Lead formation in undulated coils for dynamo-electric machine stators

A method for producing an undulating coil of wire for application to a core of a stator for a dynamo-electric machine comprising:

• gripping an initial lead of the wire in a gripper;
• coiling the wire extending from the gripper on a receiver structure to form a coil of wire having successive turns that are substantially disposed in respective planes that are substantially perpendicular to a central longitudinal axis of the coil and that are laterally spaced from one another along that axis;
• undulating the turns of wire in their respective planes while the turns are on the receiver structure, the undulations giving the turns portions that are substantially radial of the axis;
• and
• positioning the gripper relative to the receiver structure so that the initial lead is placed substantially in the plane in which a final turn of the coil is disposed and is substantially aligned with one of the portions of the turns that are substantially radial of the axis.

Apparatus for producing an undulating coil of wire for application to a core of a stator for a dynamo-electric machine comprising:

• a gripper configured to hold an initial lead of the wire;
• receiver structure configured to receive the wire extending from the gripper and to form a coil of the wire having successive turns that are substantially disposed in respective planes that are substantially perpendicular to a central longitudinal axis of the coil and laterally spaced from one another along that axis;
• forming structure configured to produce undulations in the turns of wire in their respective planes while the turns are on the receiver structure, the undulations giving the turns portions that are substantially radial of the axis;
• and
• gripper positioning structure configured to position the gripper relative to the receiver structure so that the final lead is placed substantially in the plane in which an initial turn of the coil is disposed and is substantially aligned with one of the portions of the turns that are substantially radial of the axis.

Apparatus for forming an undulating wire coil for insertion in a stator of a dynamo-electric machine, said apparatus comprising:

• a support structure configured to support wire from a source to gradually form the coil, the coil having a central axis, an initial lead, a final lead, and a plurality of wire turns, each of said wire turns defining a plane of the coil, wherein said initial and final leads are arranged in the same plane;
• a plurality of forming members;
• a gripper mounted on one of said plurality of forming members;
• and
• a plurality of slanted sides, wherein:
• each one of said plurality of slanted sides is disposed on one of said plurality of forming members;
• each of said slanted sides has a first end portion and a second end portion, said second end portion extending to a greater radial distance from said central axis than said first end portion;
• and
• wherein said plurality of slanted sides can support said plurality of wire turns.

Apparatus for forming an undulating wire coil for insertion in a stator of a dynamo-electric machine, said apparatus comprising:

• a support structure configured to support wire from a source to gradually form the coil, the coil having a central axis, an initial lead, a final lead, and a plurality of wire turns, each of said wire turns defining a plane of the coil, wherein said initial and final leads are arranged in the same plane;
• a plurality of forming members;
• a gripper mounted on one of said plurality of forming members, wherein said gripper is configured to rotatably grip said initial lead;
• and
• a plurality of slanted sides, wherein:
• each one of said plurality of slanted sides is disposed on one of said plurality of forming members;
• each of said slanted sides has a first end portion and a second end portion, said second end portion extending to a greater radial distance from said central axis than said first end portion;
• and
• wherein said plurality of slanted sides can support said plurality of wire turns.

Apparatus for forming an undulating wire coil for insertion in a stator of a dynamo-electric machine, said apparatus comprising:

• a support structure configured to support wire from a source to gradually form the coil, the coil having a central axis, an initial lead, a final lead, and a plurality of wire turns, each of said wire turns defining a plane of the coil, wherein said initial and final leads are arranged in the same plane, wherein:
• said support structure further comprises a forming member having an initial lead aperture, said initial lead aperture having an open side and being configured to receive said initial lead while said gripper grips said initial lead;
• and
• said open side permits said lead to rotate, in a plane perpendicular to said central axis, out of said initial lead aperture as said structure rotates to form said coil;
• a plurality of forming members;
• a gripper mounted on one of said plurality of forming members, wherein said gripper is configured to rotatably grip said initial lead;
• and
• a plurality of slanted sides, wherein:
• each one of said plurality of slanted sides is disposed on one of said plurality of forming members;
• each of said slanted sides has a first end portion and a second end portion, said second end portion extending to a greater radial distance from said central axis than said first end portion;
• and
• wherein said plurality of slanted sides can support said plurality of wire turns.

Apparatus for forming an undulating wire coil for insertion in a stator of a dynamo-electric machine, said apparatus comprising:

• a support structure configured to support wire from a source to gradually form the coil, the coil having a central axis, an initial lead, a final lead, and a plurality of wire turns, each of said wire turns defining a plane of the coil, wherein said initial and final leads are arranged in the same plane;
• a plurality of forming members;
• a gripper mounted on one of said plurality of forming members;
• a plurality of slanted sides, wherein:
• each one of said plurality of slanted sides is disposed on one of said plurality of forming members;
• each of said slanted sides has a first end portion and a second end portion, said second end portion extending to a greater radial distance from said central axis than said first end portion;
• wherein said plurality of slanted sides can support said plurality of wire turns;
• and
• a plurality of curved seats, wherein:
• each one of said plurality of curved seats extends from one of said plurality of slanted sides;
• and
• said plurality of curved seats receives wire from said source for forming a wire turn.

Apparatus for forming an undulating wire coil for insertion in a stator of a dynamo-electric machine, said apparatus comprising:

• a support structure configured to support wire from a source to gradually form the coil, the coil having a central axis, an initial lead, a final lead, and a plurality of wire turns, each of said wire turns defining a plane of the coil, wherein said initial and final leads are arranged in the same plane;
• a plurality of forming members;
• a gripper mounted on one of said plurality of forming members;
• a plurality of slanted sides, wherein:
• each one of said plurality of slanted sides is disposed on one of said plurality of forming members;
• each of said slanted sides has a first end portion and a second end portion, said second end portion extending to a greater radial distance from said central axis than said first end portion;
• wherein said plurality of slanted sides can support said plurality of wire turns;
• a plurality of curved seats, wherein:
• each one of said plurality of curved seats extends from one of said plurality of slanted sides;
• and
• said plurality of curved seats receives wire from said source for forming a wire turn;
• and
• a plurality of apicies, wherein:
• each one of said curved seats includes one of said apicies;
• said plurality of apicies defines a plane perpendicular to said central axis;
• and
• said gripper is mounted on a first side of said plane and said plurality of slanted sides is disposed on a second side of said plane.

Apparatus for forming an undulating wire coil for insertion in a stator of a dynamo-electric machine, said apparatus comprising:

• a support structure configured to support wire from a source to gradually form the coil, the coil having a central axis, an initial lead, a final lead, and a plurality of wire turns, each of said wire turns defining a plane of the coil, wherein said initial and final leads are arranged in the same plane;
• a plurality of forming members, wherein said plurality of forming members substantially defines a polygon about which said wire can be wound into a polygonal coil and said support structure further comprises a second plurality of forming members, wherein said second plurality can be positioned external to said polygonal coil and can be moved inward against the coil to form undulations in the coil after said wire is wound on first of said pluralities of forming members;
• a gripper mounted on one of said plurality of forming members;
• and
• a plurality of slanted sides, wherein:
• each one of said plurality of slanted sides is disposed on one of said plurality of forming members;
• each of said slanted sides has a first end portion and a second end portion, said second end portion extending to a greater radial distance from said central axis than said first end portion;
• and
• wherein said plurality of slanted sides can support said plurality of wire turns.