Abstract:
A winder for winding wire onto coil supports of dynamo-electric cores with translational, rotational, and stratification motions with respect to a central longitudinal axis of the dynamo-electric core is provided. The rotational motion may preferably be provided by the rocking motion of a gear sector. The stratification motion may preferably be provided by the implementation of a spiral groove. The spiral groove preferably shares the same longitudinal axis as the winder. The rotation of the spiral groove preferably creates a relative motion between the groove and the needles, thereby producing the radial stratification motion of the needles. Additionally, the winder includes a motor arrangement which is programmable and controllable. The motor arrangement may also provide a dampening effect to limit unwanted stratification motion.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application is a continuation of copending, commonly assigned U.S. patent application Ser. No. 09/960,550, filed Sep. 20, 2001, which claims the benefit of U.S. Provisional Patent Application No. 60/234,811, filed Sep. 22, 2000, both of which are hereby incorporated by reference herein in their entireties. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    The present application relates to winding coils of wire onto poles of dynamo-electric cores. More particularly, the present application relates to an improved method for generating translational, rotational, and stratification motions in the winding of the wires. Stratification motions—i.e., motions that distribute the winding needle in a radial direction—are performed to regularly distribute the turns along the height of a pole in a dynamo-electric component either inwardly toward the center of the core, or outwardly, from the center of the core.  
           [0003]    Wire coils for some cores may be wound using wire delivering needles moved in translational and rotational motion. Such motions and the mechanisms for generating them are similar to those described in U.S. Pat. Nos. 4,858,835 and 5,484,114, in U.S. Provisional Patent Application Nos. 60/148,473, filed Aug. 12, 1999, and 60/214,218, filed Jun. 23, 2000, and in U.S. patent application Ser. No. 09/632,281, filed Aug. 4, 2000, all of which are commonly assigned with the present application. Each of the above identified patents are hereby incorporated by reference.  
           [0004]    As described in the above-mentioned cases, a winding shaft carries a wire dispensing needle or needles. During winding, the wires are dispensed through the hollow interior of the winding shaft and needle by the relative motion of the shaft with respect to the core. Such motions deliver tensioned wires and wind them around the poles to form the turns of the coil.  
           [0005]    In view of the foregoing, it would be desirable to provide a winding apparatus with an improved method for generating rotational and translational movements of the shaft and needle while stratifying the wire along the poles of the dynamo-electric core.  
         SUMMARY OF THE INVENTION  
         [0006]    Therefore, it is an object of the invention to provide a stator core winding apparatus and methods preferably capable of rotational, translational, and stratification movements with respect to the poles of the dynamo-electric core. As mentioned above, this stratification movement may be considered a radial movement that moves the winding needle along the radial extension of the poles. This stratification allows for pre-determined placement of the wire in layered format. Pre-determined placement of the wire in layered format preferably results in deeper and denser winding of wire.  
           [0007]    The winder according to the invention preferably includes a plurality of needles. Each needle dispenses a wire. The winder also preferably includes a translation assembly. The translation assembly includes a first member. The first member is preferably a winding shaft which may be substantially hollow. A second member is preferably coupled to the first member. The second member is preferably includes a drive tube and an end tube. The translation assembly is for producing translational movement of the first member and the needle parallel to the longitudinal axis of the winder. The winder also includes a rotation assembly for producing relative rotational movement between the core and the needle about the longitudinal axis. The rotation assembly may include a gear sector which produces a rocking motion, thereby producing the rotational movement.  
           [0008]    The winder also includes a stratification assembly moveably coupled to the second member. The stratification assembly causes relative rotational movement between the second member and the first member. This relative rotational movement produces stratification—i.e., radial—movement of the needle.  
           [0009]    It should also be noted that the relative rotational movement is substantially independent from the rotational movement produced by the rotation assembly because each of the rotational movements are generated independently of one another. Thus, there are two different mechanisms by which rotation may be accomplished. Furthermore, the stratification assembly preferably includes a spiral groove. The spiral groove preferably shares the same longitudinal axis as the winder. Rotation of the spiral groove with respect to the needles creates relative motion between the groove and the needles. This relative motion causes the stratification motion of the needles.  
