Method of fabricating a stator for a multiple-pole dynamoelectric machine

The method of fabricating a stator assembly for a multiple-pole dynamoelectric machine, said stator assembly comprising a core assembled from a stack of laminations of suitable ferromagnetic sheet-material, said core having a central bore extending therethrough and a plurality of blind slots extending radially outwardly from said bore, said slots being substantially equally angularly spaced around said bore, said stator comprising an auxiliary winding and a main winding, said auxiliary winding including a first and a second auxiliary winding coil set and said main winding including a first and a second main winding coil set, each of said coil sets having a plurality of coils of magnet wire inserted in selective slots of said core, wherein the method of this invention comprises of the steps:

• A. forming said first auxiliary winding coil set from a skein of wound magnet wire having a predetermined number of turns of magnet wire therein so that said skein is a coil of petalled, serpentine shape with a series of inwardly and outwardly directing apices with generally straight coil sections extending between said inward and outward apices, said straight coil sections each being adapted to be received in a respective slot of said core and each of said apices being adapted so as to be disposed on the outside of said core and to constitute the end turns of said first auxiliary winding coil set;
• B. forming said second auxiliary winding coil set from a skein of wound magnet wire having a predetermined number of turns of magnet wire therein so that said skein is a coil of petalled, serpentine shape with a series of inwardly and outwardly directing apices with generally straight coil sections extending between said inward and outward apices, said straight coil sections each being adapted to be received in a respective slot of said core and each of said apices being adapted so as to be disposed on the outside of said core and to constitute the end turns of said second auxiliary winding coil set;
• C. forming said first main winding coil set from a skein of wound magnet wire having a predetermined number of turns of magnet wire therein so that said skein is a coil of petalled, serpentine shape with a series of inwardly and outwardly directing apices with generally straight coil sections extending between said inward and outward apices, said straight coil sections each being adapted to be received in a respective slot of said core and each of said apices being adapted so as to be disposed on the outside of said core and to constitute the end turns of said first main winding coil set;
• D. forming said second main winding coil set from a skein of wound magnet wire having a predetermined number of turns of magnet wire therein so that said skein is a coil of petalled, serpentine shape with a series of inwardly and outwardly directing apices with generally straight coil sections extending between said inward and outward apices, said straight coil sections each being adapted to be received in a respective slot of said core and each of said apices being adapted so as to be disposed on the outside of said core and to constitute the end turns of said second main winding coil set;
• E. inserting said first auxiliary winding coil set in said core so that a first straight coil section of said first auxiliary winding coil set is received in a first slot of said core and so that the next adjacent straight coil section of said first auxiliary winding coil set is received in a third slot, this insertion pattern being repeated so that a straight coil section of said first auxiliary winding coil set is inserted in the first, third, fifth . . . and next to the last slots of said core around said bore;
• F. inserting said first main winding coil set in said core so that a straight coil section of said first main winding coil set is received in a second slot of said core adjacent said first slot and so that the next adjacent straight coil section of said first main winding coil set is received in a fourth slot so that the straight coil sections of said first main winding coil set are received in said second, fourth, sixth . . . and last slots of said core;
• G. inserting said second auxiliary winding coil set in said core so that the first straight coil section of said second auxiliary winding coil set is received in the third slot of said core and so that the next straight coil section of said second auxiliary winding coil set is received in a fifth slot of said core so that the straight coil sections of the second auxiliary winding coil set are received in the third, fifth, seventh . . . and first slots of said core;
• and
• H. inserting said second main winding coil set in said core so that the first straight coil section of said second main winding coil set is received in the fourth slot of said core and so that the next straight coil section is received in the sixth slot of said core so that the straight coil sections of said second main winding coil set are received in the fourth, sixth, eighth . . . and second slot of said core.

The method of fabricating a stator assembly for a multiple-pole dynamoelectric machine, said stator assembly comprising a core assembled from a stack of laminations of suitable ferromagnetic sheet-material, said core having a central bore extending therethrough and a plurality of blind slots extending radially outwardly from said bore, said slots being substantially equally angularly spaced around said bore, said stator assembly comprising an auxiliary winding and a main winding, said auxiliary winding including a first and second auxiliary winding coil set and said main winding including a first and a second main winding coil set, wherein the method of this invention comprises of the steps:

• A. forming said first auxiliary winding coil set so as to have a plurality of coils electrically connected to one another;
• B. forming said second auxiliary winding coil set so as to have a plurality of coils electrically connected to one another;
• C. forming said first main winding coil set so as to have a plurality of coils electrically connected to one another;
• D. forming said second main winding coil set so as to have a plurality of coils electrically connected to one another, each of said coils of said auxiliary and said main winding coil sets having a pair of spaced end turns and a pair of straight coil sections interconnecting the end turns;
• and
• E. inserting first coils of each of said first auxiliary, said first main, said second auxiliary, and said second main winding coil sets in the slots of said core so that the straight coil sections of said first auxiliary winding coil set are received in the first and third slots, so that the straight coil sections of said first main winding coil set are received in the second and fourth slots of said core, so that the straight coil sections of said second auxiliary winding coil set are received in the third and fifth slots of said core, and so that the straight coil sections of said second main winding coil set are received in the fourth and sixth slots thereby to form a layered group of the coils inserted in slots 1-6 and further so that the second, third . . . coils of said coil sets are received in slots 5-10, slots 9-14, etc., with all of the coils being inserted in said slots of said core in layered groups.

The method of fabricating a stator assembly for a multiple-pole dynamoelectric machine, said stator assembly comprising a core assembled from a stack of laminations of suitable ferromagnetic sheet-material, said core having a central bore extending therethrough and a plurality of blind slots extending radially outwardly from said bore, said slots being substantially equally angularly spaced around said bore, said stator assembly comprising an auxiliary winding and a main winding, said auxiliary winding including a first and second auxiliary winding coil set and said main winding including a first and a second main winding coil set, wherein the method of this invention comprises of the steps;

• A. forming a first coil set so as to have a plurality of coils electrically connected to one another;
• B. forming a second coil set so as to have a plurality of coils electrically connected to one another;
• C. forming a third coil set so as to have a plurality of coils electrically connected to one another;
• D. forming a fourth coil set so as to have a plurality of coils electrically connected to one another, each of said coils of said first, second, third and fourth coil sets having a pair of spaced end turns and a pair of straight coil sections interconnecting the end turns;
• E. inserting one coil from said first, second, third and fourth coil sets in six adjacent slots of said core so that the straight coil sections of said one coil of said first coil set are received in said first and third slots, so that said straight coil sections of said one coil of said second coil set are received in the second and fourth slots of said core, so that the straight coil sections of said one coil of said third coil set are received in the third and fifth slots, and so that the straight coil sections of said one coil of said fourth coil set are received in the fourth and sixth slots thereby to form a layered group of coils of said first, second, third and fourth coil sets in slots 1-6;
• and
• F. repeating the steps of paragraph E so as to insert second, third, fourth, . . . etc., coils of said first, second, third and fourth coil sets in slots 5-10, slots 9-14, etc., until all of the coils of said coil sets are inserted in said slots of said core in said layered groups.

The method of fabricating a stator assembly for a multiple-pole dynamoelectric machine, said stator assembly comprising a core assembled from a stack of laminations of suitable ferromagnetic sheet-material, said core having a central bore extending therethrough and a plurality of blind slots extending radially outwardly from said bore, said slots being substantially equally angularly spaced around said bore, said stator assembly comprising an auxiliary winding and a main winding, said auxiliary winding including a first and second auxiliary winding coil set and said main winding including a first and a second main winding coil set, wherein the method of this invention comprises of the steps;

• A. forming a first coil set so as to have a plurality of coils electrically connected to one another;
• B. forming a second coil set so as to have a plurality of coils electrically connected to one another;
• C. forming a third coil set so as to have a plurality of coils electrically connected to one another;
• D. forming a fourth coil set so as to have a plurality of coils electrically connected to one another, each of said coils of said first, second, third and fourth coil sets having a pair of spaced end turns and a pair of straight coil sections interconnecting the end turns;
• E. placing said coil sets on the inserting means of an axial coil inserting apparatus with the coil sets being angularly offset relative to one another;
• and
• F. substantially simultaneously inserting first coils of said coil sets in respective slots of said core so that the straight coil sections of said first auxiliary winding coil set are received in the first and third slots, so that the straight coil sections of said first main winding coil set are received in the second and fourth slots of said core, so that the straight coil sections of said second auxiliary winding coil set are received in the third and fifth slots of said core, and so that the straight coil sections of said second main winding coil set are received in the fourth and sixth slots thereby to form a layered group of the coils inserted in slots 1-6 and further so that the second, third . . . coils of said coil sets are received in slots 5-10, slots 9-14, etc., with all of the coils being inserted in said slots of said core in layered groups.