shielding other portions of said preform frame from being engaged by said wire so that a coil of wire is wound on said preform frame having side edges spanning between said inner and outer frame structures; and rotating said preform frame so that additional coils of wire may be wound at different locations thereto. The presently preferred coil winding method and apparatus of this invention provide for both automatically winding coils of wire onto the preform frame and automatically connecting terminal ends of the coils to appropriate commutator tangs before, during, and after the winding of the coils in those cases in which the completed preform is to include a commutator. Furthermore, the coils of wire can be wound under sufficient tension and with sufficiently secure commutator connections, if the preform includes a commutator, that the completed preform has a self-supporting shape. The preform may, accordingly, readily be handled by automatic materials handling equipment, there being no loose coils or wire leads requiring attention. A full understanding in its various aspects will be gained from the following detailed description given with reference to the accompanying drawings, in which: Figure 1 is a perspective view of an armature made in accordance with this invention. Figure 2 is an axial, end view of an armature preform and an armature shaft, the preform and the shaft forming part of the armature of Figure 1. Figure 3 is a fragmentary axial, end view of a preform frame and a commutator forming part of the preform of Figure 2, and showing a first armature coil wound on the preform frame. Figure 4 is an axial, end view of the preform frame and a commutator showing the first three coils wound thereon in full lines and the fourth coil in phantom lines. Figure 5 is a cross-sectional view of a portion of the armature preform taken along line 5-5 of Figure 2. Figure 6 is a simplified, cross-sectional view of tooling 'of a plastic injection molding machine with the armature of Figure 1 shown formed therein. Figure 7 is a simplified diagrammatic and schematic view of. an armature winding machine in accordance with this invention used to wind coils and form commutator connections to the coils to produce the armature preform of Figure 2, and illustrating the armature preform frame at the winding station of the machine. Figure 8 is an enlarged, fragmentary, elevational view, partly in cross-section, of a portion of the machine of Figure 7 with the armature preform frame and the commutator at the winding station. Figure 9 is an enlarged, fragmentary, exploded, perspective view of a portion of the machine of Figures 7 and 8 and including the preform frame and the commutator. Figure 10 is a fragmentary perspective view of the machine, the preform frame, and the commutator as viewed from a point of reference different from that of Figure 9, and showing the position of parts in readiness to commence the winding of coils and the formation of commutator connections. Figure 11 is a fragmentary elevational view of parts of the machine, showing wire shielding and guiding structure by both full and phantom lines, along with a wire clamp and the preform parts, the machine elements and the preform parts being represented in the same position reached in Figure 10. Figures 12, 14, 16, 18, 20 and 22 are each similar to Figure 10 and show, in sequence, the steps taken to loop the start wire of the first coil to be wound about a commutator tang in advance of the winding of such first coil. Figures 13, 15, 17, 191 21 and 23, are each similar to Figure 11 but show the position of the parts reached in Figures 121 14, 16, 18, 20 and 22, respectively. Figures .24 and 25 are similar to Figures 10 and ll, respectively, but show the parts in readiness to wind the first coil on the preform frame. Figures 26 and 27 are views similar to Figures 10 and ll, respectively, but show the parts after the winding of the first coil is completed. Detailed Description With reference to Figure 1, an armature designed for use in a flat disc motor and made in accordance with this invention is generally designated 40, and comprises a discoidal, encapsulated winding 42, a commutator 44, and an armature shaft 46. The armature shaft 46 is designed to engage bearings within the motor housing (not shown), and may be of any conventional construction. The commutator 44 comprises a plurality of circumferentially spaced conductive segments 50 on a cylindrical body of plastic press-fit on the shaft 46. The segments 50 each have means for connection to terminal portions of the several armature coils, such connection means being shown in Figures 2 through 6 and comprising commutator tangs 52, there being one tang 52 forming part of each one of the segments 50. The winding body 42 is of a circular, disc-like configuration, having an outer ring 54, an inner hub 56, and a circular web 58. The hub 56 is formed, as will be described below, so as to be adhered both to a portion of the commutator 44 and to a portion of the armature shaft 46. The construction is such that the encapsulated winding 42 is securely affixed to the copmutator 44 and the shaft 46 so that, when in use, rotation imparted to the winding body 42 by the motor field magnets (not shown) will be transmitted directly to the shaft 46. The encapsulated winding 42 includes plural coils wound from insulated wire, preferably insulated copper wire, which are encapsulated in a resinous material. The resinous material and the wire sections forming the web 58 have a minimal thickness and are so formed that wire strands (as indicated by W in Figure 1), may be exposed at the surfaces of the web 58. The radial dimensions of the web 58 are determined by the design paramaters of the motor with which the armature 40 is to be used. More specifically, permanent magnet pole pieces in the motor housing (not shown) or the like will be located as close as possible to the web 58 and the radial dimensions of the web 58 are designed to accomodate the dimensions of the pole pieces. The pole pieces typically would be located on one side of the web 58, with steel located on the other side of the web 58, it being desirable in the construction of such motors that the spacing needed to accomodate the web 58 between the pole pieces and the steel or other motor parts be kept to a minimum. As will be described below, the portions of the armature coils lying