Abstract:
A system for simplifying the design of winding guides is provided. The flyer arm of a winder built in accordance with the principles of this invention is positioned so that the extreme delivery point of the wire is aligned and practically over the slots of the armature where the coil is being wound. Additionally, the flyer arm can be easily and quickly substituted on the winder to conform to the armature being wound, ensuring that the extreme delivery point of the wire is aligned and practically over the slots of the armature where the coil is being wound. This feature of the invention contributes to a simpler design of the winding guide. Accordingly, traditional guide surfaces for capturing the wire coming from a distant position are no longer required.

Description:
CROSS REFERENCE TO RELATED PATENT APPLICATION 
     This application claims the benefit of commonly-assigned U.S. Provisional Patent Application No. 60/109,141, filed Nov. 20, 1998. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention relates to machines for winding armatures for electric motors and the like. In particular, this invention relates to winding guides that are used to guide the wire leaving a flyer so that the wire is aligned and deposited within slots of the armature stack, and to apparatus for facilitating changing of the flyer which dispenses wire coming from a supply reel. 
     Winding guides have been used in the past to guide wire leaving a flyer such that the wire becomes aligned and deposited within the slots of the armature stack. More particularly, the wire leaving the rotating flyer is caught by such guides and runs on their appropriately configured and machined surfaces to reach alignment with the slot entrances where the coils need to be wound. Following the alignment, the wire is drawn into the slots where it is deposited as a portion of the coil. Examples of such winding guides have been described in U.S. Pat. Nos. 5,257,745 and 4,579,291, both assigned to the assignee of this application and hereby incorporated by reference in their entirety. 
     The above-described winding guides have a relatively complex spatial configuration, particularly since their configuration is governed by the configuration of the armature that needs to be wound. Consequently, designing of the winding guides of the prior art requires dedicated trial and error. 
     In view of the foregoing, it is an object of the invention to provide solutions for simplifying the complex spatial configuration of winding guides. 
     It is another object of the invention to provide solutions for avoiding the configuration of the winding guide to be dependent on the configuration of the armature that needs to be wound. 
     It is another object of the invention to reduce the manual adaptations which need to be accomplished for manufacturing winding guides. 
     It is another object of the invention to reduce the geometrical extent of the winding guide, thereby reducing the amount of wire running on the guide surface. 
     It is another object of the invention to provide solutions for obtaining the best winding position for winding armatures. 
     It is another object of the invention to improve the operation required to connect the coil leads to the tangs of the commutator. 
     SUMMARY OF THE INVENTION 
     These and other objects of the invention are accomplished in accordance with the principles of the invention by providing a system for simplifying the design of winding guides. 
     According to the principles of the invention, a support member acts as a reference surface to maintain the position of the armature during winding. The support member impedes lateral deflection of the armature. 
     The flyer arm of the winder built in accordance with the principles of this invention is positioned so that the extreme delivery point of the wire is aligned and practically over the slots of the armature where the coil is being wound. This is in direct contrast with the flyer arms of the prior art. In the prior art, the flyer arm was positioned away from the armature being wound and traditional guide surface were utilized to capture the wire from a far away position. Accordingly, only simple guide structures need to be employed to maintain wire alignment with the opening of the slots. 
     Additionally, in accordance with the principles of this invention, the flyer arm can be easily and quickly substituted on the winder in accordance with the armature being wound, ensuring that the extreme delivery point of the wire is aligned and practically over the slots of the armature where the coil is being wound. This feature of the invention contributes to a simpler design of the winding guide. 
     Accordingly, traditional guide surfaces for capturing the wire coming from a distant position are no longer required. Instead, a simplified guide surface is used in accordance with the principles of this invention. 
     The guide structure built in accordance with the principles of the invention has a leading surface that maintains the alignment of the wire with the opening of the slot. The flyer arm is positioned with respect to the guide structure in such a manner that the wire is slightly deflected against. This deflection maintains the alignment of the wire with the position of the flyer as well as the slot of the armature being wound, enabling a more secure deposition of wire in the slots. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above and other objects and advantages of the invention will be more apparent upon consideration of the following detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings, in which like reference characters refer to like elements throughout, and in which: 
     FIG. 1 is an isometric view of an illustrative winder constructed in accordance with the principles of this invention. 
