Note: Descriptions are shown in the official language in which they were submitted.
This invention relates to methods and apparatus
of particular use in the manufacture of dynamoelectric
machine magnetic stator assemblies and more particularly
to methods and apparatus involving movement of injection
tooling and a core to coil loading and transfer stations;
placement of winding turns on the injection tooling;
transfer of the tooling to a transporting mechanism and
interfitting it with; a wedge guide housing; movement
of the tooling to wedge making and injection stations;
alignment and transfer of the core into an interfitting
relationship with the injection tooling; injection
of the winding turns on the tooling into axially extending
slots of the core; and removal of the core with the
windings thereon~and the injection tooling from the
injection station.
In the manufacture of magnetic stator assemblies
used in dynamoelectric machines, windings comprising
coils formed of a predetermined number of conductor
turns are developed by a coil winding machine for
subsequent ins~rtioniinto a magnetic core. Various
methods are known for carrying out this winding
operation. In some prior art methods, winding coils are
-- 1 --
3343~:
developed on coil forms, ~ransferred to a transfer device, and
then transferred to an insertion tool used for placing the
windings ona core. Other known methods develop coils directly
in a transfer tool or directly in coil injection tooling. In
some cases, windings in the form of coils are disposed directly
on insertion tooling mounted in a wedge guide housing. Developing
coils directly in insertion toolinq improves manufacturing
eficiencies in that no inter~.ediate step is required to
transfer winding coils from a transfer tool to an insertion
tool.
~fforts have been made to further improve manufacturing
efficiencies by either both winding and inserting coils at a
single operating station, or by utilizing one or more winding
stations and an injection station with a rotating table. I~o~ever,
with either of the two above approaches, the manufacturing time
is generally controlled by the operating time of the winding
operation since generally the injection operation can be
performed within a much shorter time than the winding operation.
Another known approach for improving the stator
assembly manufacturing o~eratlon efficiencles is the utilization
of several windlng stations to dispose windings on insertion
tools fixedly mounted in wedge guide housings. With this
approach, wedge guide housings and the insertion tools attached
thereto are moved from the winding stations to another station
where a core is placed on the tooling. The combination housing,
tooling and core are then fed to an injection station for
insertion of the windings into the core. This type of an
approach removes at least some of the time interdependency
between the winding and injection operations.
However, with the above-discussed and other known
prior approaches, attempts to more fully automate the manufac-
3D-AO-4946
kuring operation and at the same time maximize equipment
utilization have required the transporting of an entire wedge
guide housing between operating stations. Providing such a
housing for each insertion tool adds considerable expense -to
the manufacturing operation; thus it would be beneficial to
provide a method and apparatus wherein insertion tooling could
alone be utilized during most of the manufacturing operation
without having to provide an accompanying wedge guide housing
for each insertion tool. Further benefits could be derived by
developing a manufacturing operation wherein no transporting of
wedge guide housings would be required, but instead, transport
only of khe insertion tooling itself on a means which could
be easily moved and aligned at various stations where operations
must be performed. Still further, benefits could be derived
by developing a transporting means having an inserting tool
support thereon which could easily be manipulated for performing
winding and transfer operations.
In some prior approaches, a stator core when transported
with insertion tooling has been positioned over the insertion
tooling. With this type of an approach, a separate station is
generally required with an additional operator and/or equipment
being provided for placement of the core since the core must be
positioned on the tooling after the winding operation has been
; completed. Thus, it would be advankageous to develop mekhods
and apparatus wherein insertion tooling and a core to be used
therewith could be selected at a single ~kation and then
kransported together to winding and injection stations.
In many known prior approaches, stator assembly
manufacturing operations have generally been set up to manufacture
stator assemblies having cores of the same axial length.
~,
3D-AO-4946
Equipment employed in such operations may often have the
capability of manufacturing stator assernblies with different
axial length stators; but such changeovers are often time
consuming, thus, causing downtime in the manufacturing opera-tion.
Therefore, it would be advantageous to develop an arrangement
whereby equipment emplo~ed in the manufacturing op~ration could
be easily and quickly adjusted to manufacture stator assemblies
having cores with different axial lengths.
Accordingly, it is a general object of the present
invention to provide new and improved methods and apparatus for
fabricating dynamoelectric machine stator core assemblies and
a more specific object is to provide new and improved rnethods
and apparatus which overcome the problems and deficiencies
mentioned above~
A further object of the invention is to provide new
and improved methods of transporting injection tooling without
wedge guide housings.
A further object is to provide transporting methods
and apparatus allowing injection tooling and core selection and
loading at a single station.
A further object is to provide means for positioning
and aligning core and injection tooling at stator assembly
fabricating stations.
A still further object is to provide new and improved
methods and apparatus for fabricating stator core assemblies
having cores of different axial lengths.
Summary of the Invention
In carrying out the present invention in one form
thereof, we provide new and improved me-thods, apparatus, and
3D-AO-4946
3~
systems for fabricating stator core assemblies.
One form of preferred system includes a selection
station where injection tooling is selected for use with a
slotted stator core. The tooling and core are positioned on a
shuttle means and both are moved to a coil winding station
where the injection tooling is positioned and aliyned with a
coil winding head located at the winding station and then
manipulated relative to -the winding head for developing and
disposing winding turns onto the tooling. The injection tooling
and core then are moved to another coil loading station where
the tooling is again positioned, aligned and manipulated to
dispose additional winding t~lrns on the injection tooling. The
injection tooling and core are then moved to a transfer station
where the tooling is moved to a predetermined position and
manipulated to be received by an injection tooling transfer
assembly. The tooling transfèr assembly transfers the tooling
to a wedge guide housing attached to an indexing table of a
turntable arrangement for movement to wedge making and injection
stations. The tooling is then moved by the indexing -table to
an alignment position with a wedge magazine of a wedge maker.
Insulating wedges are moved into the wedge guide housing and
then the tooling is moved to another wedge making station
when additional insulating wedges are moved into the housing.
The injection tooling is moved by the indexing table and
aligned with the injection mechanism at an injection station.
The slotted core is positioned, aligned, and clamped in a
stator retaining means of a core transfer assembly and then
transferred to the injection station and moved into an inter-
fitting relationship with the injection tooling. Winding turns
disposed on the injection tooling are transferred along and into
- 5 -
3D-AO-~946
3~3~
axially extending slots of the stator core, and wedges are
placed in slots of the core. The core is moved from the
injection station with winding turns thereon. Side turn
por-tions of the winding turns are moved away from the bore of
the core before the core is released by the core transfer
assembly. The empty injection tooling is moved to an unloading
station for transfer by the injection tooling transfer assembly
from the indexing table to a shuttle means.