within the web 58 are arrayed on lines extending generally radially from the axis of the armature shaft 46, and the portions of the coils located within the outer ring 54 and the hub 56 comprise end turns which are located outside of the ambit or projection of the pole pieces, such end turns extending generally coaxially around the axis of the armature shaft 46. With reference to Figures 2 through 6, the manufacture of the armature 40 may be accomplished entirely automatically by a process wherein coils of wire are wound from a continuous, uninterrupted length of wire onto a preform frame 59. Frame 59 comprises a pair of coaxially oriented and substantially coplanar frame members, namely an inner ring 60, which may be press-fit, hot-welded, molded or otherwise fixedly mounted on the commutator 44, and an outer ring 62 extending circularly around and spaced from the inner ring 60. The inner ring 60 comprises a disc-like, thin-walled toroidal, main body portion 64, the front and rear surfaces of which may be planar and further comprises a plurality of inner coil forming protrusions or lugs 66 projecting forwardly from the main body portion 64. (For convenience, the term ¯forward' as used herein, refers to the end of the armature whereat the coils are connected to the commutator tangs 52.) The lugs 66 are preferably in the form of L-shaped fingers or hooks and cooperate with the adjacent forward face of the inner ring 60 to form inner coil end turn-receiving channels 68. The outer ring 62 comprises a disc-like, thin-walled toroidal main body portion 69 having planar front and rear surfaces and further comprises plural, substantially radially extending outer coil forming lugs 70 protruding from the main body portion 69. In addition, the outer ring 62 comprises a rearwardly extending annular flange 72 surrounding its bore 62A. For reasons which will appear below, the bore 62A of the main body portion 69 of the outer ring 62 tapers inwardly from front to rear as may be best seen in Figures 5 and 8. Both the inner and the outer rings 60 and 62 may be made from a non-conductive material having sufficient strength, stability, and rigidity to have a self-supporting shape and to withstand the loads applied during and after manufacture. A glass-filled nylon is an example of a material suitable for this purpose. Numerous other thermoset or thermoplastic materials may be used. Materials other than plastic, such as metal having an insulating coating or amorphous materials would also be suitable. For proper operation of the armature 40 it is necessary that the rings 60 and 62 be non-magnetic. A resinous material is preferred because the rings can readily and inexpensively be manufactured in large quantities therefrom. The outer end turns of each armature coil extend between a pair of circumferentially spaced outer coil forming lugs 70 and the inner end turns extend between a pair of circumferentially spaced inner coil forming lugs 66 with the coil sides which form the active coil portions spanning between the inner and the outer rings 60 and 62. The location of the armature coils on the preform 59 may be best understood with reference to Figures 3 and 4, which show a first coil 74 wound on the inner and the outer rings 60 and 62. The first coil 7-4 has a first active side 74A and a second active side 74B. These lie along lines extending nearly radially from the center axis of the preform frame 59. The coil 74 further includes inner end turns 74C and outer end turns 74D spanning respectively across spaced inner coil forming lugs 66 and outer coil forming lugs 70. Because the outer coil forming lugs 70 project substantially radially in the embodiment illustrated in the drawings, whereas the inner lugs 66 extend generally parallel to the center axis of the frame 59, the coil sides 74A and 74B along with the inner coil end turns 74C lie along the front of the preform frame 59. In contrast, the outer end turns 74D are formed over the outer periphery of the outer ring body 69 alongside the outer coil forming lugs 70 which they engage and then along the backside of the body of the outer ring 62. The mid-portion of the outer end turns 74D stretching along the backside of the outer ring body 69 lie against the outer periphery of the annular flange 72 and are thereby prevented from entering the area occupied by the active coil sides 74A and 74B, i.e., the area of the web 58 of the completed armature. Since the inner end turns 74C overlie inwardly directed surfaces of a pair of inner coil forming lugs 66 and the outer end turns 74D are constrained by the outer coil forming lugs 70 they engage to overlie outwardly directed surface portions of the outer ring body 69, the preform frame 59 effectively constitutes a coil form that determines the shape of the first coil 74 and all subsequent coils wound thereon. As will be further described below, in the illustrated embodiment, when the winding of the armature 40 is commenced, the start end S of the wire W forming the first coil 74 is wrapped around one of the commutator tangs 52 (such tang being designated 52A in Figures 3 and 4) so that the start end S is extended from the selected tang 52A and coursed adjacent one of the inner coil forming lugs 66 and the wire is then wound into the first coil 74. After the first coil 74 is wound as shown in Figure 3, the finish wire portion thereof, designated F, is advanced to the commutator tang 52B next adjacent the second active side 74B of the first coil 74 looped around the tang 52B, and the wire then coursed to wind second coil 76 shown in Figure 4. The process is repeated then to wind the third coil 78 shown in Figure 4, and so forth. In the embodiment of the armature shown in the drawings, there are sixteen coils, all sixteen being shown in Figure 2. The first coil wound is identified in Figure 2 by its coil sides 74A and 74B, the second coil by its sides 76A and 76B, the third coil by its sides 78A and 78B, the fourth coil wound by its sides BOA and BOB and also by its outer end turns BOD, the fifth by its sides 82A and 82B, the sixth by its sides 84A and 84B, and the seventh by its sides 86A and 86B and also by its outer end turns 86D. The eighth through the fifteenth coils are designated in Figure 2 respectively by reference numbers 88, 90r 92, 94, 96, 98, 100 and 102, the lead lines to such coils extending from the reference number toward the first coil sides