           [0010]    Additionally, the winder includes a motor arrangement for turning a plurality of gears. The motor arrangement is preferably programmable and controllable with external feed backs such that the rotation imparted to the spiral groove may cause a controlled and predetermined stratification motion. When the motor arrangement is not activated, it may act as a brake to dampen or prevent accidental rotation. Accidental rotations may cause unwanted stratification motion. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]    The above and other objects and advantages of the present invention will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:  
         [0012]    [0012]FIG. 1 is a partial sectional view of an embodiment of a winder according to the invention;  
         [0013]    [0013]FIG. 2 is a partial sectional view of portion  118  of FIG. 1 according to the invention;  
         [0014]    [0014]FIG. 2 a  is a detailed view of a worm gear that can substitute for gear  214  of FIG. 2;  
         [0015]    [0015]FIG. 3 is a partial sectional view of portion  126  of FIG. 1 according to the invention; and  
         [0016]    [0016]FIG. 4 is an axial view of a core and a partial view of the winder according to the invention taken from lines  4 - 4  of FIG. 1. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0017]    As described in the above-mentioned cases, coils are wound around poles by using winding needles. Each needle dispenses wire onto a specific pole. The wire turns of the coils preferably become stratified along the pole. This means that each wire turn tends to occupy an individual layer along the radial axis of a pole. The stratification is such that the turns may be wound on layers progressing outwardly away from the center of the dynamo-electric core—i.e., from longitudinal axis  108  as shown in FIG. 1. Each turn is also preferably wound around the pole sides and across the opposite faces.  
         [0018]    To begin winding of the coil, the needles are provided with translation strokes, parallel to the sides of the core and parallel to the plane of the page. (Reference to the “page” as used herein indicates the plane of the drawing page of the FIGURES.). During these translation strokes, the needle tips are partially inserted into the slots of the core to place the wires along the pole sides.  
         [0019]    Substantially at the end of the translation strokes, needles can be rotated with respect to longitudinal axis  108  (as shown in FIG. 1) of the core, in order to place the wires across the end faces of the poles. It should be noted that, in an alternative embodiment (not shown), the term rotational movement may indicate that the core may be rotated around axis  108 , while the needles remain stationary. At the end of the rotations, the needle tips may be aligned with adjacent slots, where they may start opposite translation strokes.  
         [0020]    Such a combination of translational and rotational motions places single turns of coils completely around the poles. The combination of motions needs to be repeated for a number of times equal to the number of turns. Furthermore, the combination of motions also must be repeated for the number of layers of turns that are wound around the poles.  
         [0021]    Suitable criteria that may dictate when the needle should be moved along the radii, and how long the increments should be, include the thickness of the wire, the dimensions and winding requirements of the poles, etc. A correctly obtained stratification is of great importance for guaranteeing that the turns are tightly wound, and of the same length. Orderly stratification of the wires achieves more compact coils, which ultimately means that more turns may be wound in the same slot space, while preventing turns of adjacent poles from interfering with each other.  
         [0022]    In some embodiments, the invention may provide apparatus and methods for winding wire coils on dynamo-electric components in accordance with the principles of the invention. In some of these embodiments, apparatus according to the invention may include an improved drive method. An improved drive method is disclosed concerning the generation of the needles stratification motion which is performed to regularly distribute the turns along the height of a pole in a dynamo electric component.  
         [0023]    Illustrative examples of embodiments in accordance with the principles of the present invention are shown in FIGS. 1-4.  
         [0024]    [0024]FIG. 1 is a partial cross-sectional view of an apparatus for winding wire with the stratification motion discussed herein (the core has been removed from FIG. 1 for reasons of clarity).  
         [0025]    As shown in FIG. 1, winding shaft  100  is driven to move with backwards and forwards translation motions  102  and  104  by a kinematic assembly (not shown) mounted within casing  106 . The kinematic assembly, which is well-known in the art, within casing  106  is preferably positioned to the left with respect to the view shown in FIG. 1. Backwards and forwards translation motions  102  and  104  are parallel to axis  108 .  