     FIG. 2 is a top view of an illustrative winder constructed in accordance with the principles of this invention taken generally along the line  2 — 2  in FIG.  1 . 
     FIG. 3 is a simplified view of an illustrative winder constructed in accordance with the principles of this invention taken generally along the line  3 — 3  in FIG.  2 . Also shown in FIG. 3 is the simplified partial sectional view taken generally along the line  3 ′— 3 ′ in FIG.  2 . 
     FIG. 4 is a partly exploded, isometric view of an illustrative winder constructed in accordance with the principles of this invention. 
     FIG. 5 is a partial, partly exploded, isometric view of an alternative illustrative embodiment of a winder in constructed in accordance with this invention. 
     FIG. 6 is partial isometric view of an alternative illustrative winder constructed in accordance with the principles of this invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In the illustrative embodiment shown in FIGS. 1-4, an armature  11  to be wound is held and shielded by shield assembly  20 . Armature  11  is wound by means of at least wire  14 , delivered by flyer arm  10 . Flyer arm  10  rotates on circular orbit F about axis B in order to wind coils of wire on armature  11  in corresponding slots, for example,  11 ′ and  11 ″. Armature  11  is positioned coaxial to axis A of the shield tubes belonging to shield assembly  20 . 
     Shield assembly  20  can be like the equipment described in U.S. Pat. No. 5,127,594, which is hereby incorporated by reference herein. Shield assembly  20  can also be like the equipment described in commonly-assigned U.S. Pat. application Ser. No. 09/323,304, filed Jun. 1, 1999 which claims priority from U.S. provisional application No. 60/090,394, filed Jun. 23, 1998, which are both hereby incorporated by reference herein. 
     Axis B is perpendicular to axis A and, in a preferred embodiment, their intersection is the center of the armature stack. Wire  14  leaving flyer arm  10  is deposited for a predetermined number of turns in slots, for example,  11 ′ and  11 ″, to form a coil. The coil spans between corresponding slots, for example,  11 ′ and  11 ″ along both ends of the lamination stack. 
     In the prior art, winding guides were mounted on structure  18 . In accordance with an illustrative embodiment of this invention, V support member  19  is attached to structure  18  to act as a reference surface to maintain the position of armature  11  during winding. Support member  19  impedes a lateral deflection of armature  11 . 
     Guide structure  21  is maintained in position by means of support rod  32  (fixed to a face of guide structure  21 ). Support rod  32  stems from releasable bracket  33  clamped on the external tube of the shield assembly. Aperture  34  in guide structure  21  allows the gripper and cutter (not shown) used in the winder for terminating the leads to become adjacent to the tangs for their respective operations. 
     These operations, which can be traditional, will grip the final leads of the coils and cut them to free the armature. Flyer arm  10  is positioned with respect to guide structure  21  in such a manner that wire  14  is slightly deflected against it (toward the center of armature  11 ). This deflection maintains wire  14  against guide structure  21 . 
     Guide structure  21  comprises of surface  21 ′ and leading surface  21 ″. Surface  21 ′ is slightly inclined toward the center of armature  11  such that it merely represents an edge that maintains the alignment of wire  14  with the opening of a slot, for example  11 ′. Leading surface  21 ″ captures any slight misalignments of wire  14 , for example, when the orbit of the flyer is winding one end of the external portions of the coils, to bring the wire into an end opening of slot  11 ′. Leading surface  21 ″ is also inclined toward the center of armature  11 . 
     Leading surfaces  21 ′ of guide structure  21  maintains the alignment of wire  14  with the opening of the slot, for example  11 ′. As described before, flyer arm  10  is positioned with respect to guide structure  21  in such a manner that wire  14  is slightly deflected against guide structure  21 . This deflection maintains the alignment of wire  14  with the position of flyer arm  10  as well as the slot of the armature being wound, for example  11 ′. 