thereof. Finally, the sixteenth coil wound is designated in Figure 2 by its first coil side 104A and its second coil side 104B. Extending from the last side turn of coil side 104B is a terminal finish wire end T that is looped around the same commutator tang 52B about which the start wire S is looped. It may be observed in Figures 2, 3 and 4 that there are sixteen commutator tangs 52, sixteen inner coil forming lugs 66, and sixteen outer coil forming lugs 70. However, it is to be understood that other geometries are possible involving greater or lesser numbers of tangs, lugs, and coils. Also, it will be noted in the drawings that each coil spans across three of the inner coil forming lugs 66 and three of the outer coil forming lugs 70 and it will further be observed, as may be appreciated best from a study of Figure 4, that there is a spacing between subsequently wound pairs of coils of two of both the inner and outer coil forming lugs 66 and 70. Accordingly the coils are effectively wound in layers of three each. Thus it can readily be appreciated, with reference to Figure 4, that the fourth coil wound, which is shown by phantom lines 80, spans across the first side 74A of the first coil 74. Those familiar with armature windings will recognize the winding pattern is of a type known as retrogressive wave winding. A progressive wave winding could also be accomplished within the purview of this invention as well as both progressive and retrogressive lap windings. With the wave winding pattern illustrated, it will be observed that the second set or layer of three coils is 1/16th offset in a circumferential direction from the first layer. The same is true for subsequent layers. If there were to be 18 coils, each layer would be 1/18th offset from the adjacent layer and so forth. However, as mentioned above, many other winding patterns and geometries may be produced. The completed assembly, shown in.Figure 2, of the preform frame 59, the coils 74-104 wound on the frame 59, and the commutator 44, to which the coil terminal wires are connected is termed an armature preforms herein and is referred to generally by reference number 105. The coils are relatively tightly wound with as many turns per coil as dictated by the performance requirements of the motor with which the armature is to be used. With reference to Figure 5, a portion of the fully wound preform 105 and the armature shaft 46 are shown in cross-section. The first wound side 74A of the first wound coil 74 is illustrated in Figure 5, such coil side being shown to be flush against the forward surfaces of both the inner and outer rings 60 and 62. Parts of the fourth wound coil 80 span over the coil side 74A as mentioned above and are therefore visible in Figure 5, these being parts that constitute, respectively, the inner and outer end turns. Inner and outer end turns of the seventh wound coil 86, appear in Figure 5, these parts being coursed around the same inner and outer coil forming lugs 66 and 70 illustrated in Figure 5 that are engaged by the first coil end turns 74C and 74D. Also shown in Figure 5, looped about the tang 52 illustrated therein, is a wire loop 106 that interconnects the second side of coil 92 with the first side of coil 94. (Coils 92 and 94 are not shown in Figure 5.) It can be appreciated by an inspection of Figures 2 through 5 that the completed preform 105 has a circular array of tightly wound coils, each of which tends to pull the inner ring 60 toward the outer ring 62. When winding devices having an even number of slots and coils, each coil is diametrically opposed to ag essentially identical coil tending to pull the inner ring 60 in the opposite direction.Accordingly,th#e coil sides spanning between the inner and outer rings 60 and 62 are under tension and function mechanically somewhat like the spokes of a conventional bicycle wheel to hold the inner ring 60 and the outer ring 62 together and to resist relative movements of any kind therebetween. The same result will also obtain in those cases in which the device has an odd number of slots and coils or other configuration wherein each coil will be substantially, but not precisely, diametrically opposed by an essentially identical coil. For this reason, the fully wound preform has a substantially self-supporting shape and can be moved about or manipulated by mechanical devices as if it were a solid, one-piece part, there being no loose or highly flexible parts requiring special or separate handling. After the winding of the preform 105, fusing or hot-staking of each ofothe commutator tangs 52 is performed, as is conventionally done after the winding of other types of armatures having commutators with tangs. By such process, the free ends of the tangs 52 are bent, and thereby folded upon the wire portions looped therearound, from their positions almost parallel to the axis of the preform 105, such condition being shown by phantom lines in Figure 5, to positions wherein they are essentially perpendicular to such axis using an electrode that electrically heats the tangs and vaporizes the wire insulation, thereby insuring both secure electrical and secure mechanical connections to be made. Also, after the winding of the preform 105, the armature shaft 46 is press-fit within the bore of the commutator 44. After processing as described above, the preform 105 and the armature shaft 46 can be placed in an appropriate plastic molding machine, such as an injection or a compression molding machine, to encapsulate the windings as well as the inner and outer rings 60 and 62 in a matrix of molded resinous material which serves also to bond the various parts of the preform and the armature shaft together. One such operation is illustrated in Figure 6 wherein the preform 105 is shown positioned in an appropriately shaped cavity formed in confronting mold members 110 and 112. Molten plastic has been injected, using techniques that may be entirely conventional, into the mold cavity to form a pressure-shaped molded resinous matrix 114 that covers, and is ef#fectively integral with, the inner and outer tings 60 and 62 to form therewith, and with the coil portions supported thereby, the rear portion of the armature hub portion 56 and the entire outer argin 54 of the completed armature 40. The web 58 is similarly formed by an encapsulation of the coil side turns in the molded matrix 114. The forward part of the hub portion 56 is