Patent Abstract:
Method and Apparatus are provided for automatically disposing plural wires along predetermined trajectories, wherein the plural wires extend from coils wound in slots of dynamoelectric machine cores. Plural wires forming leads ( 16′, 17′ ) are located in predetermined positions and caused to extend along predetermined directions ( 33,34 ) by means of manipulating equipment and tooling ( 3 ) which operates automatically. In addition, the equipment and tooling ( 3 ) cause the plural wires to become twisted and cut to form portions ( 16′, 17′ ) for connection to terminals. The tooling ( 3 ) is provided with reference surfaces ( 21,23 ) and seats ( 26,27 ) which are used to bend the plural wires along the predetermined trajectories and to provide a position constraint for the portions becoming twisted. Apparatus can be provided for positioning portions of a plurality of restraining members ( 103, 104 ) in the spacing ( 92, 131 ) existing between the bridges of the coils ( 14, 106, 107 ) and the end faces ( 106′, 107′ ) of a dynamo electric machine core ( 105 ). The restraining members prevent the wires of the coils heads ( 106, 107 ) from damaging the insulating lining of the core slots when a manipulator twists the leads of the coils.

Full Description:
BACKGROUND OF THE INVENTION 
       [0001]    The present invention relates to methods and apparatus for terminating leads of wire coils wound on magnetic cores of dynamo-electric machine components, such as stators for electric motors or generators. 
       DESCRIPTION OF THE PRIOR ART 
       [0002]    The wire coils may be formed by simultaneously winding plural wires using a nozzle winder having one or more wire dispensing needles that deliver the plural wires directly into the slots of the magnetic core. 
         [0003]    Alternatively, the wire coils can be first wound on a winding form by using a rotating flyer, or by rotating the winding form in order to draw onto the latter the plural wire. The finished wire coils are later stripped from the winding form and placed onto a tool, which is used for transfer to an insertion unit where a pushing operation inserts the wire coils and insulation covering into the slots of the magnetic core. 
         [0004]    Generally, the wire coils are formed from a predetermined number of wire turns, where each wire turn consists of coil branches formed from a certain number of wires. The exemplary winders according to these principles are described, for example, in EP 1,076,401 and U.S. Pat. No. 6,557,238 
         [0005]    U.S. Pat. No. 6,141,864 proposes a winding tool that is applied to a stator and which has slots for temporarily receiving leads to place them together and cut them. The cut leads are later removed from the slots and connected together by twisting. The winding tool optimizes manual operations of preparing the leads together and cutting them. 
         [0006]    With modern stators, the number of leads of a core requiring the routing and mentioned termination procedures is increasing. Furthermore, the size and number of the wires used to form the plural wires is also increasing. Consequently, production times for the termination processes are becoming importantly longer and the automatic operations of the processes are becoming considerably more complex and difficult to achieve. 
         [0007]    In view of the foregoing, it is an object of this invention to provide methods and apparatus for automatically placing the lead wires in relation to the core and twisting certain portions of the same lead wires to form a required section size of plural wires. It is another object of this invention to provide the above mentioned apparatus that can be readily adjusted to account for required variations in the placement of the leads. 
         [0008]    A further problem is that the finished magnetic cores need to be extremely compact without requiring additional components for supporting the leads that have been routed proximal to the end faces of the core. To achieve this, the leads are routed directly in contact with the coils, and from here can depart in predetermined directions to become twisted. 
         [0009]    It is therefore another object of this invention to provide methods and apparatus for automatically placing the lead wires in relation to the core and twisting certain portions of the same lead wires to form a required section size without requiring the use of additional components that need to be permanently assembled on the finished core for supporting the leads. 
       SUMMARY OF THE INVENTION 
       [0010]    The invention foresees using termination members temporarily applied to at least one end of the magnetic core, after having wound the wire coils with plural wires drawn simultaneously. Initially, the leads formed from the plural wires are drawn in predetermined positions around the core as a result of the winding procedures. Successively, a wire manipulator selectively grasps the leads formed from the plural wires and moves them along the end faces of the core. At certain locations, the manipulator draws the plural wires within respective seats of the termination members. When moving the plural wires with the manipulator, these can be drawn against predetermined surfaces of the termination members so that the plural wires become deformed to follow predetermined configurations that correspond to the paths where the leads need to be permanently positioned adjacent to the ends of the coils. 
         [0011]    Along the paths the plural wires can be passed through respective seats of the termination members. In doing so, the plural wires can be made to change direction so that they finally extend in predetermined directions. The direction change occurs by bending the plural wires against reference surfaces existing adjacent the entrance of the seat. Consequently, the plural wires forming a typical lead will exit the seat and extend beyond it in a predetermined direction. A portion of the plural wires extending in the predetermined direction can be twisted together for a certain length by programmed movements of the manipulator. The programmed movements of the manipulator are such that the plural wires become twisted together and pulled against the reference surfaces that are adjacent to the entrances of the seats. Each seat maintains the plural wires in a predetermined position during the twisting operations. Consequently, the resulting twisted portion will be located in a predetermined position determined by the seat and extends in the predetermined direction for a required length 
         [0012]    A cutter can later cut the twisted portions at a predetermined length from the core in order to form accurate extremities for connection to terminals. 
