Patent ID: 7721413

Claim:
A method of insertion of preformed hairpin conductors formed of a rectangular cross section wire and having first and second legs joined at one end by an integral conductor loop into a motor conductor forming fixture for forming conductors for a motor rotor or stator comprising: a) providing a forming fixture having a plurality of pockets distributed in equal number in an even number of adjacent circles concentric with a center of the forming fixture; b) receiving hairpin conductors positioned side by side from a feeder and feeding the hairpins, one by one, into a hairpin insertion assembly oriented relative to the forming fixture so that the legs are side by side along a line passing through the center of the forming fixture and disposed adjacent a pair of pockets in first and second adjacent circles; c) with the forming fixture angularly indexed relative to the hairpin insertion assembly, pushing a hairpin conductor toward the forming fixture so that the legs thereof extend into a respective pair of pockets; and, d) indexing the forming fixture about the center to align an additional pair of pockets with the hairpin insertion assembly; and, e) repeating c) and d) a plurality of times.