formed by the molten resin, which serves to encapsulate the inner coil forming lugs 66, the wire portions extending therearound, and also the tangs 52 and the wire parts that loop therearound. The resinous material used to form the molded matrix 114 may comprise any one of numerous available thermoset or thermoplastic materials; Polyethylene terephthalÅate (PET) is an example of a suitable material. The molding operation may occur using various different processes with the advantage that the parts of the preform 105, because they are self-supporting and of a substantially rigid configuration, can simply be placed into the mold cavity either by hand or by automatically operating machinery. As a preliminary to the molding operation, one may optionally flatten the coil sides because of the desirability of having the web 58 of absolute minimum thickness. Apparatus for winding the coils and forming the commutator connections is illustrated in Figures 7 through 27. Figure 7 is a simplified, somewhat diagrammatic and schematic view of the machine which is generally designated 120. The winding machine 120 has a flier spindle 122 driven by a motor 124 for rotation about a flier axis 126. A flier 128 is mounted on the spindle 122 for rotation therewith. Wire from a suitable source of wire 130 placed under tension by dereeler 131, which may be entirely conventional, is coursed through the spindle 122 and outwardly therefrom around a wire exit pulley 132 adjacent to the flier 128 and a flier--pulley 134 at the free end of--the flier 128. The wire W may be held by a clamp 136 which may be associated with a cutter mechanism (not shown) for severing the wire portions between the winding of subsequently wound armatures. Those familiar with flier type armature winding machines will recognize that the structure as thus far described in Figure 7 may be entirely conventional, various types of flier-type winding machines being well known. For this reason the flier drive is not described in further detail herein. The machine 120 illustrated in Figure 7 further includes a winding form assembly 138, that will be further described below, and a preform clamp and rotator assembly, generally designated 140. The preform clamp and rotator assembly 140 holds the inner and outer rings 60 and 62 in relatively fixed coaxial, substantially coplanar, and rotational positions, only the outer ring 62 being visible in Figure 7. The clamp and rotator assembly 140 includes a drive motor 142 and a clamp release cylinder 144 which, together with the remainder of the assembly 140, are mounted on a frame 146 which can be affixed to the bed of the machine (not shown). With continued reference to Figure 7, and also with reference to Figures 8 and 9, the commutator 44 is shown clamped by a split collet 148 which is held in clamping relation thereto by a spring washer assembly 150 surrounding a collet operating shaft 152 and biasing a collet operating ram 154 affixed to the end of the collet operating shaft 152 to the left as shown in Figure 8 so that the split collet 148 grippingly engages the commutator 44. It will be noted in Figures 7 and 8 that a collet operating lever 156 may be driven by the clamp release cylinder 144 so as to overcome the bias of the spring washer assembly 150 and thereby cause the collet operating ram 154 to be moved to the right as shown in Figure 8, whereupon the gripping pressure exerted by the collet 148 upon the commutator 44 will be reduced so as to permit insertion or removal of the commutator. The collet operating ram 154 cooperates, as is obvious, with a collet cam 158 to cause the'collet 148 to grip the commutator. The collet cam 158 forms part of a collet housing 160 which has on its forward face 161, i.e. the face confronting the winding form assembly 138, a forwardly extending projection or key 162 adapted to fit within a notch 164 in the rear face of the inner ring 60 (see Figure 9) for purposes of holding the inner ring 60 in a predetermined rotary relationship relative to the outer ring 62 as will be made more apparent below. The housing 160 is generally tubular and has four slots 166 spaced equally therearound within which are located clamp levers 168 mounted for pivotal movement on the housing 160 by pivot pins 170 and which are formed at their outer ends to innerfit within the bore of the outer ring 62. Three of the levers 168 are formed so as to snugly mate with and clamp against the tapered inner bore surface 62A of the outer ring 62. The fourth arm 168 is formed with a projection or key 172 for engaging a cooperating notch 174 (see Figure 9) in the bore 62A of the outer ring 62 so that the outer ring 62 is held in a predetermined rotary position relative to the four clamp levers 168. The levers 168 are each biased by springs 176 connected thereto any to the housing 160 so that the free ends of the levers 168, ire., those ends designed to engage the bore 62A, are biased outwardly to securely bold the outer ring 62. At such time as the collet release cylinder 144 is energized to release the grip on the commutator 44, the outer ring clamp levers, 168 are caused to be pivoted inwardly of the bore 62A and become disengaged from the outer ring 62 by virtue of engagement of the margins of a groove 178 encircling the collet ram 154 with pawl-like, radially inwardly projecting lugs 169 forming parts of the levers 168. The collet mechanism described above, including the collet 148, the collet ram 154, the housing 160, and the levers 168 are all rotatable about a collet axis 180 (see Figure 7 coincident with the axis of the commutator 44 and the preform frame 59. In Figure 7, the collet axis 180 is shown parallel to and offset from the flier axis 126 (as it would appear in a plan view), a condition necessary to enable the coils to-be successively wound about axes which are offset from the axis of the preform frame 59. As will be described below, the collet parts are caused to rotate by the clamp and rotator assembly drive motor 142 through a repeating series of steps to effect connection of the wire W to the commutator tangs and to wind the coils. Referring to Figures 8 and 9, the winding form assembly 1# includes a winding form 190 which, as conventional, is mounted by a bearing located within a housing 192 on the end of the flier spindle 122 and includes a pair of winding form support plates 194 and 196 on which is supported a form mounting