         [0013]    Twisting causes each wire to form a helix having turns that will be placed adjacent and in contact with turns of the helixes formed with the other wires. The helixes of the various wires should be similar, i.e. their diameter and pitch should be the same so that crossing of the wires is avoided. 
         [0014]    The wire termination tool may also include surfaces for pressing the routed leads against the coils to thereby limit the overall size of the finished core. 
         [0015]    Due to the high number of leads that can be present in the core, and also for the complexity of the paths where the leads need to be placed, routing and twisting of the various leads can occur in various stages, which are performed in sequence to finish the core. More specifically, in each stage a limited number of finished leads of the total number of leads can be routed and twisted by using specific wire termination members. Accordingly, multiple termination apparatuses, each having wire manipulators and specific wire termination members can process in succession a given core to finish it. At the same time the multiple apparatuses can be working in parallel for performing respective stages of the termination cycle on different cores in order to reduce the production time for a core, and thereby increase productivity. 
         [0016]    For certain number of wires that need to be twisted, there can be a wire that does not become twisted, which is located centrally amongst the plural wires. This wire can have less contact with the terminal because it becomes completely buried by the other wires. It is preferable to avoid that such a wire remains centrally and without twisting. In this situation, a lower number of plural wires can be twisted together in order to avoid that one wire remains centrally and without twisting. The lower number of wires that are twisted together is such as to avoid that one wire remains centrally and without twisting. Successively, the twisted portions with the lower number of wires can be twisted together to achieve the final result of a final twisted portion that has all the required wires. 
         [0017]    Restraining members are placed in the free space of the bridges of the coils to prevent the coil wires from moving towards the faces of the core when the manipulator pulls on portions of the leads during twisting. 
         [0018]    More particularly, the restraining members act as bearing surfaces for coils in planes approximately parallel to the end faces of the core. 
         [0019]    Consequently, the wires of a coil engage the bearing surfaces during twisting and prevent movement of the coil heads towards the faces of the core. In this way a damaging contact is avoided between the coil heads and the slot insulating lining that protrudes beyond the end faces of the core. The final result is that the coil heads are impeded from engaging and crushing, or tearing, the insulating lining of the slots. 
         [0020]    The restraining members can simultaneously move on respective radiuses with respect to the core, from an outward position that allows clearance for loading and unloading of the core to an inward position where the restraining members carry out their function of support surfaces during twisting of the coil leads. 
         [0021]    The restraining members and the members for moving the restraining members in the radial directions can constitute a support assembly, which is mounted on a table. The table can have the purpose of transferring and positioning of the cores at various working stations where routing and twisting of the leads need to be performed. 
         [0022]    The core can be supported and referenced by the support assembly. 
         [0023]    In turn, the support assembly can be referenced and supported by the table. 
         [0024]    The table can require various support positions for the cores. Consequently, a support assembly having the restraining members for a core can be mounted in each of the support positions of the table. 
         [0025]    The actuator for moving the restraining members in the radial directions can belong to an actuating unit that is external both to the support assembly and the table. The actuator can cause movement of the restraining members when the support assembly becomes aligned with the actuating unit, as a result of movement of the table for transferring the cores. 
         [0026]    The restraining members may be used to support only the wires of the coils heads that are adjacent to one face of the core. In this case, just the portions of one series of restraining members are positioned in the free spacing of the coils heads adjacent to that face of the core. 
         [0027]    When the support function is required for the coil heads adjacent to both faces of the core, two series of restraining members are foreseen. More particularly, during twisting one series of restraining members support the coils heads adjacent to one face of the core and a second series of restraining members support the coil heads adjacent to the other face of the core 
         [0028]    The support assembly can be easily adapted for supporting cores of different height. The different height of a core requires aligning the restraining members with the different positions occupied by the free spacing existing between the coil heads. 
         [0029]    The support assembly can easily be assembled on the table so that substitution of a support assembly can occur rapidly. 
         [0030]    Therefore according to another aspect of the invention an apparatus for twisting plural wires comprises restraining members with portions positioned in spacing of the bridges of the coils to resist movement of the coils towards a face of the core during twisting of the plural wires; means for guiding the restraining members in the radial direction of the core to position the portions of the restraining members in the spacing of the bridges adjacent to an end face of the core; 
         [0031]    means for moving the restraining members in the radial direction. According to another aspect of the invention, the apparatus comprises means for rotating the means for moving the restraining members in order to collectively move the restraining members in the radial direction with a synchronized motion and means for supporting the means for moving and the means for rotating. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0032]    Further characteristics and advantages of the method and apparatus according to the invention will be more apparent from the following detailed description and the accompanying drawings of the preferred embodiments, which is made to be exemplary without being limitative. 