     One of the advantages of having wire  14  deflected against leading surface  21 ′ of guide structure  21  is that wire  14  can be better aligned with the slots, for example  11 ′ and  11 ″, of armature  11  being wound. This alignment with the slots of armature  11  being wound assists in the winding of wire  14  not only with respect to the opening of the slots, for example  11 ′ and  11 ″, of armature  14 , but also with the shape of the slots. Thus, this feature of the invention enables a more secure winding of wire  14 , thereby preventing wire laid within slots from climbing up. It will be understood that climbing of the wire up the side of the slot is undesirable because it impedes wire from being wound at the bottom of the slot, thereby reducing slot fill. 
     A corresponding guide structure, similar to the above-described guide structure  21 , is also applied near corresponding slot  11 ″. This corresponding guide structure achieves wire alignment for corresponding slot  11 ″ and maintains it during flyer rotations. The leading surface of the corresponding guide structure (similar to leading surface  21 ″ of guide structure  21 ) is positioned adjacent to the corresponding end of armature  11 , indicated as  01  in FIG. 2, which is opposite to where leading surface  21 ′ of guide structure  21  has been shown (see end indicated as  02  in FIG.  2 ). 
     The leading surface of the corresponding guide structure is positioned adjacent to the corresponding end of armature  11  (indicated as  01  in FIG. 2) because wire  14  has to be led into slot  11 ″ from end  01 , while for slot  11 ′, wire  14  is led in from end  02 . This is consistent with the direction R (FIG. 1) of rotation of flyer arm  10  about axis B. However, it will be understood that if the direction of rotation of the flyer arm  10  were to be reversed, the positioning of the leading surfaces of guide structure  21  and its corresponding guide structure would also have to be reversed. 
     FIG. 3 is a simplified view of an illustrative winder constructed in accordance with the principles of this invention taken generally along the line  3 — 3  in FIG.  2 . Also shown in FIG. 3 is the simplified partial sectional view taken generally along the line  3 ′— 3 ′ in FIG.  2 . 
     As shown in FIG. 3, flyer arm  10  has been positioned so that its extreme wire delivery point, pulley wheel  12  (FIG.  2 ), is at distances X and Y (X-measured along an axis perpendicular to axis B about which the flyer rotates; and Y-measured along an axis parallel to axis B about which the flyer rotates) from the center of armature  11  being wound. In accordance with the principles of this invention, distances X and Y are chosen to align orbit F (FIG. 1) over the slots, for example,  11 ′ and  11 ″, where wire  14  is being wound. Thus, in accordance with the invention, flyer arm  10  is so positioned that the extreme wire delivery point of flyer  10  is dimensionally within a diameter distance of armature  11  being wound. It will, however, be understood that flyer arm  10  can be positioned in any other manner to suit the operation being performed, for example, by varying the X and Y coordinates. 
     In accordance with the principles of this invention, even the distance from the extreme wire delivery point of flyer arm  10  to the slots, for example,  11 ′ and  11 ″, is very small. Accordingly, traditional guide surfaces for capturing the wire coming from a far away position (like area P) are no longer required. In accordance with the principles of this invention, only simple guide structures like  21  need to be employed. 
     In accordance with an illustrative embodiment of this invention, flyer arm  10  can be easily and quickly substituted on a winder to adopt the best values of distances X and Y for winding a particular armature configuration. Accordingly, flyer arm  10  can be used as a tool that can be changed on a winder by a motor manufacturer to best suit the disposition and size of the slots that need to be wound. Thus, a motor manufacturer can change flyer arm  10  easily and quickly each time for a different batch of armatures having corresponding configurations. The geometrical measurement of the flyer arm is the fundamental characteristic that achieves the needed measurements of X and Y. The geometrical measurement of flyer arm  10  can also be used to distinguish each flyer arm, in the sense of it being a tool. 
     As shown in FIG. 1, flyer arm  10  is formed from two separate arms  10 ′ and  10 ″. The spacing between arms  10 ′ and  10 ″ is required to receive pulley wheels  12  and  13 , and to allow passage of wire  14 . Flyer arm  10  is provided with base structure  22  on an end opposite to pulley wheel  12 . Base structure  22  is bolted to plane  15   a  of collar  15  by means of bolts passing through passageways  22 ′ (FIG.  2 ). Base structure  22  is formed by securing base structures  22 ″ and  22 ″′, corresponding to arms  10 ′ and  10 ″, respectively, a certain distance apart to plane  15   a  of collar  15  by means of bolts passing through passageways  22 ′ (FIG.  2 ). 