block 197 on which wire guide plates 198, 206, and 214, to be described below, are mounted. The winding form 190 includes an outer wire guide plate 198 which has a concavely curved surface 200 adapted to shield a portion of the outer ring 62 to prevent the wire sliding along the plate 198 from engaging the outer ring 62. Adjacent curved surface 200, the outer guide plate 198 has sloping lower and upper wire guide edge surfaces 202 and 204, respectively, for guiding the wire around the outer coil forming lugs 70 across which extend the outer end turns of the coil to be wound. The winding form 190 further includes an inner wire guide plate 206 having sloping lower and upper wire guide edge surfaces 208 and 210, respectively, for guiding the wire around the inner coil forming lugs 66 across which the inner end turns of the coil extend. The center portion of the face of the inner guide plate 206 has a recess 212 designed to provide a pocket for the inner coil forming lugs 66 across which the inner end turns of the coil extend and is provided with an arcuate wire guide lip 213 designed to be located between the pocketed lugs 66 and the adjacent commutator tangs 52. As the flier 128 rotates during the winding of a coil to draw wire across the inner guide plate 206, the wire slides along the surface 208 and, as it enters the recess 212, engages along one side of one of the inner coil forming lugs 66 and is then forced by the arcuate wire guide lip 213 into the inner end turn receiving channels 68 shown in Figure 5. As the flier 128 continues to rotate, the wire is guided by the upper edge guide surface 210 to the other one of the inner coil forming lugs 66 which it engages. The outer wire guide plate 198 is spaced from the inner wire guide plate 206 by an intermediate guide plate 214 having a polished, planar guide surface 215 provided to closely confine the coil side turns adjacent the front surface of the rings 60 and 62 as the winding progresses. Referring to Figures 7, 9, and 10, an inner pin and commutator shield assembly 216 is provided to prevent the wire from engaging the commutator tangs or the wrong inner coil forming lugs 66. The assembly 216 includes an inner pin and commutator shield plate 218 to which is rigidly attached a positioning arm 220 that is pivotally supported by a clevis 222 at the end of a drive rod 224 of an inner pin and commutator shield positioning air actuator 226. The end of the positioning arm 220 remote from the shield plate 218 has S guide pin 228 that rides in an arcuate guide slot 230 in a guide plate 232. The inner pin and commutator shield plate 218 has a recess 234 shown in Figure 9 for receiving, selected ones of the inner coil forming lugs 66 and the commutator tangs, the recess being located in the face of the shield confronting the preform frame 59. The shield 218 is selectively located in either one of two positions, namely an extended position and a retracted position. Figure 27 shows in full lines the extended position which the shield plate 218 occupies during the time a coil is being wound. There it will be noted that the shield plate 218 overlies a sufficiently large portion of the front face of the inner ring 60 that only three of the inner coil forming lugs 66 are fully exposed, these being the same three pins pocketed by the central recess 212 of the inner guide plate 206. The shield plate 218, accordingly, shields all of the other inner coil forming lugs 66 as well as all of the commutator tangs 52 during the winding of a coil and thereby prevents the wire from hooking any portion of the inner ring 60 but for the lugs 66 about which the inner coil end turns are being formed. The face of the shield plate 218 opposite the face confronting the inner ring 60 is concavely contoured as needed to permit the wire to enter the center recess 212 of the inner guide plate 206 as the flier 128 rotates to wind a coil. The free end edge, designated 236, of the shield plate 218 is also contoured to assist in guiding the wire into the channels 68. In Figure 26 it can be seen that, in the extended position of the shield plate 218, its free end edge 236 is located closely adjacent to the inner wire guide plate 206. In the retracted position of the shield plate 218, shown in Figures 10 through 25 and in phantom lines in Figures 26 and 27, it is moved horizontally away from the inner guide plate 206 and is also pivoted in a counterclockwise direction, as viewed therein, for reasons which will become apparent. Figures 10 through 27 show in sequence the manner in which the apparatus of this invention operates to wind the preform shown in Figure 2. First, it may be noted that Figure 11 shows the same position of the parts that are illustrated in Figure 10. The same scheme is followed throughout the remaining Figures 12 through 27, with the odd numbered figures illustrating the parts in the same position as the immediately preceeding figure. Also, the odd numbered figures beginning with Figure 11 illustrate the winding form assembly 190 by phantom lines 190A. The margins of the winding form guide surfaces that cooperate with the inner ring 60 and the outer ring 62 to determine the shape of the coils are indicated by phantom lines 190B. In general, Figures 10 through 23 illustrate a sequence of steps that may be taken to loop the start wire end 8 around its associated tang 52A in preparation for the winding of the first coil 74. Figures 24 and 25 illustrate the position of parts at the commencement of the winding of the first coil 74 and Figures 26 and 27 show the position of the parts at the end of the winding of the first coil 74. After the parts have reached the position shown in Figure 27, the sequence of steps shown in Figures 14 through 27 are repeated for each coil to be wound. The looping of the wire portions about the tangs 52 is accomplished by a series of rotary movements of both the flier 128 and the preform assembly of the rings 60 and 62 and the commutator 44. During the looping operation, the shield plate 218 is located in its retracted position to enable the wire to be guided by the inner guide plate 206 along the side of the tang 52A around which it is to be looped, as is illustrated in Figures 12 and 13. To enable the rotary positions of the preform assembly to be quickly grasped, the key 172 engaging in the outer ring notch 174 is marked with hatch lines in the odd numbered figures beginning with