           [0033]      FIG. 1  is a perspective view of an illustrative embodiment of a stator at an intermediate stage of being manufactured in accordance with the principles of the invention 
           [0034]      FIG. 2  is a perspective view of an embodiment of termination members which can be used for manufacturing the stator shown in  FIG. 1 . In  FIG. 2  the termination members have been shown transparent for sake of clarity.  FIG. 2  also illustrates portions of leads formed from plural wires routed and twisted in accordance with the principles of the invention, although in  FIG. 2  the stator has been omitted for sake of clarity 
           [0035]      FIG. 3  is a view from direction  3  of  FIG. 2 . In  FIG. 3  the termination members have been shown transparent for reasons of clarity.  FIG. 3  also shows that the termination members can be assembled on the stator of  FIG. 1 , which is shown with dashed line representation. Furthermore,  FIG. 3  shows a manipulator in the process of routing a lead formed from plural wires 
           [0036]      FIG. 4  is a partial section view as seen from directions  4 - 4  of  FIG. 3  illustrating the termination members applied to the stator shown in  FIGS. 1 and 3 . For reasons of clarity,  FIG. 4  shows the leads of  FIGS. 2 and 3  in their condition prior to twisting and without the manipulator shown in  FIG. 3 . 
           [0037]      FIG. 4   a  is a partial section view as seen from directions  4   a - 4   a  of  FIG. 4 . 
           [0038]      FIG. 4   b  is a partial section view as seen from directions  4   b - 4   b  of  FIG. 4   
           [0039]      FIG. 4   c  is a partial section as seen from a direction like  4   c  of  FIG. 4  illustrating parts which have been omitted in  FIG. 4 , due to the interruption made in  FIG. 4  for reasons of clarity 
           [0040]      FIG. 5  is a partial view from direction  5  of  FIG. 4  illustrating stages of routing a lead in accordance with the principles of the invention. 
           [0041]      FIGS. 6-9  are partial views from direction  6  of  FIG. 4 , with certain parts omitted for sake of clarity, illustrating various stages of routing and forming a twisted portion of a lead in accordance with the principles of the invention. 
           [0042]      FIG. 10-13  are views similar to  FIGS. 5 and 6  illustrating different stages of routing and forming a twisted portion of a lead in accordance with the principles of the invention. 
           [0043]      FIG. 14  is a view similar to  FIG. 3  showing a manufacturing environment with multiple stations for terminating the core. 
           [0044]      FIG. 15  is a plan view like the view of  FIG. 14  illustrating a support assembly for the core with restraining members positioned in an inner radial position, like is the condition for supporting coil heads during twisting operations. In  FIG. 15  the core has been omitted for reasons of clarity and the support assembly is assembled on a table, like the table of  FIG. 14  adopted for transferring and positioning of the core at various stations where twisting of the coil leads occurs. 
           [0045]      FIG. 16  is a section view as seen from directions  216 - 216  of  FIG. 15  illustrating the support assembly of the invention for positioning the restraining members and supporting the cores. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0046]      FIGS. 1 ,  3  and  4  illustrate stator  10  wound with coils  11  and leads  12  each consisting of plural wires W. The coils have been wound in slots  13 . The ends  14  of the coils extend beyond faces  15  of the core. In  FIG. 1  certain leads  12  have been drawn to predetermined radial positions around the stator core in preparation for routing along predetermined paths and termination into terminals in accordance with the principles of the invention. In  FIGS. 1 ,  2  and  3  other leads  16  and  17  are already routed, twisted and cut in accordance with the principles of the invention 
         [0047]    More particularly, twisted portion  16 ′ of lead  16  is upstanding in direction  33  with respect to the ends  14  of the coils due to bending at position  18 . Furthermore, twisted portion  16 ′ has been cut at a predetermined distance with respect to end face  15 . (see also  FIGS. 2 and 3 ) 
         [0048]    Similarly, twisted portion  17 ′ of lead  17  is upstanding in direction  34  with respect to the ends  14  of the coils due to bending at position  19 . Also twisted portion  17 ′ has been cut to a predetermined distance with respect to end face  15  (see also  FIGS. 2 and 3 ). 
         [0049]    The diameter D of twisted portions  16 ′ and  17 ′ (see  FIG. 2 ) needs to be within prescribed tolerances for correct joining to terminals. 
         [0050]      FIG. 2  illustrates termination tool  21  consisting of two members  22  and  23  without the presence of stator  10 .  FIGS. 3 and 4  illustrate members  22  and  23  assembled on the stator, as is required for routing leads  16  and  17  and for forming twisted portions  16 ′ and  17 ′. 
         [0051]    More particularly, and with reference to  FIG. 4 , members  22  and  23  have been mounted coaxial to the axis  10 ′ of stator  10 . This can be accomplished by having abutment and centering of cylindrical shoulder  24  of member  23  with face  15  and the hollow walls of the stator. 
         [0052]    Member  22  is sleeved into the cylindrical cavity  25  of member  23 . In addition, member  22  is referenced angularly around axis  10 ′ with respect to member  23  by a key engagement (not shown) existing between member  22  and member  23 . Similarly, member  23  is referenced angularly around axis  10 ′ with respect to stator by a key engagement (not shown) existing between member  23  and stator  10 . As a result, member  22  will be referenced angularly around axis  10 ′ with respect to stator  10 . This chain of referencing achieves that the leads coming from the stator slots will result referenced with respect to routing surfaces of members  22  and  23 . 
         [0053]    When requiring to route and twist the leads, members  22  and  23  can be locked to stator  10  by means of assembly  50  (see  FIGS. 4 ,  4   a,    4   b  and  4   c ). The same assembly will lock stator  10  to an appropriate seat of a station as will become more apparent in the following. 