         [0026]    Winding shaft  100  is also provided with oscillatory rotation motions  110  and  112 . Rotation motions  110  and  112  may be performed about axis  108 . Rotation motions  110  and  112  accomplished by winding shaft  100  are preferably implemented in a predetermined time relation or position relation with respect to translation motions  102  and  104 .  
         [0027]    As regards the stratification motion, a certain increment of stratification motion may be accomplished once winding shaft  100  has completed a sequence of backwards and forwards translational motions  102  and  104  and two opposite rotation motions  110  and  112 —i.e., following each completed cycle. This preferably corresponds to the needles having moved once around a respective pole that they are winding in order to form a turn.  
         [0028]    Rotational and translation motions and the mechanisms for generating them are similar to those described in commonly-assigned U.S. Pat. Nos. 4,858,835 and 5,484,114, and stratification motions and the mechanisms for generating them are described in commonly-assigned U.S. Provisional Patent Application Nos. 60/148,473, filed Aug. 12, 1999, and 60/214,218, filed Jun. 23, 2000, and in commonly-assigned U.S. patent application Ser. No. 09/632,281, filed Aug. 4, 2000, all of which are hereby incorporated by reference herein in their entireties.  
         [0029]    In this embodiment, rotational motions  110  and  112  may be obtained by a rocking motion of winding shaft  100  driven by the rotation of gear wheel  114 . Gear wheel  114  is preferably driven by kinematic mechanisms such as those described in the above-cited patents and applications, and discussed above with respect to translation motions. The kinematic assembly may be used to coordinate the translation motions described above and the rotation motions. In the alternative, the kinematic assembly may be used to coordinate the translation motions with the rotation of the core, as described above with respect to the alternative embodiment of the invention.  
         [0030]    Gear  114  meshes with gear  116 . Gear  116  is preferably mounted on bearings  119  (as shown in FIG. 2) of casing  106 . The interior portion of gear wheel  116  is preferably hollow and the interior of gear  116  is provided with key  117 . Key  117  of gear  116  is received in a keyway  171  of winding shaft  100 . Winding shaft  100  passes through the hollow interior portion of gear  116 , thereby coaxially assembling gear  116  with winding shaft  100 . Consequently, the rotation of gear wheel  116  caused by gear wheel  114  is imparted to winding shaft  100 —i.e., in the form of rotation motion  110  and  112 . Additionally, it should be noted that winding shaft  100  is also able to accomplish translation motions  102  and  104  as referred to above with respect to U.S. Pat. Nos. 4,858,835 and 5,484,114.  
         [0031]    [0031]FIG. 2 is a partial cross-sectional view of portion  118  of FIG. 1. As shown in FIG. 2, gear  116  preferably meshes with gear  202 . Gear  202  is preferably disposed on bearing shaft arrangement  205 . Bearing shaft arrangement  205  may be carried by extension  203  such that it is rigidly connected to casing  106 . Gear  202  may also mesh with crown  207  of ring  204 . Ring  204  is preferably idle on bearings  209  that are supported by casing  106 . In addition to meshing with gear  202 , crown  207  also meshes with gear  206 . Gear  206  is preferably idle on bearing shaft arrangement  211 . It should be noted that bearing shaft arrangement  211  is preferably carried by support gear  208 . Gear  206  preferably meshes with gear  210 , which is preferably fixed to the rear of drive tube  212 .  
         [0032]    Drive tube  212 , which serves as a drive member for the radial movements of needle  310  as will be explained, is preferably hollow so that it may be assembled coaxially on winding shaft  100  and so that it may contain winding shaft  100  and the wire.  
         [0033]    As mentioned above, rotation of gear  114  imparts motions  110  or  112  to winding shaft  100 . Rotation of gear  114  causes winding shaft  100  to rotate because of the connection obtained between gear  114  and keyway  171 . Winding shaft  100  has key  117  received in gear  116 , for transmission of rotations between gear  116  and winding shaft  100 .  