For stator cores of different heights or axial
lengths, an adjustment is made which progressively adjusts
equipment located at the wedge making and injection stations
in accordance with movement of injection tooling that is to
be employed with the stator core of a different axial length.
In accordance with other aspects of the invention,
apparatus are disclosed for fabricating stator core assemblies.
In one preferred embodiment described in more detail hereinbelow,
a shuttle means having a slotted stator core and injection tooling
supported at spaced apart locations thereon is moved toward a
first coil winding station, A first fetching assembly at the
winding station engages and moves the shuttle means to position
the injection tooling underneath a winding head of a coil
winding machine. A clamping assemblv clamps a tool receiver
supporting the injection tooling to position the injection
tooling relative the winding head. A first indexing mechanism
including a homing device rotates the injection tooling to a
home position and then cooperates with the winding machine to
index the tooling for disposing winding turns developed by the
winding machine at predetermined locations of the tooling. After
winding turns have been developed and disposed on the injection
tooling at the first winding s-tation, the injection tooling is
--~ 3D-AO-4946
3~:
released and moved to a second winding station which receives,
positions, aligns and manipulates the tooling in the same
manner as the first winding station to dispose addi-tional
winding turns on the tooling.
The shuttle means is moved from the second winding
station to a transfer station. A second fetchincJ assembly at
the transfer station engages and moves the shuttle means to
position the injection tooling relative to an injection tooling
transfer assembly. A homing device rotates the tooling to an
aligned receiving position relative the tooling transfer
assembly, whereupon the tooling transfer assembly engages and
transfers the injection tooling from the shuttle means to a
wedge guide housing attached to an indexing table of a turntable
arrangement.
The indexing table rotates to position and align the
injection tooling at a first wedge making station, whereupon
insulating wedges contained in a wedge magazine are inserted
into wedge guides of the wedge guide housing. The indexing
table then moves the tooling to a second wedge making station
where additional insulating wedges are inserted into the wedge
guide housing. The injection tooling is then moved and aligned
with an injection machine at an injection station.
An adjustment arrangement is provided for rapidly
performing machine set-up for the wedge making and injection
operations. The adjustment arrangement adjusts wedge makers
at each wedge making station to fabricate insulating wedges with
a length appropriate for the axial length of the core. Further,
the adjustment arrangement adjusts the injection mechanism at
the injection station so that the insulating wedge and winding
turn insertion operation is in accordance with -the axial length
of the core.
-- 7 --
/,
3D-AO-4946
The slotted stator core is removed from the shuttle
means to a core holder on a core transfer assembly. The core
holder retains the core in a position so as to assure subse~uent
alignment with the injection tooling~ The core transfer
assembly also includes a blade aligner to assure aliynment and
clamping mechanism to retain the core in the aligned position~
The core transfer assembly moves the core to the injection
station and into an interfitting relationship with the injection ''
tooling. An injection mechanism then moves injection tooling
blades and a stripper through`the'bore of the core to transfer
the winding turns along and into the axially extending slots
of the stator core~
After winding turn insertion, the core transfer ',
assembly is returned to its home position where a blade
separator operates to move end turns of the winding turns away
from the bore of the core. The indexing table moves the
injection tooling to an unloading station where the injection
tooling transfer assembIy engages and moves the tooling to a
shuttle means.
B'r'i'e'f'D'e'sc~ript'i'on o th'e''Dra~ings
Othér objects of the present invention and their
attendant advantages will become'readily apparent from the
following description taken in conjunction with the accompanying
figures in which like reference characters are used to describe
like parts throughout the several views wherein:
FIG. 1 is a schematic representation of a manufacturing
system operable`in accordance with`and emhodying teachings of
the present invention in one form thereof;
FIG. 2 is a perspective view of injection tooling
usable`in the system of FIG. l;
,,~ _ % _
D3~L3~
FIG. 3 is.a cross-sectional view of the injection
tooling of FIG. 2 illustrating latching engagement of a tooling
stripper and injectlon rod of an injection mechanism;
FIG. ~ is a bottom vie~ of the injection tooling
illustrating blade spacing and grooved or channel outer blade
surface configuration;
FIG. 5 is a perspective view of a shuttle tray usable
in the system, and shows core receiver and tooling receiver
details;
FIG. 6 is a cross-sectional view of the shuttle tray
illustrating clamping bar mounting details;
FIG. 7 is a perspectlve view of a fetching assembly,
a clamping assembly and an indexing mechanism from the system
of FIG. l;
FIG. ~ is a plan vi.ew of the fetching assembly
illustrating mountin~ an~ control details;
FIG. 9 is a side elevational view of the fetching
assembly illustrating assembly operational interrelationship
with the shuttle trays;
FIG. 10 is a plan view o.f an indexing mechanism and
clamping assembly from the system, with a tooling receiver in
position for manipulation by the assemblies;
FIG. 11 is a side elevational view with parts removed
showing details of the clamping assembly and the indexing
mechanism of FIG. 10, with the tooling receiver in position to
be received and manipulated thereby;
FIG. 12 is a perspective view of the transfer station,
turntable arrangement, injection tooling transfer assembly and
core transfer assembly of the system;
~3gL3~:
FIG. 13 is a partial side elevation, with parts
removed, of the .injection toollng transfer assembly and injection
tooling in position for transfer by the assembly;
FIG. l~ is a fragmentar~ side elevational view,
partly in cross-section, of a gripper of the injection tooling
transfer assembly, showing the gripper receiving the injection
tooling;
FIG. 15 is a fragmentary side elevational view,
partly in cross-section, oF the gripper of the injection tooling
transfer assembly, showing the injection tooling retained
therein;
FIG. 16 is a side elevation of a first wedge making
station, illustrating mounting and control details for
fabrication and insertion of insulating wedges into ~ledge guides
of a wedge guide housin~;
FIG. 17 is a side elevation, ~ith parts removed, of
the core transfer assembly and an end turn separator, showing
mounting details and injection tooling positioned on the index
table at the injection station;
FIG. 18 is a fragmentary side elevation with parts
removed, of the end turn separator and core transfer assembly
illustrating separator controls and rotational control details
for the core transfer assembly;
FIG. 19 is a side elevation, partly in cross section,
of the injection mechanism at the injection station showing the
injection tooling in position for effecting a transfer of
insulating wedges ancl winding turns from the tooling to a stator
core;
FIG. 20 is a front view of a portion of the stator
height adjustment arrangement illustrating interconnection
.. , ..... .. ____ . _. .. . ... _. _, . . , ... --. _ . . .... . .__ _.. _
L3~2
details-between adjusting cables and an adjustment wheel
employed to set up the wedge ma];ing and injection stations in
accordance with the axial length of the core;
FIG. 2]. is a side elevation of the portion of the
stator hei~ht adjustment arrangement shown in FIG. 20,
illustrating mounting and interconnection details;
FIG. 22 is a front view of a portion of the stator
height adjustment arrangement employed to adjust a wedge r
ma]cer for fabrication of insulating wedges in accordance with
the axial length of the core as selected by the arrangement
shown in FIGS. 20 ancl 21;
FIG. 23 lS a slde elevation of the portion of the
: stator height adjustment arrangement shown in FIG. 22
illustrating mounting and interconnection details;
FIG. 24 is a Plan view of a portion of the stator
height adjustment arrangement employed to adjust the injection
mechanism in accordance wlth the axial length of the core as
selected by the arrangement lllustrated in FIGS. 20 and 21; and
FIG. 25 is a side elevation of the position of the
stator height adjustment arrangement illustrated in FIG. 26
showing mounting and interconnection details.