         [0054]    Member  22  can be locked to the stator by means of shaft  51 , which has enlarged end  51 ′ that presses on shelf  58  of member  22  when shaft  51  is pulled in direction  52 ′ (parallel to axis  10 ′) by linear actuator  53 . 
         [0055]    Similarly, member  23  can be locked by means of tube  55 , which has enlarged end  55 ′ that presses on shelf  59  of member  23  when tube  55  is pulled in direction  52 ′ by linear actuator  56 . 
         [0056]    Member  22  can move in direction  52  and  52 ′ with respect to member  23  due to the sleeve assembly existing in cavity  25 . Pin  70  which can abut against shelves  71  and  72  of member  23  limits the movement of member  22  with respect to member  23 . In addition, pin  70  can act as a pressing connection between member  22  and  23 . In fact, locking of members  22  and  23  to stator  10  can be accomplished by pressing with enlarged end  51 ′ on shelf  58  and with enlarged end  55 ′ on shelf  59 , i.e. in direction  52 ′. As a result, pin  70  can press on shelf  71  whilst cylindrical shoulder  24  of member  23  presses on face  15  to lock members  23  to the stator. Consequently member  22  becomes locked to the stator through pressing of pin  70  on shelf  71 . 
         [0057]    Linear actuator  53  is connected to shaft  51  by means of coupling  54 , which allows rotation around axis  10 ′. Similarly, linear actuator  56  is connected to tube  55  by means of coupling arm  57 , which allows rotation around axis  10 ′ due to bearing  57 ′ assembled between tube  55  and coupling arm  57 . 
         [0058]    Shaft  51  can be rotated around axis  10 ′ to orient enlarged head  51 ′ with respect to passage  60  of member  22  in order to lock member  22 . In the position of  FIG. 4   a,  enlarged head  51 ′ is pressing on shelf  58  and therefore is oriented at 90 degrees with respect to axis  60 ′. To pass enlarged head  51 ′ through passage  60  in order to remove members  22  from the stator, shaft  51  needs to be rotated 90 degrees to align at zero degrees enlarged head  51 ′ with axis  60 ′. In this way, the elliptical form of head  51 ′ will be able to pass through the corresponding form of passage  60 . 
         [0059]    Similarly, enlarged head  55 ′ of tube  55  has an elliptical form that needs to pass through a corresponding form of passage  61 . Tube  55  can be rotated around axis  10 ′ to orient enlarged head  55 ′ with respect to passage  61  of member  23 . In the position of  FIG. 4   b,  enlarged head  55 ′ is pressing on shelf  59  and therefore is oriented at 90 degrees with respect axis  61 ′. To pass enlarged head  55 ′ through passage  61  in order to remove members  23  from the stator, tube  55  needs to be rotated 90 degrees to align at zero degrees enlarged head  55 ′ with axis  61 ′. 
         [0060]    Rotation of shaft  51  around axis  10 ′ to orient enlarged head  51 ′ can be accomplished using assembly  62 , which consists of linear actuator  63  that is able to translate forward and backwards rack  64 . Rack  64  meshes with gear  65  assembled on shaft  51  and is capable of transmitting rotation through key  66 . Key  66  is assembled on shaft  51  and is capable of running in a way of gear  65  when shaft  51  is moved in direction  52  and  52 ′. 
         [0061]    Similarly, rotation of tube  55  around axis  10 ′ to orient enlarged head  55 ′ can be accomplished using assembly  67 , which consists of linear actuator  68  that is able to translate forward and backwards rack  69 . Rack  69  meshes with gear  69 ′ assembled on tube  55  and is capable of transmitting rotation through key  69 ″. Key  69 ″ is assembled on shaft tube  55  and is capable of running in a way of gear  69 ′ when tube  55  is moved in direction  52  and  52 ′. 
         [0062]    Therefore, enlarged heads  51 ′ and  55 ′ can be rotated between a position which locks members  22  and  23  and a position which releases members  22  and  23 . 
         [0063]    When members  22  and  23  are released they can be removed from stator  10  by inserting gripper head  73  in bore  74  of member  22 . Gripper head  73  has expandable keys  73 ′ which can grip the inside surface of bore  74 . Gripper head  73  also has abutment ring  73 ″ which can engage the upper surface of member  22  to guarantee precise referencing between gripper  73  and member  22 . Member  22  is part of a transfer device  105  shown in  FIG. 14 . Gripper  73  moves in direction  52  to remove members  22  and  23 . Abutment of pin  72  against shelf  72  will guarantee that member  22  carries with it member  23  when gripper  73  moves in direction  52  (parallel to axis  10 ′) to remove members  22  and  23 . 
         [0064]      FIG. 4   c  shows holder  80  which has groove  81  for seating stator  10  in alignment with axis  10 ′. Stator  10  can be kept pressed on the bottom of groove  81  by the pressure exerted with abutment surface  24  of member  23  on face  15 . Holder  80  can be assembled on a transfer table like is described with reference to  FIG. 14 . Holder  80  becomes aligned with shaft  51  and tube  55  by movement of the transfer table 
         [0065]      FIG. 4   c  shows that members like  82  and  83  can be inserted in the free space created between the bridges  92  of predetermined coils. Members  82  and  83  can be supported in slots like  84  of holder  80  to achieve radial motion (by means of an actuator—not shown) in order to become positioned as shown in  FIG. 4   c.  Furthermore, the support in the slots is needed to make members  82  and  83  react when acting as support arms to resist that the coils become pulled in direction  52  during the operations to twist leads  16  and  17 . In this way any tendency of the coils to move in direction  52  during the operations to twist the leads is avoided. The stator can be placed on holder  80  by being moved in direction  52 ′ while it centered with respect to the center of holder  80 . In this way the stator becomes aligned also with shaft  51  and tube  55 , which need to lock members  22  and  23 . 