         [0034]    Gear  208  is preferably mounted on bearings  213 . Bearings  213  are preferably supported by drive tube  212 . Gear  208  preferably meshes with gear  214 , which is mounted on shaft  216 .  
         [0035]    Motor belt arrangement  120  (as shown in FIG. 1) is preferably mounted on the opposite end of shaft  216 . In some embodiments, motor belt arrangement  120  may include a belt wheel  160  driven by a belt  162 , which derives motion from a pinion wheel of a motor  164 .  
         [0036]    Gear  214  may be substituted with other mechanisms. For example, in some embodiments, gear  214  may be a worm gear  215  as shown in FIG. 2 a  and described in the following.  
         [0037]    As shown in FIGS. 1 and 2, ring  204 , crown  207 , gear  208 , drive tube  212 , and gear  210  are coaxial with respect to winding shaft  100  and longitudinal axis  108 . Also shown in FIGS. 1 and 2, bearing  213  is supported by drive tube  212 .  
         [0038]    In an alternative embodiment, bearing  213  may be supported by casing  106 . Casing  106  is preferably provided with a cut-out portion  218 , thereby allowing gear  214  to mesh with gear  208 .  
         [0039]    The gear ratios between gear  116  and gear  202 , gear  202  and crown  207 , crown  207  and gear  206 , and gear  208  and gear  210  are such that drive tube  212  preferably rotates in synchronism and for the same amount of rotation—i.e., rotation motions  110  and  112 —with respect to the motion imparted on winding shaft  100 . As described previously, the motion imparted on winding shaft  100  is caused by the rotation of gear  114 . Drive tube  212  is preferably supported on bearings  122  of casing  106 , thereby allowing the rotation of drive tube  212 . Persons skilled in the art will appreciate that achieving the transmission of rotation motions  110  and  112  to drive tube  212  can be practiced by other than the described embodiments, which are presented for purposes of illustration and not of limitation.  
         [0040]    Referring back to FIG. 1, portion  128  of drive tube  212  preferably has angular key portions  129 . Key portions  129  are received in a keyway of end tube  124 . These keyways are preferably long enough to allow end tube  124  to accomplish translation motions in directions  102  and  104  together with winding shaft  100  while still accommodating key portion  129 .  
         [0041]    End tube  124  is preferably mounted on bearings  131 , which are assembled coaxially with respect to winding shaft  100 . Bearings  131  are interposed between winding shaft  100  and end tube  124 .  
         [0042]    As described above in the summary of the invention, the winder accomplishes an additional rotation motion around axis  108  with respect to winding shaft  100 . This additional rotational motion is preferably implemented by causing an additional rotation of end tube  124 . This additional rotation motion is additional to the initial rotation motion imparted to drive tube  212  by gear  116  (through gear  202 , ring  204 , gear  206 , crown  207 , and bearing shaft arrangement  211  to reach drive tube  212 ). Thus, end tube  124 , which is constrained to move translationally with winding shaft  212  parallel to directions  102  and  104  (as will be explained in more detail below), and which moves rotationally with rotation motions  110  and  112  of winding shaft  100  because of motions generated by gears  114  and  116 , is also capable of accomplishing additional relative rotations around axis  108  with respect to winding shaft  100 . These additional rotations, which are implemented by gear  214 , cause the rotation of drive tube  212  as well as end tube  124 .  
         [0043]    [0043]FIG. 3 is an enlargement of portion  126  of FIG. 1. FIG. 4 is a view from directions  4 - 4  of FIG. 1. FIG. 4 also shows a stator  406  with poles  404  being wound by needles  310 ,  311 , and  312 .  