Description of the Preferred Embodiments
Operation of an injection shuttle system embod~ing~
~eatures of the present invention may be carried out in one
form thereo as illustrated schematically by ~IG. 1. ~t a
selection station 50, one of the slotted magnetic cores 52
having axially extending slots 53 is selected and posi-tioned on a
shuttle means illustrated for purposes of exemplifica~ion as shuttle
trays 54 each having injection tooling 56 which is utilized in
~ 3~
subsequent operations. As illustrated, there are three different
feed lines 58, 60, 62 for injection tooling at the selection
station~ The injection tooling of each line differ in that each
can accommodate different wire sizes or different wire size
combinations.
After a core is positioned on a shuttle tray having
the particular tooling required to fabricate a desired stator
assembly, the shuttle tray is moved to either of two winding
lines 64 or 66. Each winding line is provided with two coil
loading stations 68 and 70. The two lines are substantially
identical in operation, thus for purposes of brevity, further
detailed description presented herein is in terms of line 64.
The shuttle tray with the slotted core and injection
tooling supported thereon is moved along winding line 64 to a
first coil loading station 68 having a winding machine 72 of a .
known type such as, for example, disclosed in Cutler et al
U.S. Patent 3,672,026 which issued June 27, 1972 or Cutler et al
U.S. Patent 3,522,650 which issued August 4, 1970 and which was
reissued as U.S. Patent Re. 27,415 on June 27, 1972, except
with the machine and forms being oriented so that winding turns
are moved vertically downward into the injection tooling.
The shuttle tra~ is engated and moved at the first
loading station by a first fetching assemhly 7~ so as to position
the injection tooling underneath a winding head of the
winding machine. The injection tooling is then manipulated
by a first indexing device or assembly 76 (only general
locations being depicted in FIG. 1) to move the injection
tooling to a home position, align the tooling with the
winding machine, and then perform incremental rotation
of the tooling between predetermined index positions in
- 12 -
3~3~
order to dlispose winding turns developed by the ~7inding machlne
on the injection tooling.
After the winding turns have been developéd and
disposed on the tooling, the shuttle tray is pushed from the
first coil loading station as the first fetching assembly
engages and moves another shuttle tray into position at the coil
loading station.
The shuttle tray is moved to the second coil loading
station 70 having another winding machine 78. A second fetching
assembly 80 and a second indexing devi.ce or assembly 82 are
proyided at the second coil loading station for performing
identical functions as the first of such devices located at the
first coil loading station. In one specific ap~lication, the
first coil loading station may be employed to develop winding
turns for a motor start winding and the second loading station
may ~e used to develop winding turns for a main winding of the
motor.
After winding turns have been developed and loaded
into the injection tooling at the second coil loading station,
the shuttle tray is pushed from the station as the second
fetching assembly moves another transporting means into position.
The shuttle tray ~lith the slotted core and injection
tooling with winding turns 8~ thereon is then moved to a
transfer station ~6.
At the transfer station, the shuttle tray is engaged
by a third fetching assembly ~8 to move the shuttle tray so
as to position the loaded injection tooling relative to injection
tooling transfer assembly 90. Once positioned, the injection
tooling is manipulated by a homing device 92 to align the tooling
relative the tooling transfer assen~ly. Once aligned, the
~3~3~
tooling transfer assembly removes the injection tooling
from the shuttle tray and positions tooling within
a wedge guide housing located on an indexing table 94 of
turntable arrangement 96.
After the injection tooling is loaded onto
the indexing table, the table is rotated or indexed
so as to mo~e the tooling into an alignment position at
a first wedge making station 98~ Insulated wedges fabricated
at this station are inserted into the wedge guide
housing.
The injection tooling is then moved to a
second wedge making station 100 by moving the indexing
table where additional wedges are inserted into the wedge
guide housing~
After the wedge making and insertion into
the housing has been completed at the two wedge making
stations, the injection tooling is then moved to an
injection station 102 by moving the indexing table.
The slotted ma~netic core which was conveyed
along with the particular injection tooling to the
transfer station is then removed from the shuttle tray
and placed in an aligned position on a core transfer
assembly 104. The core is then transferred by the assembly
to the injection station and interfitted with the injection
tooling. An injection mechanism of a known type such
as, for example, disclosed in Hill U.S. patent 3,324,536
which issued June 13, 1967 or Smith U.S~ patent 3,698,063
which issued October 17, 1972, except with additions or
modifications described hereinbelow, is then employed to transfer
the winding turns from the tooling axially along and into
axially extending slots of the core. A~ter the winding turns
r ~ ~ 14
have been transferred to the core, the empty injection tooling
is moved by the indeY.ing table to a tool unloading station 106
which in this embodiment is the same location as whére the
tooling was initialiy positioned on the indexing table. The
injection tooling transfer assembly then removes the tooling
from the wedge guide housing and positions it on a shuttle tray.
The toolincJ transfer assembly could be simultaneously moving
another-loaded injection tool onto the indexing table.
The core with winding turns inserted in the slots
thereof is moved by the core transEer assembly from the
injection station back to a core unloadiny station 108 which in
the system of FIG. 1 is at the same location as where the core
was initially loaded on the transfer assembly. ~t the core
unloading position, an end turn separator is activated to move
end turns of -the windings away from the bore of the core.
Simu]taneous with the removal of the core from the injection
station, the core transfer assembly moves another core into
position at the injection station and interfits this core with
another loaded injection tool.
The core with the windinc~ turns inserted therein and
the end turns moved ~way from its bore is then conveyed away
from the core unloading station.