         [0066]      FIGS. 2 ,  3  and  4  show the result of having grasped leads  16  and  17  with manipulator  30  in the condition of the leads  12  being like is shown in  FIG. 1  and having routed them as plural wires through slots  26  and  27  and into seats  28  and  29  of member  22 . 
         [0067]    Member  22  can be moved in direction  52  to position it more distant from stator  15  in order to create spacing  91  (see  FIG. 6 ) for routing the wires around the stator. This can be accomplished by actuating actuator  53  which moves enlarged head  51 ′ against elastic ring  90  to translate member  22  in direction  52   
         [0068]    Slots  26  and  27  are radial passages for the wire and present access from the periphery of member  22 . Slots  26  and  27  communicate with seats  28  and  29 , respectively. Seats  28  and  29  can have the configuration of bores, where each bore is able to receive at least the total section of the number of wires which need to form the twisted portion of a lead. 
         [0069]    To grasp the leads and route them as has been shown in  FIGS. 2 ,  3  and  4 , manipulator  30  can move in directions X, Y and Z and accomplish rotations AO (see  FIGS. 2 and 3 ) around axis Z. The mechanisms  111  (see  FIG. 14 ) for accomplishing these movements can be similar to the equipment that has been described in EP 469.426. 
         [0070]    Manipulator  30  can draw the leads against surfaces  31  and  32  of member  23  to route the plural wires along predetermined paths in order to reach locations  18  and  19  where the bends occur. When the manipulator draws the wires W along these paths, the wires can run through the gripper section  30 ′ of the manipulator. The manipulator initially grips the wires W in the condition of leads  12  in  FIG. 1 . The grip can be at a point along the wires that will allow the wires to run through the gripping section  30 ′ during routing. 
         [0071]    Preferably wires W can be held by gripping section  30 ′ so that they do not cross a s shown in  FIG. 3 . This result can be achieved by providing gripping section  30 ′ with respective seats for seating each of the wires W. The seats can be grooves (hidden in  FIG. 3  by the presence of wire pressing members  30 ″). 
         [0072]    Due to the fact that wires W are seated in their respective seats of the gripping section  30 ′ during the movements of the manipulator  30 , wires W do not cross each other when routed along the trajectories and wound in the helixes of the twisted portions. 
         [0073]    Surfaces  31  and  32  can be cylindrical sides respectively of portions  31 ′ and  32 ′ of member  23  (see  FIGS. 2 and 3 ), and can be located over coil ends  14  (see also  FIG. 4 ). As a result, the leads reach slots like  26  and  27  by being routed along predetermined paths which follow the contour of surfaces  31  and  32 . Portions  31 ′ and  32 ′ can be received in recesses of member  22  as shown for example in  FIGS. 2 and 4 . 
         [0074]    At slots like  26  and  27 , the manipulator draws the leads through the radial passage portions in order to locate the end portions of the leads within seats  28  and  29 —see for example  FIGS. 4 to 6 . 
         [0075]    As illustrated in  FIGS. 5 and 6 , the manipulator can first move to draw the plural wires against surfaces  31  and  32  and then into slots like  26  and  27  to reach the required position in seats  28  and  29  and alignment in predetermined directions  33  and  34 . 
         [0076]    A lead like  17  shown in  FIG. 6  that is coming from two separate slots of the stator can be brought into slot  26  and seat  28  in two stages; i.e. in a first stage, lead portion  17   a  can be brought into slot  26  and seat  28  by manipulator  30 . Successively, in a second stage, lead portion  17   b  can be brought into slot  26  and seat  28  by manipulator  30 . Lead  17  is thus formed of two portions  17   a  and  17   b.  Both portions form bends at  19  and pass in seat  28  to become directed in direction  34 . The bends can be formed by bending the plural wire against surface  22 ′, which is located in the area adjacent to seat  28  and faces the stator 
         [0077]    A lead like  16  shown in  FIG. 5 , which is coming from a single slot of the stator, can be brought into slot  27  and seat  29  in one stage of grasping and movement on behalf of manipulator  30 . Lead  16  forms a bend at  18  and passes in seat  29  to become directed in direction  33 . The bend can be formed by bending the plural wires against surface  22 ′,′ which is located in the area adjacent to seat  29  and faces the stator. 
         [0078]    To start forming the twisted portions, the plural wires of leads like  16  and  17  need to be held contemporarily by the manipulator respectively in predetermined directions  33  or  34 , with the plural wires constrained in the positions of seats  28  and  29 , see  FIGS. 5 and 6 . A pressing member like  93  (see  FIG. 4 ) can press on the plural wires in their extents just outside seats  28  and  29  to assure increased constraint of the plural wires in seat  28  and  29 . In  FIG. 4 , member  93  is pressing on the wires in a radial direction  93 ′ towards axis  10 ′ of the stator. 