Figure 11, and it should be recognized that the hatch lines do not in this case represent that the part is shown in cross-section. Those familiar with flier-type armature winding machines will appreciate that the process for winding the armature preform and making the appropriate connections to the commutator tangs is related to procedures disclosed in United States patent Nos. Re. 27,893 and 3,705,459, and will be able to comprehend the winding and tang looping procedures by studying Figures 3, 4, and 10 through 27 herein. At the commencement of the tang looping and coil winding process, the inner and outer rings 60 and 62 along with the commutator 44 are clamped in the position shown in Figures 10 and 11 and the free end of the wire W is held by the wire clamp 136. The looping of the start wire S around a tang 52 is begun by rotation of the flier in a "forward" direction, which is the same direction in which the flier is rotated to wind the coils. This is counterclockwise or stop-goingw as viewed in Figures 10 and 12. The wire W is thereby extended alongside the outer coil forming pin designated 70A in Figure 13 and also alongside the commutator tang 52A around which the start wire portion S is to be looped. The preform 105 is then rotated in a clockwise direction, as indicated by the arrow 242 in Figures 14 and 15, through an angle of slightly less than 90 degrees. During this rotary movement of the preform 105, the section of wire extending from the tang 52A to the flier pulley 134 is prevented by the shield plate 218 from hooking any of the tangs other than tang 52A. At the same time, the outer coil forming lug 70A moves out of engagement with the wire W, so that the length of the section of the wire W between the clamp 136 and the flier pulley 13; is shortened. Those familiar with armature winding machines will recognize that the dereeler 131 may be,#used to substantially remove the slack wire condition that would result from the shortening of such wire section. After the clockwise rotation of the preform frame 59 shown in Figures 14 and 15, the flier is rotated further in the forward direction as indicated by the arrows in Figures 16 and 17 through an angle of approximately 60 degrees in order to more securely hook the wire on the tang 52A. The wire is then looped around the tang 52A by rotating the preform frame 59 in a clockwise direction, as indicated by the arrows in Figures 18 and 19, through an additional angle on the order of 50 to 60 degrees which c,auses the tang 52A to move under the shield plate 218. The section of the wire W between the tang 52A and the flier pulley and also the section of wire between the flier pulley 134 and the tang 52A extend over the end edge of the tang shield plate 218 and the wire is almost completely looped around the tang 52A. After the parts have reached their positions shown in Figures 18 and 19, the flier is again rotated in its forward direction through approximately 60 degrees to complete the looping of the wire about the tang 52A as shown in Figures 20 and 21. During the increment of flier rotation between the positions of parts illustrated in Figures 18 and 19 and the positions illustrated in Figures 20 and 21, the stretch of wire between the tang 52A and the flier pulley 134 begins sliding along the upper wire guide surface 210 of the inner guide plate 206 so that the wire is guided to a position wherein it partly lies between the inner ring lug 66 next adjacent the tang 52A and the next adjacent counterclockwise inner ring lug 66. Accordingly, the preform 105 may then be further rotated to the position shown in Figures 22 and 23 to bring the lug 66A into engagement with such stretch of wire whereupon the preform parts and the flier are positioned to initiate the winding of the first coil 74. At or before the commencement of the winding of the first coil, the shield actuator 226 is energized to move the tang shield plate 218 into its maximum shielding or extended position shown in Figures 24 and 25. Thus, the shield plate 218 is pivoted in the clockwise direction and translated horizontally toward the winding form assembly 190. The flier may then be rotated in its forward direction to wind the first coil 74. During the winding operation, the wire is prevented from engaging the commutator tangs and all but the intended inner ring lugs 66 by the shield plate 218. During the winding of the first coil 74, the section of wire between the commutator tang 52A and the clamp 136 is severed. This is preferably done immediately adjacent the tang 52A and may be accomplished in various ways. The presently preferred method would be to cause the wire to be severed against the edge of the tang by abruptly moving the clamp 136 away from the commutator 44 clamped in the winding station by the clamp and rotator assembly 140. This method is described in U.S. patent No. 3,812,577, and a further discussion of the method or of apparatus for accomplishing the same is deemed unnecessary. A comparison of Figure 27, showing the first coil 74 fully wound, and Figure 13, reveals that the stretch of wire leading to the flier in in approximately the same orientation and that it leads to the flier from an outer coil forming pin 70 shown in Figure 27 that is in the same position as the outer coil forming lug 70A about which the lead wire was booked in the position shown in Figure 12. Accordingly, the parts are position when the winding of the first coil is completed to initiate the looping of the terminal end of the first coil 74 about the next adjacent tang 52B. The first step is to return the tang shield plate to its upper and outer or retracted position, as is indicated by phantom lines in Figures 26 and 27, to expose the tang 52B for engagement by the wire. The' sequence of steps illustrated and described in connection with Figures 14 through 27 are then epeated to accomplish the complete looping of the wire around the tang 52B and the¯winding of the second coil 76. These same steps are then repeated throughout the winding of the armature until all sixteen coils are wound. At the end of the winding operation, the finish wire T of the last wound coil 104 is looped around the same tang 52A about which the start wire S was looped by a repetition of the steps illustrated and described in connection with Figures 14 through 23. The next step is to sever the wire between the flier pulley and the wound