~he empty injection tooling, after being removed from
the indexing table and positioned on a shuttle tray/ is pushed
away from the transfer station as the third fetching assembly
moves another shuttle tray with loaded injection tooling thereon
into position relative the tooling transfer assembly.
~he shuttle tray with the empty tooling thereon is
then moved back to the selection station for use with another
slotted magnetic core and a repeat of the above-described
operations.
3~3~
FIGS. 2--4 further illustrate details of the injection
tooling 56 employed with the present invention. ~s shown, the
tooling comprises a plurality of blades 110 with each provided
with a groove or channel type outer surface 112 and a pick-up
recess 114 at the top portion thereof. The blades are attached
to a blade pack base 116 which is provided with two angle
portions 118, 120 with the angled portion 11~ having alignment
recess-122. The injection tooling also includes a stripper 124
slideably mounted within the blades. All the injection tooling
employed with the equipment illustrated herein are essentially
the same with the exception that openings 126 between each of
the blades may be varied from one tool pack to another, depending
on the wire diameter or the diameter of different wire
combinations employed to produce the winding turns at the coil
loading stations. As will be dlscussed hereinbelow, the pick-
up recesses facilitate transfer~of the tool pack on and off the
indexing table and the groove surfaces allow interfitting of
the slotted core with the tooling in that the grooves are sized
such that stator core teeth slide therein. ~he stripper is
slideably mounted within the blades in order to transfer the
winding turns from the tooling into the core slots as will be
subse~uently discussed.
~fter se].ection, the injection tooling and core are
placed in a supporting position on a shuttle means which is the
shuttle tray 54 as shown in FIGS. 5 and 6. ~he slotted core is
placed in core receiver 128 located on a first portion of the
shuttle tray and the injection tooling is placed on tool
receiver 130 located on a second portion of the shuttle tray.
~he tooling is placed oVer post 132 with aligning pin 134 being
received in the alignment recess 122 of the angled portion 11
1~
_ _ , _, ,_ ,,, ,, , _, _ , ,_ ,__ _ . . .. _ , . . .......... ... ..
3~
of the tooling base. A loose fit between the tooling and post
may be provided, if desired, to aid centering of the injection
tooliny relative winding forms of a winding machine of a ]~nown
type such as disclosed, for example, in the hereinabove
referenced Cutler et al patent 3,672,026 or Cutler et al patent
Re. 2'7, 415 . ~lovement of winding turns from forms of the winding
machine onto the tooling would have a tendency to deflect
loosely mounted tooling into an aligned and centered position
relative the forms for compensating for radial and/or transverse
r.tisalignment of the tooling blades relative the winding forms
caused by such things as differences be-tween different injection
tooling or out of tolerance elements of the winding machine.
The post is mounted for rotation, by way of gear 136, on clamping
block 13~ which is in turn~loosely mounted to the tray base by
~15 way of four brackets 140 and pins 142 so as to allow movement
between the brackets when clamping force is applied. Loose
mounting o, the clar.ping block provides means for compensating
for variances in fabrication between the different shuttle
trays and for variances in the conveyor on which the trays are
moved, thus allowing clamping of the tool receiver at the
various operating stations as discussed hereinbelow. The clamping
block has four clamping pins 144 mounted therein for interfitting
with clamping assemblies at coil loading and transfer stations.
The tool receiver also includes end turn protecting plate 146
attached to the gear by three mounting posts 14~ and a home
switch bloc]~ 150 also attached to the gear for assuring proper
rotational orientation of the tooling at the coil loading and
transfer stations as will be discussed hereinbelow. In order
to allow engagement by the fetching assemblies for movement
into position at these stations, the shuttle tray is provided
with an aperture 152.
17
\
3~
After the core and tooling have been positioned
thereon, the shuttle tray is moved to the first coll loading
station 68. As mentioned previously, the shuttle tray is
engaged at the first coiling station by a first fetching
assembly which moves the tray so as to position the injection
toolin~ underneath a winding head of the winding machine 72.
Once in position, the tooling receiver is clamped, rotated to
a home position and then indexed to dispose winding turns, r
developed by the winding machine, on the tooling.
The fetching assemblies employed at the different
stations are of the same type, thus for brevity, only one (the
first fetching assembly 7~) will be described. ~eferring to
FIGS. 7-9, the fetching assembly includes a hydraulic motor 15~
for operating a crank arm 156 which moves bottom and top slides
158 anci 160 along rails 162. As the slides are moved, fetch
pin 164 is cammed upward into the aperture of the shuttle tray,
thus engaging the tray for movement of the injection tooling
by the first fetching assembly into position underneath the
winding head of the injection machine. As the tooling is moved
into position, the fetch pin is cammed downward, thus disengaging
the tray allowing the fetching assembly to recycle or return to
engage another shuttle tray and move it into position once the
winding turns have been disposed on the injection tooling
previously positioned underneath the winding head.
As illustrated by FIGS. 7-9, the crank arm 156 is
attached to the bottom slide 158 for causing move.ment thereof.
The top slide 160 is slideably mounted within the bottom slide
and is provided with latches 166 and 168 pivotally mounted by
way of pins 170-172, respectively for alternately engaging the
bottom slide in order to prevent rela-tive movement between the
1~
3~
two slides during movement along the rails 162. The fetch pin
16~ is slideably retained within the top slide with its base
portion 174 moveable along cam surface 176 of the bottom slide
for camming in and out of engager.lent with the shut-tle trays.
In operation, the hydraulic motor is activated to
move the crank arm to "fetch" the shuttle tray 54 as shown in
FIG. 9. The crank arm moves the bottom slide 158 along the rails
162 in direction 178. During this movement, the latch lG8 of
the top slide 160 is enyaged with the bottom slide and the
latch 166 is disengaged from the bottom slide. As the slides
aproach the tray pick-up position, roller 180 engages the latch
168 disengaging it from the bottom slide and stop boltsl82 engage
the top slide stopping its movement. However, the bottom slide
continues to move with this relative movement between the two
slides causin~g the fetch pin 164 to move upward along the cam
surface 176 and into engagement with the shuttle tray aperture
152 and causing latch 166 to engage the bottom slide as
; illustrated in FIG. 9.
.~fter the shuttle tray is engaged, the fetching
assembly crank arm moves the shuttle tray toward the winding
head by moving the slides along the rails in direction 184.