     FIG. 4 is a partly exploded, isometric view of an illustrative winder constructed in accordance with the principles of this invention. In FIG. 4, the flyer arm assembly has been removed from the winder assembly in accordance with an illustrative embodiment of this invention. Collar  15  of the flyer assembly has a circular form with an opening  15   b . The inside of collar  15  has two opposite parallel planes  15   c  and  15   d . Portion  15   e  is circular and connects plane  15   c  to plane  15   d.    
     Shaft member  17  of the winder assembly is provided with two opposite parallel planes  17   a  and  17   b . Part of planes  17   a  and  17   b  are formed by extension  17 ′, which is a portion protruding from shaft member  17 . As shown in FIG. 4, flyer arm  10  can be mounted on the winder by aligning opening  15   b  with the portion of shaft member  17  which is delimited by planes  17   a  and  17   b . This has to occur on the side of shaft member  17  which is opposite to extension  17 ′. 
     Once the above-described alignment has been reached, flyer arm  10  can be moved in direction C, i.e., perpendicularly to shaft member  17  to make planes  15   c  and  15   d  slide on planes  17   a  and  17   b , respectively. This movement will end when circular portion  15   e  abuts against corresponding circular portion  17   c , which is opposite to extension  17 ′. It will be understood that flyer arm  10  can be easily removed from the winder by moving it in direction D, which is opposite to direction C. This movement in direction D will cause planes  15   c  and  15   d  to slide off planes  17   a  and  17   b , respectively. 
     As shown in FIG. 3, and with particular reference to the sectioned portion, as seen from directions  3 ′ and  3 ′ of FIG. 2, shaft member  17  is encircled by two rings  23  and  24 . Ring  23  is fixed to shaft member  17 , while ring  24  is capable of rotating around axis B (ring  24  has an internal threaded portion so that it will thread on to threaded portion  24 ″ of shaft member  17 ). The inside of rings  23  and  24  are provided, respectively, with internal cone surfaces  23 ′ and  24 ′ which are opposite to each other, and coaxial with respect to axis B (when rings  23  and  24  have been mounted on shaft  17 ). Ring  24  is provided with external slits  24 ′″, placed at equiangular distances from each other around axis B. 
     Ring  25  is mounted on a rear cylindrical extension of ring  24 , and is able to rotate around axis B. A number of balls, for example, like ball  26 , are mounted through respective bores of the rear cylindrical extension of ring  24 . These balls support the rotation of ring  25 . Individual V-shaped seats, for example, like seat  26 ′, for seating a respective ball are present on shaft  17 . Ring  25  is also provided with bores parallel to axis B for receiving spring biased plungers  27 . Plungers  27  maintain rings  24  and  25  apart, for example, by maintaining distance E. In doing so, the edges of the bores where balls  26  are received, push on balls  26  to engage them against sides V′ of V-shaped seats, for example,  26 ′. When this occurs, a locking action is obtained between rings  24  and  25  that impedes any relative rotations between rings  24  and  25  around axis B, and that also impedes any movement of ring  25  off the rear extension of ring  24 . 
     The use of this locking action will become more apparent from the following. Ring  25  is provided with extensions  25 ′ placed at equal angular distances from each other around axis B. The angular distances between slits  24 ″′ and extensions  25 ′ are the same. Extensions  25 ′ are aligned with the slits by turning ring  25 . Subsequently, extensions  25 ′ are received in slits  24 ″′ by moving ring  25  in direction G. Once extensions  25 ′ have been received in slits  24 ″′, ring  25  can be rotated around axis B causing ring  24  to also rotate around axis B. This occurs because extensions  25 ′ engage the side walls of slits  24 ″′. With the rotating of ring  25 , ring  24  will move axially on thread  24 ″ in direction G, or oppositely to direction G, depending on the direction ring  24  is turned. 