armature. Again, this may be accomplished in known ways, the method described in patent No. 3,812,577 being preferred for this purpose. Those familiar with the art of armature winding will recognize that the aforedescribed steps for winding the armature may be varied for different armature configurations. Some of the steeps may not be needed for certain armature configurations, while others may require additional steps. The operÅation of the machine 120 is controlled by machine control circuitry, schematically illustrated at 250 in Figure 7, by which the motors 124 and 142 and the actuators 142 and 226 are selectvely energized to perform their functions in proper sequence. Those familiar with flier-type armature winding machines will recognize that control circuitry used for armature rotators, such as that shown in United States patent No. 3,673,878, may be used for controlling the clamp and rotator assembly drive motor 142. More recently developed electronic controlled rotators, which are well known and widely used in the art, could also be used. Electronic controls for operating fliers are also well known in the industry,; United States patent No. 4,163,931, discloses one form of circuitry for this purpose. Because the machine control 250 could take various forms and may be old and well known, it is not further illustrated or described herein. The preform 105 described above includes the commutator 44. Such is preferred in the case of armature winding because all of the commutator connection steps are performed entirely automatically as the winding progresses. The preform 105 does not include the armature shaft 46 although it could optionally be mounted in place before the armature is wound. It clearly is an advantage to have the armature shaft 46 in place when the resinous material is molded so such material will be engaged with the shaft 46 as shown in Figures 1 and 6. . Although the preferred embodiment of the present invention has been described, it will be understood that various changes may be made within the scope of the appended claims.

Claims: CLAIMS; 1. A preform for a flat coil dynamoelectric device, comprising an outer frame structure (62) having a selfsupporting shape and being substantially symmetrical about a center axis, an inner frame structure (60) substantially symmetrical about said center axis located within and substantially coplanar with said outer frame structure and having a self-supporting shape, and plural coils of wire ((74-104) wound on said frame structures, said coils having sides spanning between said frame structures and end turns (74C,74D-104C,104D) extending generally along said frame structures. 2. A preform as defined in claim 19, wherein said inner and outer frame structures each have lugs around which said coils are wound. 3. A flat coil dynamoelectric device comprising a preform (105) having an outer frame structure (62) having a self-supporting shape and being substantially symmetrical about a center axis, an inner frame structure (60) substantially symmetrical about said center axis located within and substantially coplanar with said outer frame structure and having a selfsupporting shape, plural coils of wire (74-104) wound on said frame structures, said coils having sides (74A,74B104A,104B) spanning between said frame structures and end turns extending generally along said frame structures, and a matrix of resinous material (114) encapsulating said frame structures and said coils. 4. A device according to claim 1, wherein said inner and outer frame structures comprise inner and outer ring structures, respectively, and a commutator (44) is located in the bore of said inner ring structure. 5. An armature as claimed in claim 4, wherein said inner and outer ring structures each have lugs (66,70) around which said coils are wound. 6. An armature as claimed in claim 5, wherein said lugs (70) on said outer ring .structure project outwardly from said outer ring structure with respect to the axis of said ring structures. 7. An armature as claimed in claim 6, wherein said outer end turns (74D-104D) are formed around the outer margin of said outer ring structure and hook over spaced pairs of said lugs projecting therefrom. s. An armature as claimed in claim 5,6 or 7, wherein said lugs (66) on said inner ring structure include surface portions facing generally towards said axis, said coils being wound from turns of wire coursed around a pair of said lugs on said outer ring structure and said surface portions of a pair of said lugs on said inner ring structure. 9. An armature as claimed in claim 8 wherein said lugs (66) on said inner ring structure are hook-shaped and form with the adjacent face of said inner ring structure wirereceiving grooves (68), and wherein said inner end turns (74C-104C) are located substantially within said grooves. 10. An armature as claimed in any one of claims 4 to 9 wherein said outer ring structure has a circular flange (72) engaged by the outer end turns of said coils and preventing said outer end turns from entering the area between said ring structures. 11. An armature as claimed in any one of claims 4 to 10, wherein said ring structures each comprise generally circular, thin-walled body members. 12. An armature as claimed in any one of claims 4 to 11, wherein said ring structures have substantially coplanar forwardly facing surfaces and said coil sides overlie and span between said forwardly facing surfaces. 13. An armature as claimed in claim 12, wherein said inner end turns extend along said forwardly facing surface of said inner ring structure. 14. An armature as claimed in claim 12 or 13, wherein said outer end turns extend over the outer periphery and along the backside of said outer ring structure. 15. An armature as claimed in any one of claims 4 to 14, wherein said coils are wound under tension so that each coil exerts a force tending to pull said ring structures toward one another. 16. An armature as claimed in claim 15, wherein for each of said coils there is a substantially diametrically opposed one of said coils tending to pull said ring structures together in the opposite direction. 17. A method of manufacturing a flat disc armature, comprising the steps of: providing an inner frame structure and an outer frame structure; winding coils of wire having outer end turns adjacent and engaging said outer ring structure, inner end turns adjacent and engaging said inner ring structures, and side turns spanning between said inner and outer structures; and after the winding of all coils has been completed, encapsulating said inner and outer frame structures and said coils in a matrix of resinous material. 