Methods and apparatus for use in producing wound coils and placing such coils on magnetic cores

A method of utilizing a coil injection tool pack at least involving placing the tool pack in winding turn receiving relationship with coil winding apparatus having a tool pack nest, wherein the tool pack includes a plurality of elongate elements that mutually define a plurality of axially extending gaps spaced apart about the periphery of the tool pack and a base supporting the elongate elements;

• said method further comprising:
• moving the tool pack laterally, relative to the longitudinal extent of the elongate elements, toward the tool pack nest;
• disposing a portion of the base adjacent to tool pack retainer means, and disposing the tool pack in overlying relationship with respect to a movable support located at the tool pack nest;
• moving the movable support, axially relative to the longitudinal extent of the elongate elements, and thereby clamping at least a portion of the base against the tool pack retainer means.

A method of utilizing a coil injection tool pack, having a plurality of elongate elements and a base supporting the elongate elements, with coil injection apparatus having a tool pack nest and also having actuator means movable within the nest;

• said method comprising:
• transporting the tool pack to the tool pack nest and into overlying relationship with the nest by moving the tool pack laterally relative to the longitudinal extent of the elongate elements;
• depressing a portion of the tool pack nest, and thereby actuating clamp means and clamping the tool pack to the nest;
• and thereafter moving the actuator means into engagement with selected parts of the tool pack.

A transportable tool pack for use at at least one coil winding station, at least one coil injection station, and particularly suitable for use in the manufacture of fractional horsepower electric motor stators;

• said tool pack comprising:
• a wedge guide housing;
• a plurality of wedge guides;
• a plurality of elongate gap defining members;
• a first base interconnected with the gap defining members and movable therewith relative to the wedge guides;
• a second base for supporting the wedge guide housing;
• and means for limiting movement of the first base relative to the wedge guides in at least one direction;
• said first base including means for interfitting with a movable portion of a coil injection machine power unit.

A method of utilizing a coil injection tool pack at least involving placing the tool pack in winding turn receiving relationship with coil winding apparatus having a tool pack nest, wherein the tool pack includes a plurality of elongate elements that mutually define a plurality of axially extending gaps spaced apart about the periphery of the tool pack and a base supporting the elongate elements, the method further comprising:

• moving the tool pack laterally, relative to the longitudinal extent of the elongate elements, toward the tool pack nest;
• disposing a portion of the base adjacent to tool pack retainer means, and disposing the tool pack in overlying relationship with respect to aligning means for assuring mutual alignment of the tool pack and the tool pack nest;
• moving the aligning means axially, relative to the longitudinal extent of the elongate elements, and thereby causing the aligning means to assure mutual alignment of the tool pack and tool pack nest;
• clamping at least a portion of the base against the tool pack retainer means;
• placing at least a first plurality of turns of an electrical conductor along at least first preselected ones of the axially extending gaps;
• unclamping the tool pack base and moving the tool pack laterally, relative to the longitudinal extent of the elongate elements, away from the tool pack nest;
• transporting the tool pack with the winding turns supported thereon to a second tool pack nest at a coil injection station;
• aligning the tool pack at the second tool pack nest, depressing the second tool pack nest, and thereby actuating tool pack clamping means for clamping at least a portion of the base of the tool pack at the second tool pack nest;
• placing an axially slotted magnetic core on the tool pack;
• transferring the at least a first plurality of turns of the electrical conductor from the tool pack to the magnetic core;
• removing the core and the at least a first plurality of turns from the tool pack;
• unclamping the tool pack at the second tool pack nest;
• and transporting the tool pack away from the second tool pack nest.