         [0044]    As shown in FIG. 3, end tube  124  is preferably flanged. The flange on end tube  124  allows it to be attached to support cylinder  302  by means of bolts (only the axes of the bolts are shown). In this way, support cylinder  302  moves together with end tube  124  both in translation motions  102  and  104  and in rotation motions  110  and  112 . Support cylinder  302  is provided with spiral groove  305  (also shown with dashed line representation in FIG. 4). As previously described, end tube  124  is capable of accomplishing additional rotations with respect to winding shaft  100 . Consequently, the additional rotation of end tube  124  may cause spiral groove  305  to accomplish the same additional rotation with respect to winding shaft  100 .  
         [0045]    Guide member  308  (it should be noted that the lead line guide member  308  is shown as connected to the cap of guide member  308 ) may support a plurality of needles, such as needles  310 ,  311 , and  312  (as shown in FIG. 4). Needles  310 ,  311 , and  312  have main trunk portions  315 ,  316 , and  317 , respectively. In the same manner, needles  310 ,  311 , and  312  have distal portions  320 ,  321 , and  322 .  
         [0046]    The main trunk portions  315 ,  316 , and  317  of needles  310 ,  311 ,  312  are received in respective ways of guide member  308 . As shown in FIGS. 3 and 4, the sides  402  and bottom  324  of the ways of guide member  308  support the trunk portions and the distal portions of needles  310 ,  311 , and  312 . Because the needles are fully supported, the positions of needles  310 ,  311 , and  312  may be maintained even under the action of the applied forces—e.g., the tension of the wire. Furthermore, bottom  324  (shown in FIG. 3) of guide member  308  preferably provides a low-friction surface, thereby allowing the radial stratification movement perpendicular to axis  108  of the needles.  
         [0047]    Each needle preferably has a bore—e.g., bore  312  of needle  310 . The bores of every needle are preferably in a parallel plane  326  perpendicular to longitudinal axis  108 . In the area around longitudinal axis  108 , sectors of trunk portions  315 ,  316 , and  317  must be in different planes and cross over each other as shown in FIGS. 3 and 4. Common plane  328  containing the bottom  324  of guide member  308  is nearer to the end of winding shaft  100  than the nearest one of trunk portions  315 ,  316 , and  317  is to the end of winding shaft  100 . As shown in FIG. 3, since common plane  328  is nearer to the end of the winding shaft than any one of trunk portions  315 ,  316 , and  317 , spacing  330  is left allowing the passage of wire  382  through winding shaft  100  and bore  325 .  
         [0048]    As shown in FIG. 4, needles  310 ,  311 , and  312  preferably become narrower in trunk portions  315 ,  316 , and  317 , respectively, adjacent to the extensions from poles  404 , thereby allowing needles  310 ,  311 , and  312  to pass in the space between poles  404 . To give needles  310 ,  311 , and  312  substantial strength where they become narrow, the configuration of the needles is extended in a direction parallel to axis  108 . The needles may be extended such that the dimension of the needles in the direction parallel to axis  108  is at least twice the narrow dimension of the needles that passes between the poles.  
         [0049]    The distal portion of each needle is provided with a respective pin—i.e., pin  410  for needle  310 , pin  411  for needle  311 , and pin  412  for needle  312 —with the extreme portion received within spiral groove  305  to engage the delimiting side walls of spiral groove  305 . Guide member  308  is provided with windows  332 , thereby allowing the pins  410 ,  411 , and  412  to protrude to spiral groove  305 . Spiral groove  305  develops as a spiral from the smallest radius near axis  108 , and extends for a predetermined number of turns as shown in FIG. 4. Pins  410 ,  411 , and  412  are each in distinct angular positions with respect to each other in spiral groove  305 . Each pin will travel along a respective portion of spiral groove  305 . The radius growth of the spiral should be sufficiently gradual to guarantee an unobstructed travel of the pins through spiral groove  305 . As will be more fully described in the following, rotation of spiral groove  305  around axis  108  by rotating support cylinder  302  causes spiral groove  305  to move with respect to pins  410 ,  411 , and  412 . Consequently, this movement may cause the radial stratification motion of the needles.  
         [0050]    It should be noted that the respective portions of spiral groove  305  relating to where the pins travel are preferably long enough to accomplish the radial stratification motions required by the needle or needles.  