         [0079]    Then to twist the leads (see  FIGS. 7 and 8 ), manipulator  30  in the condition of holding the plural wires as shown in  FIGS. 5 and 6 , rotates around its axis Z (rotation A 1  or AO) and at the same time rotates around axis Z′ (rotation A 2 ), which is where the leads are positioned to be in directions  33  or  34 . To complete a turn of the various helixes one rotation around axis Z and a simultaneous rotation around axis Z′ is needed. 
         [0080]    In addition, manipulator  30  needs to move in direction  52 ′ to avoid excessive strain on the wires as twisting progresses This movement of manipulator  30  can be with a law of motion that maintains tension on the wires by pulling them against surface  22 ′. During this pull, wires W are prevented from moving towards the manipulator in direction  52  due to their engagement against surface  22 ′. As a result, during these movements for twisting, the twisted portions will result in a precise location above the heads of the coils, due to the position constraint given by seats  28  and  29 , and aligned in directions  33  and  34  due to the pull of manipulator  30 . 
         [0081]    Prior to starting rotation of the manipulator for twisting, termination member  22  can be moved in direction  52 ′, i.e. towards the core (see  FIGS. 7 and 8  showing member  22  nearer to the core ). Contemporarily, manipulator  30  which is holding all the wires of the lead is moved in direction  52 ′ so that the wires do not become over strained due to the movement of member  22  in direction  52 ′. The movement in direction  52 ′ of member  22  will bring surface  22 ′ nearer to the coil heads  14  (see the conditions of  FIGS. 7 and 8 ), which will later impede portions  16   a ,  17   a  and  17   b  from moving in opposite direction  52  during rotations of the manipulator to twist the leads. In addition, movement in direction  52 ′ of member  22  compacts portions of leads like  17   a,    17   b  and  16   a  against the heads of the coils  14 . 
         [0082]    Correct twisting transforms the wires into a number of adjacent helixes, where each helix is formed from a wire (see  FIGS. 7 and 8 ). The turns of a helix correspond to the number of rotations accomplished by manipulator  30 . In addition the various helixes should be formed adjacent to each other without crossing, i.e. with turns of the same diameter D and with constant pitch, as shown in  FIGS. 7 and 8 . Imperfect forming of the helixes would cause disorderly winding of the helixes on each other, thereby creating abnormal bulges and voids along the length of the twisted portions. 
         [0083]    Rotations of the manipulator can be stopped when a predetermined number of turns of the helixes have been formed. This can guarantee that a predetermined length of twisted portion exists from member  22  to cutting level  37 . At level  37 , cutters  40  and  41  can approach each other in directions  40 ′ and  41 ′, respectively, to cut the twisted portions, as shown in  FIG. 9 . 
         [0084]    If requiring to twist further portions of the leads remaining in seat  28  and  29 , then prior to cutting the twisted portions, termination member  22  can be moved further in direction  52 ′ to cause the required lead portions to move in direction  52  in order to exit seats  28  and  29 . Then rotation of the manipulator can be resumed to continue twisting the wires up to the upper surface  22 ′″ of member  22 . 
         [0085]    When a high number of wires need to be twisted together, it can occur that at least one wire remains untwisted at the center of the section of the twisted wires. To manage to twist even this wire, the wires can be twisted together in lower numbers, and successively the resulting twisted portions can be twisted together to form a single twisted portion—see  FIGS. 10-13  concerning operations for twisting a lead having portions like  17   a  and  17   b  described in the foregoing. 
         [0086]    As shown in  FIGS. 10 and 11 , a certain number of wires  42  of branch  17   a  are brought into seat  28  and twisted together to form a first twisted portion  42   a . Successively, a further number of wires  42 ′ of branch  17   b  are brought into seat  28  and twisted together to form a second twisted portion  42 ′ a  (see  FIG. 12 ). 
         [0087]    Then, as shown in  FIGS. 12 and 13  the two twisted portions can be grasped by manipulator  30  and a resulting twisted portions  42   b  can be formed by rotations A 1  and A 3 . In this case rotation A 3  can be around axis Z′ located between the two twisted portions, as shown in  FIGS. 12 and 13 . 
         [0088]      FIG. 14  shows a layout of a rotating table transfer machine in which the principles of the invention can be applied. Transfer table  102  is capable of rotating around center  201  in directions  201 ′. Holders like  80  are fixed on the transfer table at positions like  202 ,  203 ,  204 ,  205 , which are equidistant from each other for seating stators  10 . Table  102  stops rotation around center  201  to align the holders with manipulators like  30  present in each of stations A, B and C. Also present at each station of stations A, B and C is an assembly like  50  for locking/unlocking members  22  and  23  as has been described in the foregoing with reference to  FIG. 4 . Furthermore at each of stations A, B and C a transfer arm  305  is capable of rotating around axis like  206 . Each transfer arm  305  is provided with a gripper like  73  for applying and removing members  22  and  23  from the stator positioned in the station where the arm is located. Dashed lines  207  show a typical trajectory that a gripper like  73  can accomplish to align members  22  and  23  with the stators, prior to moving in direction  52 ′ to actually apply members  22  and  23  to the stator. In each of stations A, B and C, a certain number of the total leads of a stator can be terminated according to the cycle principles that have been described in the foregoing for leads  16  and  17 . Therefore, in each of stations A. B and C a specific cycle of the three in sequence required to finish stator  10  will be accomplished. The sequence will start in station A and be finished in station C. Station DX can be a station for loading and unloading the stator between the table and a conveyor (not shown). 