This movement of the tray into position simultaneously causes
the tray previously underneath the winding head to be pushed
from the coil loading station. Continued movement of the tray
causes roller l~G to en~age the latch 166 of the top slide
disengaginy it from the bottom slide and causes stop bolts 188
to engage and stop further movement of the top slide. The
crank arm continues to move the bottom slide wlth -this relative
movement between the two slides causing the fetch pin to cam
downward along the cam surface 176 to move the pin out of
1~
` 3D~AO-4946
39L~
engagement with the shuttle tray, thus releasing the tray at a
position such that the injection tooling thereon is underneath
the winding head of the winding machine. The stroke of the
crank arm is controlled by deenergiza-tion of the hydraulic
motor by limit switch 190 which is actuated by recessed cam '''
surface 192 of the crank arm assembly. Valve 194 is also
actuated by the recessed cam surface to cause operation of
clamping assembly 196 for retaining the injection tooling in
position underneath the winding head. If another shuttle tray
is in a "fetch" position, the'hydraulic motor is again energi~ed
to cause the slides and fetching pin to move in the reverse
direction for engagement with the'next shuttle tray,
In order to move'the~shuttle tray into a proper
position for engagement by the fetching assembly, conveyor 198,
along which the' trays are'moved, is sloped so that incoming
shuttle trays stop in the proper pick-up position. Of course,
other provisions could be'provided to accomplish this positioning
of incoming trays such'as cylinder operated stops (not shown)
which'would engage each incoming tra~ and then be released when
the fetching assembly is ready to move the particular shuttle
tray into position at the winding machine~
In order to assure that the injection tooling is in
the pic]c-up position and i5 of a proper height, a magnetic
switch'unit 20~ and a vane asser~Iy 202 are provided as
illustrated in FIG~ 7. Movement of a shuttle tray into the
pick-up position for the fetching assernbly causes pivotally
rnounted flap 204 of the' vane'assembly to be engaged and pivoted
by the injection tooling. The flap in turn causes vane 206 to
move within the'magnetic switch'unit, thus allowing fetching
assembly operation. On the other hand, if injection tooling
20 -
~"
3D-AO-4946
~ ,.~D~'~
ls not on the shuttle tray or .is of an improper height, the
vane will not be moved a sufficient distance or will be moved
beyond the magnetic switch'unit, thus preventing fetching
assembly operation. This provision can also be used to stop
the feeding of injection tooling at a certain point if desired
by the placement of tooling of improper he'ight tooling on a
tray wherein it is desired to stop operation.
After the first fetching assembly has moved the
injection tooling into position underneath the winding head
of the injection machine'at thé first coil loading station, the
clamping assembIy 196'illustrated in FIG. 7 is activated by the
valve 194 to clamp the tool receiver of the shuttle tray by
moving its jaws 208 inwardly so as to cause the clamping pins
of the tool receiver to be'received within recesses 210 of the
jaws~
FIGS~ 10 and.ll illustrate t~e details of the clamping
assembIy and an indexing assembly 2I2. In order to clamp the
tool receiver 130, double'acting clamping cylinder 2I4, which
is interconnected to the'two jaws 208 by way of arm 216 and
linkages ZI8, is activated which'.in turn causes the jaws to move
inwardl~ to interfit the'clamping pins 144 of the tool receiver
within the recesses 2I0 of the'jaws. The arm actuates limit
switch 220 to'indicate'that the clamping jaws have been closed.
The'clamping jaw movement.to cause clamping of the
tool receiver also activates thé indexing assembly to move chain
222:into enyagement with'the'gear 136 of the shuttle tray.
The chain is interconnected for movement by driving motor 224
by way of gears 226 and driving gear 228. When the chain engages
the tooling receiver gear, the driving motor is activated to
rotate thé injection tooling to a home position as indicated by
~/
3~
the home switch block 150 engaging home limit switch 230. Upon
actuation of home limit switch, pinion gear 232 is moved
downwardly by cylinder 234 to cause simultaneous engagement of
index gear 23~ and gear 2~. The gear 238 ls attached to the
driving gear 228 by pin 240; thus, the downward movement of thè
pinion gear interconnects the indexing gear and the driving
gear.
As illustrated in ~IGS. 10 and 11, the index gear has
an index plate 242 attached thereto. This plate functions to
~10 control rotational position of the injection tooling relative
to the winding head of the winding machine. Four index blocks
24~ are attached to the index plate with the blocks alternating
in height. Lhe index plate is also provided with four stop
recesses 246 for receiving stop pin 24~ operated by stoP cvlinder
250. Thus, in operation, the sliding pinion gear moves down to
cause interconnection of the driving and index gears. The
driving motor then rotatès the index gear until one of the index
bloc]cs engages either or both limit switches 252 and 254. Once
engaged, the stop cylinder is activated to move the stop pin
within one o~ the stop recesses of the index plate to lock the
index plate and. thus the injection tooling in position. Once
positioned and locked, the winding machine is activated to cause
coils to be developed on its winding head and loaded onto the
injection tooling. The direction of winding is determined by
the two limit switches 252 and 25~. If both are activated by
one of the switch blocks, the winding will be in one direction;
however, if a short switch block is encountered, only the limit
switch 252 will be activated, thus signaling the winding machine
to develop coils wound in an opposite direction.
2~
--~' 3D-AO-4946
3~3~
After the coils, each comprising a predetermined
num~er of winding turns, have been developed at the index
position, the driving motor is again activated to move the index
gear and plate to another index position, whereupon additional
coils are deveIoped by the winding machine and loaded onto the
injection tooling. After all the indexing and winding has been
performed, the clamping assembIy releases the tooling receiver.
After the tooling receiver is reIeased by the clamping
assembly, the ~irst fetching assembly moves another shuttle tray
into position underneath'the winding head of the winding machine.
This movement of another shuttle tray pushes the shuttle tray
underneath'the'winding head away from the first coil loading
station. The shuttle tray with stator core and injection tooliny
having winding turns the'reon is then moved to the second coil
loading station 70 (illustrated in FIG. 1). The second coil
loading station is provided with a second fetching assembly, a
second clamping assembly, and second indexing assembly for '
performing substantially the'same operations as those performed
at the'first loading station Thus, the second winding machine
develops additional coils-comprising winding turns and loads
these coils onto thé injection tooling. After these additional
coils have'been developed and loaded onto the injection tooling,
the tooling receiver is reIeased and then the second fetching
assembly moves another shuttle tray into position causing the
tray with loaded tooling thereon to be pushed from the second
coil loading station.
The shuttle tray 54 with the core 52 and injection
tooling 56 having winding turns 84 théreon is moved from the
second coil loading station to thé transfer station 86 illustrated
in FIG. 12.
- 23 -
. _ , .