     Flyer arm  10  is provided with opposite cone surfaces  15   f  and  15   g . When flyer arm  10  has been mounted on shaft member  17 (as described above), cone surface  15   f  can be made to engage complementary recess portion  24 ′ in ring  24  by moving ring  24  axially in direction G (through rotation of ring  25 , as described above). This movement in direction G will first engage and center cone surface  15   f  with complementary recess portion  24 ′ and then bring them to mate precisely. This is possible because, simultaneously, cone surface  15   f  and corresponding complementary recess portion  23 ′ in ring  23  will also become centered and mate between themselves. The presence of thread  24 ″ on shaft member  17  secures this final mating condition at a certain force created when turning ring  25 . Accordingly, plane  15   c  will be clamped against plane  17   a , and plane  15   d  will be clamped against plane  17   b , thereby securing flyer arm  10  to shaft member  17 . 
     It will be understood that the hand of a human can turn ring  25  to achieve these operations. It will also be understood that although for illustration purposes ring  25  is used to attain axial displacement of ring  24  relative to ring  23  in order to secure flyer arm  10  to the winder assembly, other mechanisms can be employed to achieve the desired axial displacement of ring  24 . 
     In the above-described manner, flyer arm  10  can be secured to the winder in a predetermined position to achieve the required distances X and Y, as shown in FIG.  3 . Once ring  25  is no longer held by the hand of the operator, plungers  27  will move ring  25  in a direction opposite to G, removing extensions  25 ′ from slits  24 ″′. This movement will be stopped by engagement of the inside of ring  25  with balls  26 . Any tendency of ring  24  to unloosen on thread  24 ″ is impeded by this engagement with the balls. This engagement with balls  26  is counter reacted by engagement of balls  26  with inclined sides V′ of V seat  26 ′. 
     Counter arm  28  is also part of flyer arm  10  and is bolted to plane  15   h  of collar  15 . Plane  15   h  is opposite and parallel to plane  15   a . Counter arm  28  is used to counter the centrifugal forces of flyer arm  10 . 
     Flyer arm  10  can be easily and quickly removed by turning ring  25  opposite to the direction used above to secure flyer arm  10 , and by moving flyer arm  10  in direction D (FIG.  4 ). One hand of the human operator can turn ring  25 , and the other hand can grasp flyer arm  10  and withdraw it in direction D. 
     Alternatively, the flyer arm can be rotated, prior to its substitution, so that directions C and D become C′ and D′, respectively (at 90° to C and D). In this rotated condition, the flyer arm can be removed toward the upper area of the winder where access for the human operator is more convenient. 
     Shaft member  17  needs to be hollow to allow the passage of wire  14  coming from a traditional wire drum and wire tensioner. Pulley wheel  29  is mounted in slot  30  of shaft member  17  and is required for directing wire  14  to pulley wheels  12  and  13 . Slot  30  (FIG. 3) is open on plane  17   a  for allowing passage of wire  14  to reach pulley wheels  12  and  13 . Slot  35  is also present on collar  15  to allow passage of wire  14  to pulley wheels  12  and  13 . Structure  18  is connected to the end of shaft member  17  by flange/bolt connection  31 . 
     The armature holding device of shield assembly  20  can be turned (in order to index the armature) by means of traditional equipment not shown. Similarly, it will be understood that shaft member  17  can be turned (in order to rotate the flyer) by traditional equipment not shown. 
     Indexing of armature  11  is required for aligning other slots with guide structure  21  when moving on to wind further coils by means of the flyer arm. Indexing of armature  11  is also required for positioning tangs  33 ′ of the commutator in relation to the flyer when the coil leads need to be formed. These coil leads are connected to the tangs by a combination of flyer rotations and indexing of armature  11 , as accomplished in the prior art. 
     However, as described earlier, in accordance with the principles of this invention, the distance from the extreme wire delivery point of flyer arm  10  to the slots, for example,  11 ′ and  11 ″, is very small. Accordingly, it is possible to draw wire  14  directly around the tang without the use of guide equipment like the traditional hooking plate that was applied to the side of structure  18 . Indexing of armature  11  to bring tangs  33 ′ in flyer orbit F can assist in this connection of coil leads to tangs  33 ′. 