         [0089]    At stations like A, B and C, members like  22  and  23  will be dedicated for the cycle to be accomplished, i.e. configured for predetermined lead trajectories, and having seats like  28  and  29  and reference surfaces like  22 ′ and  22 ″ positioned and configured specifically for the routing, bending and twisting that is required in the specific cycle of the stator. Station A. B and C can be operating at the same time so that a stator can be processed in a fraction of the time that would be required for an entirely sequential non parallel processing of the leads. 
         [0090]    Control means  310  (see  FIG. 14 ) can be programmed to move manipulators  30  according to the variable lead trajectories that characterize the stator which needs to be processed. The control means causes the manipulator to perform the movements and tensioning cycle required during the twisting processes mentioned in the foregoing 
         [0091]    The programs foresee sequencing movements of member  22  in order to compact the leads and function for twisting operations as has been mentioned. 
         [0092]    The same control means can sequence operations of table  102  and transfer arms  305  to be synchronized with the operating cycle of manipulators  30 . 
         [0093]    Signal and supply lines will be available to connect the various actuators to control means  310  as shown in  FIGS. 4 and 14 . 
         [0094]    With reference to  FIG. 16  a wound core  105  is shown positioned in support assembly  100  of table  102  in preparation for routing and twisting of the leads. In  FIG. 16 , the leads have been omitted for reasons of clarity. Coil heads  106  and  107  are shown adjacent to respective end faces  106 ′ and  107 ′ of the cores. Restraining members like  82  and  83  mentioned above with reference to  FIG. 4C  are referenced either  103  or  104  in the embodiment of  FIGS. 15 and 16   
         [0095]    More particularly, in  FIG. 16  portions of a first series of restraining members  103  are shown positioned in the free spacing  131  existing between coil heads  106  and the adjacent face  106 ′ of the core  105 .  FIG. 16  also illustrates a second series of restraining members  104  shown in the free spacing existing between coil heads  107  and adjacent face  107 ′. The position of the restraining members illustrated in  FIGS. 15 and 16  is the radial inner most position of the restraining members towards the central axis  105 ′ of the core, and is required for supporting the portions of wires forming the coil heads during twisting. In this position the end portions of the restraining members prevent the portions of wires of the coils from moving towards the adjacent faces  106 ′ and  107 ′ of the core when the leads of a coil are pulled by the manipulator during the twisting operations. 
         [0096]    The outermost radial position (not shown) of the restraining members is a retracted position that allows core  105  to be inserted and positioned in the support assembly, like is shown in  FIG. 16 , by moving the core in direction DZ. More particularly, with the movement in direction DZ, core  105  becomes positioned in the support assembly when face  107 ′ bears against ridge  115 ″ of member  115 , as is shown in  FIG. 16 . The core can be oriented specifically around axis  105 ′, which is also the axis of symmetry of the support assembly, by engaging a protuberance (not shown) of member  112  in a slit of core  105 . An automatic gripping device (not shown) of a load/unload unit present in station DX of  FIG. 14  can be used for positioning and orienting the core in the support assembly by translation and rotation of the core, respectively in direction DZ and around axis  105 ′. 
         [0097]    Cover member  108  seats each restraining member  103  of the first series in a respective channel  121  placed along a radius that intersects axis  105 ′ of the core (see also  FIG. 15  where the cover portions  122  of the channels are shown). The sides of each channel  121  guides a restraining member  103  along a respective radius during the alternative radial movement between the coil head support position and the outermost radial position. 
         [0098]    Bottom member  109  is a disk member attached to cover member  108 . Bottom member  109  acts as a support surface for the sliding movement of restraining members  103  during the radial movement. 
         [0099]    A cam follower pin  103 ′ is assembled by means of a bolt on each of restraining members  103 . The cam  109 ′ of bottom member  109  and finds seating and engagement in respective slots  110 ′ of driving member  110 . More in detail, the engagement of the cam follower pin in slots  110 ′ can occur against a side of slot  110 ′. 
         [0100]    Driving member  110  is seated and centered in containing member  111  for rotating around central axis  105 ′ of the core. 
         [0101]    Containing member  111  is centered by support member  112 . Containing member  111  bears on spacer member  113 , which is supported inside support member  112 . Support member  112  is supported and fixed on the surface of table  102  by means of fixing plates  120 . 
         [0102]    The height H of spacer member  113  determines the height of restraining members  103  from ridge  115 ″ where the core to be processed is supported. By substituting spacer member  113  with a spacer member  113  of different height, different positions of restraining members  103  can be reached to compensate for differences in the height of the cores that need to be processed. 