         [0051]    Bottom  324  of guide member  308  is preferably fixed to winding shaft  100  by means of locking bush  334 . Locking bush  334  is preferably threaded to the interior of winding shaft  100  by means of thread  335 . Key member  336  (shown in section) preferably has radial arms  337  at equidistant angular positions for engaging in equidistant ways of locking bush  334  and bottom  324  of guide member  308 . Portions of key member  336  are two of the radial arms which are received in respective ways of locking bush  334  and guide member  308 . By pushing locking bush  334  against key member  336  (through the pull generated by thread  335  and because of the presence of the radial arms), guide member  308  is preferably secure to winding shaft  100 . When locking bush  334  is pulled through thread  335 , locking bush  334  pushes guide member  308  against axial bearing  340 , which is shouldered against end tube  124 . This combination causes guide member  308  to move with winding shaft  100  such that the needles preferably accomplish the translation motion parallel to directions  102  and  104  and the rotation motions  110  and  112 .  
         [0052]    The presence of axial bearing  340  allows the additional rotations of end tube  124  and support cylinder  302  with respect to winding shaft  100  and guide member  308 . The push on axial bearing  340  finds a reaction in axial bearing  220 . In turn, axial bearing  220  (as shown in FIG. 2) is shouldered by bush  222  (also shown in FIG. 2). The reaction passes through end tube  124  mounted between axial bearings  340  and  220 . Bush  222  is shouldered against the extreme of external keyway  171  present on winding shaft  100 . In this way, end tube  124  is fixed longitudinally along winding shaft  100  and, therefore, end tube  124  translates longitudinally with winding shaft  100 . End tube  124  is able to translate with winding tube  100  (and to rotate with drive tube  212 ) at least because end tube is supported with respect to casing  106  by bush  130  and with respect to drive tube  212  by bearings  224 .  
         [0053]    When stratification motion in directions  345  and  346  needs to be imparted to the needles, motor belt unit  120  can be activated causing a required amount of turning of gear  214 . This causes the additional rotation described above to end tube  124  by way of gear  208  and drive tube  212 . Spiral groove  305  may turn due to this additional rotation and cause movement of pins  410 ,  411 , and  412  in directions  345  and  346 . Needles  310 ,  311 , and  312  may move in directions  345  and  346  as a consequence of the movements of the pins in directions  345  and  346 . Therefore, end tube  124  and support cylinder  302  (provided with spiral groove  305 ) may move with the same rotation motions  110  and  112  of winding shaft  100  and may also have an additional rotation (in either of directions  345  and  346  as required) generated by motor drive arrangement (motor belt unit)  120  when the stratification motions of the needles is required.  
         [0054]    The motor of belt arrangement  120  is preferably programmable and controllable with external feedbacks so that rotation imparted to the spiral groove  305  (to cause the stratification motion) may occur at predetermined timing or with a predetermined relation to the translational and rotational motions of winding shaft  100 .  
         [0055]    When motor drive  120  is not activated to cause the additional rotation which causes the stratification motion, it may be implemented to act as a brake to dampen accidental rotation that may be caused to gear  210 . Such accidental rotations may cause unwanted stratification motion of the needles in directions  345  and  346 .  
         [0056]    A motorized worm gear  215  (as shown in FIG. 2 a ) engaging gear  208  may substitute the motor belt arrangement  120  and gear  214  to achieve the brake action needed to prevent the accidental rotations of gear  208 . The tooth characteristics of worm gear  215  would preferably oppose accidental rotations of gear  208 .  
         [0057]    In conclusion, winding shaft  100  is able to make the needles accomplish the required translational and rotational motions referenced with directions  102 ,  104 , and  110 ,  112 .  
         [0058]    Thus, a stator core winding apparatus and methods preferably capable of rotational and translation movements with respect to the poles of the dynamo-electric core is provided. Persons skilled in the art will appreciate that the principles of the present invention can be practices by other than the described embodiments, which are presented for purposes of illustration and not of limitation, and the present invention is limited only by the claims which follow.