` 3D-AO-4946
~ 3~3~ :
Referring to FIG. 12, the shuttle tray is moved into
position underneath the tooling transfer assembly 90 by the
third fetching assembly 88 which is of the same type as the
previously discussed first and second fetching assemblies (see
FIGS. 7-9). The tooling receiver is then clamped by a third
clamping assembly 256 which is of the same type as the first
clamping assembly (see FIGS. lO, 11) located at the first coil
loading station~ A homing device generally designated by
reference number 258 which is of the same type as the homing
portion of the first and second indexing devices (see FIGS. lO,
11), is then activated to rotate the injection tooling into an
aligned position for pick-up by the tooling transfer assembly.
The transfer assembly is activated causing its pick-
up arm 260 to move downwardly to interfit and pick up the loaded
injection tooling with winding turns 84 thereon and the empty
injection tooling within wedge guide housing 262. The pick-up
arm is then retracted and pivoted to align the loaded injection
tooling with the wedge guide housing 262 attached to the index
table 94. The arm is again moved downwardly to slideably
position the loaded tooling within the wedge guide housing and
to position the empty tooling on the shuttle tray from which
the loaded tooling was removed.
FIGS. 13-15 illu~trate further details of the tooling
transfer assembly 90. In FIG. 13, t'ne transfer assembly is
shown with the pick-up arm 260 in the retracted position ready
to pick up both the empty injection tooling located on the
index table within the wedge guide housing 262 and the loaded
injection tooling with winding turns 84 thereon located on the
shuttle tray 54 in order to transfer the loaded injection
tooling onto the index table and simultaneously remove the empty
- 24 -
. ,~
~ 3D-AO-4946
3;~: ~
injection tooling from the table. In effecting the transfer,
arm cylinder 264 is activated to move the pick-up arm 260
downward so that two tool grippers 266, located on each end
portion of the arm, move slideably over and in an interfitting
relationship with the empty and loaded injection tooling. This
movement of the grippers over the injection tooling is
illustrated by FIGS. 14 and 15 which show details of one of the
grippers. Both grippers are identical, thus the details and
operation of only one will be described. In operation, as the
arm of the tooling transfer assembly is moved downward to pick
up the injection tooling, the gripper is in a receiving position
as illustrated in FIG. 14. The gripper is moved downward
causing its member 268, which is similar in structure to the
injection tooling stripper, to move slideably within the interior
of the blades 110. Cylinder 270, which is interconnected with
cam mel~ers 272 by way of plate 274 and bolt 276, is then
deactivated allowing spring 282 to move the cam downward causing
locking pins 278 to move along cam surface 280 and thus,
outwardly into the pick-up recesses 114 of the injection tooling
blades as illustrated in FIG. 15. The member 268 prevents
flexing of the blades, thus assuring positive locking by the
pins. The spring 282 mounted on the bolt 276 biases the cam so
that the gripping means is in a gripping position when the
cylinder is not activated.
Referring to FIG. 13, after the two tool grippers have
gripped or locked both the empty and loaded injection tooling
in place by way of the locking pins, the arm cylinder 264, is
operated to move the pick-up arm 260 upwardly with the injection
tools gripped thereon. Hydraulic motor 284 is then activated
to rotate the pick-up arm about vertical axis 286 with the
, - 25 -
~ 3D-AO-4946
33~a3;~
rotation travel distance being controlled by limit switch 288
actuated by switch actuator 290 attached to the hydraulic
motor shaft 292 in order to position the empty injection tooling
over the slluttle tray 54 and to position the loaded injection
tooling over the wedge guide housing 262 attached to the index
table. The arm cylinder is again operated to move the tooling
downwardly, thus positioning the loaded tooling slideably within
wedge guides 294 of the wedge guide housing 262 and simultaneously
positioning the empty tooIing on the shuttle -tray. Each wedge
guide is provided with an angle portion (not shown) at its base
which extends inwardly toward the center of the wedge guide
housing; thus, the injection tool is prevented from sliding
through the housing by the wedge guides. The cylinders 270 of
the grippers 266 are then again activated to move their
respective cams 272 upwardly (see FIG. 14), thus causing the
locking pins 278 to move out of engagement to release the
toolings. Once released, the arm cy:Linder is again operated to
move the arm upwardly without the injection toolings.
After the loaded injection tooling has been positioned
on the index table 94, the table is indexed or rotated in 90
degree increments by motor 296 connected to an intermitter gear
drive arrangement 298 (shown in FIG. 13), with attached vane
and reed switch arrangement 299 for correct alignment of the
injection tooling at the two wedge making stations 98, 100, the
injection station 102 and the unload station 106 (see FIG. 12~.
Referring to FIG. 16, the index table 94 is initially
rotated 90 degrees to the first wedge making station 98. During
movement of the index table, wedge magazine 300 is at a lowered
position as shown in FIG. 16 to provide clearance with the
injection tooling locking means or angled portions 118, 120
- 26 -
3~3Z
(see FIG. 2). Insulating wedges (not shown) are fabricated
by a known wedge maker 301 such as, for example, taught in
Arnold et al U.S. patent 3,579,818 which issued
May 25, 1971. The insulating wedges are inserted into
wedge holders 302 of the wedge magazine. In the
wedge making operation, the wedge mazine is indexed
relative to the wedge maker. Screws such as screw 304
are attached to wedge magazine plate 306 opposite each
wedge holder where an insulating wedge is to be inserted.
~s the wedge magazine is rotated, the screws actuate
limit switch 308 to stop feed of the wedge material for
fabrication and insertion of insulating wedges into the
proper wedge holders. Ball operated limit switch 310 is
actuated after a complete rotation o~ the wedge magazine,
thus indicating that a home position has been reached.
After the injection tooling 56 (only tooling
angled portions 118, 120 illustrated in FIG. 16)
is in proper alignment position at the first wedge
making station 98, pusher cylinder 312 is operated to
cause pusher plate 314 attached to cylinder rod 313
by coupling arrangement 315 to move upwardly along
guide rods 316. Platen 318 attachea to the pusher plate
and having wedge pushers 3~0 attached thsrein is
also moved upwardly with the pusher plate. As the pusher
cylinder operates to move the pusher plate up~ardly,
compression on two springs 322 is thereby relieved causing
plate 324 and xods 326 attached thereto to be moved
upwardly with rods 326 slideably moving within fixed
support 32~. This upward movement of the rods 326 moves the
wedge magazine 300 attached to the rods into position adjacent
the index table 94 with the wedge holders 302 being in alignment
with the wedge guides 294 (see FIG. 12) of the wedge guide
,. .
- 27 -
3~3~
housing 262. The cylinder continues to move the pusher plate
and platen upward, thus moviny the wed~e pushers slideably
-through the fixed support 328 and through the wedge magazine.
