Methods and apparatus for inserting coils into dynamoelectric machine stator assemblies

A method of transferring at least one winding, comprising a plurality of concentric coils each of different sizes formed of a plurality of conductor turns and each having spaced apart end turn portions interconnected by side turn portions, from coil placing means into axially extending slots of a stator assembly including a magnetic core having an axially extending bore and a pair of spaced apart end faces communicating with the axially extending slots and the bore, the method comprising:

• holding a core in alignment with the coil placing means with all of the leading end turn portions aligned for axial passage through the bore of the core, with the trailing end portions disposed radially outwardly from an alignment position relative to the bore, and with the trailing end turn portions of the larger of the coils initially positioned radially outwardly of the trailing end turn portions of smaller ones of the coils;
• moving the plurality of coils in a direction to move the leading end turn portions of the coils axially with respect to the core;
• and yieldably intercepting and engaging the trailing end turn portion of a larger first one of the coils and deflecting the end turn portion so engaged radially inwardly with respect to the bore and the end turn portion of a smaller one of the coils adjacent to the first one of the coils so that the intercepted end turn portion is positioned radially inwardly of the end turn portion of the smaller one of the coils during the insertion process.

Apparatus for transferring at least one winding comprising a plurality of coils formed of a plurality of conductor turns into axially extending slots of a stator assembly, said stator assembly including a magnetic core having an axially extending bore and a pair of spaced apart end faces communicating with the axially extending slots and the bore;

• the apparatus comprising:
• a. means for supporting a magnetic core;
• b. form means for cooperating in the formation of a plurality of conductor turns for a plurality of coils for a magnetic core, said form means being operable for releasing at least a portion of each of the plurality of the wound coils;
• and
• c. yieldable means for intercepting a released portion of a first coil of said plurality of coils and for engaging and moving the released portion of the first coil to a position laterally inside of the released portion of a second coil.