         [0103]    Slots  110 ′ are present for each cam follower pin  103 ′ and have an extension in a plane perpendicular to axis  105 ′ (see  FIG. 15  for the dashed line representation of the extension of the slots), which makes the side of slots  110 ′ engaged by cam follower pin  103 ′ produce a radial motion of a restraining member  103  when driving member  110  is rotated around axis  105 ′ in direction R. Therefore, rotation in direction R around axis  105 ′ will cause synchronized inward radial movement of all the restraining members  103 , whilst rotation in opposite direction R′ around axis  105 ′ will cause synchronized outward radial movement of all the restraining members  103 . 
         [0104]    A first series of bolts (not shown) have their heads pressing against member  108  and are screwed into member  111 . The stems of these bolts pass through openings of members  109  and  110 . Accordingly member  108  is joined to member  111 . Members  103  and drive member  110  are packed in between members  108  and  111  and are able to accomplish their respective movements due to an adequate play that is typically foreseen between stationary and moving parts. 
         [0105]    A second series of bolts  130  (the heads of which are shown in  FIG. 15 , whilst one of the axes of their stems is shown in  FIG. 16 ) have heads pressing against member  111  and are screwed into member  112 . Accordingly, member  111  is joined to member  112 . Therefore member  108  becomes joined to member  112  because member  108  is joined to member  111  by means of the first series of bolts. 
         [0106]    This arrangement makes it possible to provide the support assembly  100  only with a first series of restraining members  103  for supporting the coils heads, i.e. without the second series of restraining members  104 , if required. 
         [0107]    When the second series of retraining members are foreseen, each restraining members  104  of the second series can be seated in a respective radial channel  115 ″ of member  115 . The radial channel  115 ′ guides the restraining member during the radial movement to reach the coil head support position shown in  FIGS. 15 and 16 . 
         [0108]    Member  115  is fixed to support member  112  by bolts (not shown). Member  114  is interposed between member  115  and support member  112 , and acts as a running surface for restraining members  104  when restraining members  104  move in the radial directions. 
         [0109]    A cam follower pin  104 ′, like  103 ′, is assembled by means of a bolt on each of restraining members  104 . The cam follower pin  104 ′ passes through a respective radial slot of bottom member  115  and finds seating and engagement in respective slots  116 ′ of second driving member  116 . The engagement of a cam follower pin  104 ′ in a respective slot  116 ′ occurs against a side of slot  116 ′. 
         [0110]    Driving member  116  is assembled on the outer ring of bearing  119 . The inner ring of bearing is assembled in a seat of member  115 . Cap  117  is fixed by bolts (shown with the dashed line  117 ′) to member  115  in order to secure the inner ring of bearing  119  to member  115 . Similarly, cap  118  is fixed by bolts (shown with the dashed line  118 ′) to member  116  in order to secure the outer ring of bearing  119  to member  116 . 
         [0111]    Slots  116 ′ have an extension in the plane perpendicular to axis  105 ′ that is identical to the extension of slots  110 ′ in their previously mentioned parallel plane. Therefore, cam follower pin  104 ′ engages a side of slots  116 ′ to produce a radial motion of a restraining member  104  when driving member  116  is rotated around axis  105 ′ in direction R. Therefore, rotation in direction R around axis  105 ′ will cause inward synchronized radial movement of all the restraining members  104 , whilst rotation in opposite direction R′ around axis  105 ′ will cause outward synchronized radial movement of all the restraining members  104 . 
         [0112]    The assembly of bottom member  115  to support member  112  and the assembly of drive member  116  to bottom member  115  is an arrangement that allows the support assembly to be provided only with the second series of restraining members  104 , i.e. without the first series of restraining members  103 , if required. 
         [0113]    Driving member  110  is provided with an arm portion  123  that extends outwardly from the support assembly through a slotted portions of member  111 . Similarly, second driving member  116  is provided with arm portion  124  that extends outwardly from the support assembly. A cylindrical bush member  125  can be interposed between arm portion  123  and arm portion  124  by being assembled on the stem of bolt  126 . Bolt  126  passes though bores of arm portions  123  and  124 . 
         [0114]    Arm  129  of an actuating unit  128  (see  FIG. 15 ) can rotate around fulcrum  127  in either directions of rotation Q or Q′ to engage and push on bush member  125 . Accordingly, arm portion  123  and arm portion  124  will be rotated in direction R or R′ respectively by rotation Q or Q′ of arm  129  around fulcrum  127  to produce the required radial motions of restraining members  103  and  104 . 
         [0115]    It should be contemplated that arm portion  123  by itself can be rotated by an arm like  129  when only the first series of restraining members  103  are present in the support assembly. Similarly, arm portion  124  by itself can be rotated by an arm like  129  when only the second series of restraining members  104  are present in the support assembly. 
         [0116]    Removal of support assembly  100  from the table and its substitution with another support assembly can occur by removing bolts  130  that fix member  111  to support member  112  and by releasing bolt  126 . In this way member  108 , the series of restraining members  103 , member  109 , driving member  110  and member  111  can be removed as a unit from table  102 . 
         [0117]    Furthermore, removal of plates  120  from engagement with the slots of support member  112  allows support member  112 , member  114 , member  115 , the series of restraining members  104  and member  116  to be removed as a unit from the underside of the table  102 , by movement of support member  112  in direction DZ. 
         [0118]    The foregoing is merely illustrative of the principles of this invention and various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention.

Technology Classification (CPC): 8