Insulating wedges (no-t shown) contained within the wedge holders
of the wedge mayazine are moved upwardly by the wedge pushers
in-to the wedge guides of the wedge guide housing. Vane 330
attached to the pusher plate is moved to the position shown by
the broken lines to actuate maynetic switch 332, thus indicatiny
that the cylinder rod 313 has extended to insert the insulatiny
wedges.
After the wedges have been transferred to the wedge
guides, the pusher cylinder 312 is operated to retract its
cylinder rod 313 to the position shown in ~IG. 16 with the
pusher plate 314 resting against stops 334 attached to the guide
rods3316. Magnetic switch 336 is actuated by the vane to
indicate that the pusher cylinder rod is fully retracted. The
two sprinys 322 are again compressed by the pusher plate, thus
causing the wedge magazine to be moved to the "down" position
ln order to provide clearance with the angled base portions
11~, 120 of the injection tooling.
~eferring to FIG. 12, the index table 94 is then
rotated or indexed to the second wedge making station 100 for
insertion of addltional insulating wedyes into the wedge guides
294. The second wedge making station is provided with identical
elements as those described above for the first wedye making
station 98 and also operates in the same manner as the first
wedge making station.
~fter additional insulating wedges have heen inserted
at the second wedc~e making station, the index table is indexed
or rotated another 90 degrees to move the loaded injection
~f~3~2
tooling fromthe second wedge making station to the coil
injection station 102. At the injection station, the respective
stator core 52 which was transferred in the same shuttle tray
54 as the loaded injection tooling is interEitted with the
tooling. The winding turns 34 are then injected or transferred
~rom the injection tooling into the axially extending slots 53
of the stator core.
- ~he core transfer assembly 10~ illustrated in ~IG. 12
is provided for transferring the respective stator core into
the interfitting relationship with the injection tooling at the
coil injection station 102. For illustration purposes, the
core transfer assembly is shown in FIG. 12 with its arm 342
in the "up" position with one of the stator cores 52 thereon.
Two core holders 33~, 340 located at each end of the arm 342
allow removal of a core from the injection station after winding
turns have been inserted into slots of the respective core
simultaneously with the transfer of another core into position
at the injection station. In order to assure proper alignment
of the cores and thus assure that the cores do interfit
properly with the injection tooling, each core holder is
provided with alignment pins 344 which inter-Eit with recesses
345 of each core. In addition, cyllnder operated blade aligners
346, 34~ which operate independently of each other are provided
to further assure proper core alignment with the injection
tooling and to assure proper alignment of the injection tooling
blades 110 (see rIG. 3) at the injection station. Core
alignment is provided ~y keys 347 oE the blade aligners which
interfit between adjacent teeth 3~9 of a core, that is, within
the open ends 351 of the slots at the bores 353 of the cores.
Blade alignment of the injection tooling is provi~ed by recesses
29
_, .. .. . . .. . . .. . .
gL3;~:
353 of the blade aligners which receive the blades of the
injection too],ing at the injection station. To retain this
alignment, two cylinder operated clamps 350, 352, which also
operate independently of each other, are provided with the
clamps also functioning to retain the core durinq injection of
the winding turns 84 and duriny movement o:E injected wlnding
turns away from the bore of the core by cylinder operated end
turn separator 354.
The operation will be described w],th reference to
FIGS. 12, 17 and 18. Referring initially to FIG. 12, the arm
cylinder 360 (see FIG. 17) is activated to move arm 342 to a
"down" position from the "up" position as shown in FIG. 12.
The respective one of the stator cores 52, which was transferred
in the same shuttle tray with the injection tooling located at
the second wedge making station 100, is removed from its shuttle
tray and placed in the core holder 338 while the arm is in the
down position. Core alignment is assured because the alignment
pins 344 must be received in corresponding recesses 345 of the
core. ~ gate (not shown) is then closed around the core loading
area. After the gate is closed, one of the two clamp cylinders
356 is energized to move the core clamp 350 downward around the
periphery of the core to retain the core in position. One of
the two blade aligner cylinders 358 is then energized to move
the blade aligner 346 downward and slideably into the interior
bore of the core. ~he arm cylinder 360 (see FI~,. 17~ is then
operated to raise the arm 3a2 with the respective stator core
thereon to a full "up" position. The index table 94 is indexed
90 degrees to move the respective injection tooling to the
in~Jection st~tion 102. ~eferring to ~IG. 18, motor 362 is
energized after the core assembly arm has reached its Eull "up"
posi-tion, causing the arm to pivot for moving the core into an
aligned position over the injection tooling located at -the
injection station. Limit switches 364, 366 are employed to
stop the motor at this aligned position with both limit switches
being actuated by bloc]~ 368 attached to gear 370 when one of
the core holders is in position over the injection tooling and
with shortex block 372 also attached to the gear causing
actuation of only the limit switch 364 when the oppositely
disposed core holder is over the tooling at the injection station.
After rotating the arm 342 so tha't the empty stator
core within core holder 33~ is in position over the tooling at
the injection station, the arm cylinder 360 is deenergized to
move the arm downward to the position as illustrated in ~IG. 17.
As illustrated, the stator core within stator holder 3~0 which
was previously at the injection station is now positioned over
end turn separator 354 wlth its respective wlnding turns 84
accommodated in slots thereof; whereas, the empty s-tator core
within core holder 338 has been interfitted or moved slideably
over its respective injection tooling 56, also having winding
turns 84 disposed thereon. During lowering of the arm, the
respective blade aligner cylinder 358 i5 moved to a neutral
position in order to allow the blades of the injection tooling
to push them up~7ard during the interfitting operation and during
the injection cycle described hereinbelo~
~IG. 19 shows the respective stator core 52 (illustrated
with broken line) in position over the injection tooling 56
(shown in cross-section) at the injection station. The clamp
350 (see FIG. 17) retains the core in position over the tooling
and the blade aligner 346 (see FIG. 17) is positioned within the
core. ~n injection mechanism 37a, located at the injection
33~32
station is employed to transfer the winding turns 8a from the
injection tooling into the axial extending slots of the stator
core. The injection tooling 56 having blades 110 and stripper
124 (shown in cross-section) is loc]~ed into an align position
by its angled base portions 118, 120 being received in flange
portion 376 of the injection mechanism.
After the core is interfitted with the tooling, the
injection mechanism is activated to transfer winding turns r
from the tooling into the axial extending slots of the core.
In per-orming the insertion, the blades of the injection tooling
are moved upward and slideably through the interior bore of
the core with the outer grooves of the blades sliding along~
the teeth of the core. ~he blade travel distance is varied in
accordance with the axial lenyth or stack height of the core.