     FIG. 5 is a partial, partly exploded, isometric view of an alternative illustrative embodiment of a winder constructed in accordance with the invention. In accordance with the illustrative embodiment of this invention depicted in FIG. 5, the winder comprises hub  40  which is concentrically displaced along shaft  17 . Shaft  17  has an outwardly extending flange (not shown) to which hub  40  is bolted to, for example, by bolt  42 . Shaft  17  extends past hub  40  to buttress support member  19  (not shown) which acts as a reference surface to maintain the position of the armature during winding (as described earlier in reference to FIGS.  1 - 5 ). 
     Flyer arm  10 ′ constructed in accordance with the embodiment of the invention illustrated in FIG. 5, has a base portion  46  which has laterally spaced extensions  48 . Base portion  46  also has a bore  50  at its distal end for receiving locking pin  52 . Hub  40  has a rectangular or prismatic shaped sleeve  54  which is designed to receive base portion  46  of flyer arm  10 ′. Sleeve  54  has a removable locking pin  52  on its distal end which is removed prior to sliding in base portion  46  of flyer arm  10 ′. Extensions  48  of base portion  46  slide into complementary recesses  56  in sleeve  54  which receive corresponding extensions  48  to form a snug fit. 
     In order to attach the flyer arm assembly to the winder assembly, locking pin  52  is removed from sleeve  54  of hub  40 . Thereafter, extensions  48  of base  46  of flyer arm  10 ′ are slid in direction A into corresponding complementary recesses  56 . Subsequent to sliding extensions  48  of base portion  46  of flyer arm  10 ′ into corresponding complementary recesses  56 , locking pin  52  is slid back into place and is received by bore  50  in the distal end of base portion  46  of flyer arm  10 ′, thereby securing flyer arm  10 ′ to hub  40 . 
     It will be understood that for disassembling flyer arm  10 ′ from hub  40 , locking pin  52  would have to be extracted from bore  50  in the distal end of base portion  46  of flyer arm  10 ′, and flyer arm  10 ′ would be slid in direction D, i.e., opposite to direction A, thereby disassembling flyer arm  10 ′ from hub  40 . 
     FIG. 6 is partial isometric view of the alternative illustrative winder constructed in accordance with the principles of this invention and also illustrated in FIG.  5 . In the illustrative embodiment shown in FIG. 6, flyer arm  10 ′ is shown mounted on to hub  40 . Also shown in FIG. 6 is counterweight  60 . Counterweight  60  is used to counter balance the centrifugal forces created by the rotation of flyer arm  10 ′ during the winding process of armature  11  (not shown). 
     In a preferred embodiment in accordance with the principles of this invention, counterweight  60  is manufactured to counter balance the centrifugal force generated by the heaviest flyer arm  10 ′. However, in the event lighter flyer arms are used in place, for example, to achieve a certain X, Y attribute specific to the configuration of an armature, mass can be added to the, for example, base of the lighter flyer arm such that the centrifugal forces created by the weighed flyer arm equals that of counter weight  60 . This mass could be, for example, added in a bore within the base of the lighter flyer arm. 
     Although not illustrated, it will, however, be understood that flyer arm  10 ′ comprises a passage (similar to flyer arm  10 ) for receiving wire  14  (not shown) from the winder assembly (not shown). 
     Although the principles of this invention have been illustrated by showing the winder equipped with only one flyer arm  10  for winding one slot at a time, it will be understood that the principles of this invention can be duplicated, and used on the opposite side of the armature to achieve winding of two armature at the same time. In such a case, guide structures like  21  will have surfaces like  211  and  21 ″ for operating with both flyers. 
     It will also be understood that for winding operations at low speeds of rotation of flyer arm  10  (which has been changed to obtain ideal distances X and Y), wire alignment with the slots being wound is not as critical. In such instances, guide structures like  21  may be eliminated. 
     It will also be understood that the foregoing is only illustrative of the principles of the invention, and that various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention. The described embodiments are presented for the purpose of illustration rather than limitation, and the present invention is limited only by the claims which follow.