18. A method as defined in claim 17, wherein said inner and outer frame structures comprise inner and outer ring structures, respectively, the method further comprising the steps of: positioning a commutator in the bore of said inner ring structure; and connecting the terminal portions of said coils to said commutator segments. 19. An apparatus for use in manufacturing a preform for a dynamoelectric device, the preform having a frame comprising an inner frame structure and an outer frame structure, said frame structures being spaced apart and having a common axis, and a plurality of coils extending around said axis, said coils having outer end turns retained by retaining means provided on said outer frame structure and inner end turns retained by retaining means provided on said inner frame structure, the apparatus comprising: : preform clamp means (140) for holding said inner and said outer frame structures in a predetermined, substantially coplanar, relative rotary, and mutually coaxial relation on a predetermined axis; a wire guide flier (128) rotatable about a winding axis parallel to and spaced from said predetermined axis; means (124) for rotating said flier about said winding axis; wire guide shield means (190) for guiding wire exiting from said flier, when said flier is rotating, into engagement with both said inner coil end turns retaining means and said outer coil end turns retaining means and shielding other portions of said preform frame from being engaged by said wire so that a coil of wire. is wound on said preform frame having sides spanning between said frame structures; and means (142) for rotating said clamp means about said predetermined axis so that additional coils or wire may be wound on said preform frame at different positions thereon. 20. An apparatus as defined in claim 19, wherein said clamp means and said frame structures are provided with interfitting surfaces (162,172,164,174) for maintaining said predetermined relative rotary positions between said frame structures. 21. An apparatus as defined in claim 19 or 20, wherein said clamp means includes a collet (148) operating shaft (152) and said means for rotating said clamp means comprises means for rotating said collet operating shaft. 22. An apparatus as defined in claim 21, wherein said collet is engageably fixed in relation to said inner frame structure, said collet (148) being located in a collet housing (160) and said clamp means further comprises plural clamp members (168) pivotally mounted on said housing and adapted to clampingly engage inside said outer frame structure. 23. An apparatus as defined in claim 22, wherein said clamp members are spring biased into clamping relation to said outer frame structure and pivoted out of clamping relation to said outer frame structure in response to movements of said collet operating shaft. 24. An apparatus as defined in any one of claims 19 to 23, for manufacturing an armature preform having a inner and outer ring structures, a commutator having a plurality of tangs located within the bore of said inner ring structure and coaxial therewith, and said coils having terminal portions connected to said commutator tangs, wherein the wire guide shield means is arranged for guiding the wire so that the coil of wire is wound on said preform frame with the end turns extending along said inner and said outer rings, and the wire guide and shield means includes a movable commutator shield means (216) and means (226) for moving said movable commutator shield means between the winding of coils so that terminal portions of said coils may be connected to said tangs by a succession of rotary movements of said flier and said clamp means. 25. A method of winding coils of wire in the manllfacture of a preform for a dynamoelectric device having a preform frame comprising an inner frame structure having inner coil end turns retaining means and an outer frame structure having outer coil end turns retaining means, said frame structures being spaced apart and having a common axis, and said preform having a plurality of coils extending around said axis, said coils having outer end turns retained by said outer coil end turns retaining means and inner end turns retained by said inner coil end turns retaining means, said method comprising the steps of: : holding said inner and outer frame structures in a predetermined relative rotary and mutually coaxial relation on an axis parallel to and spaced from a. predetermined axis of rotation of a wire guide flier; rotating said flier and, while said flier is rotating, guiding wire exiting from said flier into engagement with both said inner coil end turns retaining means and said outer coil end turns retaining means while shielding other portions of said preform frame from being engaged by said wire so that a coil of wire is wound on said preform frame having side edges spanning between said inner and outer frame structures; and rotating said preform frame so that additional coils of wire may be wound at different locations thereon. 26. A method according to claii:i 10 whereun said frame structures are held in a substantially mutually coplanar relation while the coils are being wound. 27. A method according to claim 25 or 26, for manufacturing an armature preform having inner and outer ring structures, and a commutator having a plurality of tangs located within the bore of said inner ring structure and coaxial therewith, the coils having terminal portions connected to said commutator tangs, wherein shield means shield said other portions of said preform frame during winding a coil, at least part of said shield means is moved after the winding of each coil to expose at least one of the tangs so that wire exiting from said flier may be connected to one of said tangs, the wire is connected to said one tang by a series of rotational movements of said flier and said clamp means. 28. A method according to claim 27, wherein said wire is connected to each of said tangs by being looped therearound.

Inventors: DOLGAS, PATRICK A., FINEGOLD, HYMAN BERNARD
Applicants: GLOBE PRODUCTS INC.
Application year: 1985
Main classification: H02K23
IPC codes: H02K15, H02K3, H02K23