~he insulating wedges previously fabricated at the first and
second wedge making stations 98, 100, respectively (see FIG. 12)
are also moved upward by wedge pushers 392 through the wedge
guides 294 and into~the slots of the~core with the travel of ~'
the wedge pushers also being varied in accordance with stack
height. 'Following the insulating wedges are the winding turns
which are moved upwardly by the s-trlpper lZ~ along the tooling
blades and a~ially along and into the slots of the core.
Details of the injection mechanism are illustrated in
FIG. 19 and details,of the core height adjustment arrangement
are illustrated in FIGS. 20-25. Referring to FIG. 19, injection
cyllnder 378 having injection rod 380 is provided for ~oving
the stripper 12~ along the interior of the blades 110 ~nd thus,
stripping or transferriny the winding turns 8~ disposed on the
hlades from the blades into the axial slots of the core 52. The
injection rod is provided with height adjustment gear 382 and
~3~3~
has wedge adjustment flange 384 threaded thereon. The injection
rod extends slideably through push plate 386, pusher platen
388 and sleeve 390. I~edge pushers 392 are attached at one end
thereo to the pusher platen which is attached to the push
plate. The pushers extend slideably through plate 394, support
ring 396 and frame support 398. The plate 394 and the push
plate are slideably mounted on guide rods 400 attached at each
end thereof to frame suppor-ts 398 and 402 with the push plate
moving between stops 404 and ~06 mounted on the rods. The
plate 394 is engaged by c~linder rod 408 of blade cylinder 410
and also is threadably engaged with the sleeve 390.
In operation, the injection cylinder 378 and blade
cylinder 410 are actlvated slmultaneously. The injection
cylinder rod 380 moves upward causing the wedge adjust flange
384 to engage the push plate 386. The push plate then moves
upward away from the stop 404 and pushes the pusher platen 388
upward which causes the pushers 392 to move to the tlps of the
wed~e ~uides 294 and thus push the insulatin~ wedges (not
shown) from the guides into the slots of the core. mhe blade
cylinder rod 408 pushes the plate 394 upward which causes the
sleeve 390 to move upward. The sleeve is moved until the
pusher support ring 396 abuts the frame support 398; thus the
blades of the injection tooling are moved upward within the
interior bore of the core to the height or axial length of the
core. The blades push the blade aligner 346 (see FIG. 17)
upward as they move within the bore.
The injection rod continues to move upwarcl and
engages the stripper. Engagement is accomplished by providing
the strip~er with a push-pull type connector socket 412, one
~ of which that has been used bein~ a ~lansen "PU,SI-I-mITE"~series
33
., ' ,
t3~3~:
3000 manufactured by the ~lansen Manufacturing Company under
that tradename, except with the check valve usually contained
therein being removed. As the injection rod is moved into
the socket, pins or balls (not shown) within the socket are
moved inwardly to engage recess portion 413 of the injection
rod. A vane 414 attached to the pwsh plate actuates magnetic
switch 416 (vane position shown in broken line) causing the
respective one of the blade aligner cylinders 358 (see FIG. 17)
to be moved from a neutral position to a position for retracting
the blade aligner. As the stripper 124 is moved upwardly, the
winding turns 84 contained on the blades 110 are stripped or
transferred from the blades into the axial extending slots of
the core. This upward movement of the stripper continues until
the push plate engages the stop 406. ~agnetic switch 418 is
actuated by the vane 414 attached to the push plate, thus
indicating full extension o the injection cylinder rod 3~0.
After the winding turns and insulating wedges have
been inserted into the slots of the stator core, the injection
cylinder 37~ and blade cylinder 410 are retracted causing the
23 injection rod 3~0 to pull the stripper back through the interior
of the blades and the blades back to their retracted positions
within the wedge guide housing. The collar 419 of the socket
412 engages surface 421 of the tooling causing the pins or balls
(not shown) located ~ithin the socket to move outwardly to
2$ disengage the injection rod, thus allowi.ng full retraction of
the injection rod with the push plate abutting the stop 404
and nut 420 attached to the blade cylinder rod. ~lagnetic switch
422 is activated by the vane 414 indicating that the injection
cylinder rod has been fully retracted.
3~
3~
As mentioned previously, the injection mechanism 374
of FIG. 19 is adjusted in accordance with the heiyht or axial
length of the particular stator core during set-up of the
machine. Further, the wedge makers at each of the two wedge
making stations 9~ and 100 (see FIG. 12) are also acljusted to ',
fabricate insulating wedges with an axial length appropriate
for stator cores of a partlcular height or axial length. The -
adjustment is performed progressively in order to assure
adjustment at the proper time corresponding to the se~uential ~
movement of the injection tooling to the stations. For es~ample, , '
referring to FIG. 12, an adjust ent for a different core height
would be made when the injection tooling to be used with the
core of a different height is transferred to the indexing table
94. ~he flrst wedge ma]clny statlon 98 ~lould in turn delay
fabrication of lnsulating wedges of a proper length until the
tooling is moved into posltion at the first wedge making station.
In a like manner, the second wedge ma}cing station 98 and the ~'
injection station 100 would delay adjustment for the different
core height until the injection tooling to be used with the
core of a different height is being moved into position at the
respective stations. ~he sequential control of the stator
height,adjustment and the entire turntable and transfer
arrangements illustrated in FIG. 12 can be accomplished by a '
known programmable controller or computer such as, for example,
a ~I 102 Se~uencer manufactured by the ~exas Instruments
Corporation.
FIGS~ 20-25 illustrate de-tails of a stator height
adjustment arrangement which is interconnected with the turn-
table arrangement for accomplishing adjustment of the wedge
ma]cers and injection mechanism in accordance with the axial
3~
32
length o~ the stator core. To perform the adjustments~
adjustment wheel 424, attached to adjustment screw 426 as
illustrated in FIGS. 20 and 21 is rotated with such
rotation causing movement of adjustment cables or linkages
428, 430, 432 which are interconnected for movement by
the adjustment screw by way of sleeve 434 and plate 436. The
adjustment screw is rotated until index pointer 438 attached to
the plate is aligned with the particular core height graduation
contained on index plate 440 which is marked or graduated
in accordance with different stator heights. The illustrated
index plate or scale is graduated from zero to six inches.
FIGS. 22 and 23 illustrated an arrangement
for adjusting the length of insulating wedges in accordance
with the axial length of the stator core. The adjustment
arrangement is identical for both wedge making stations,
thus only the arrangement for the first wedge making
station is illustrated. The length of the insulating
wedges is determined by the position of wedge linkage 442
which is connected to the wedge make:r 301 (see FIG. 16).
The linkage 442 may be employed to vary the
wedge length fabricated by the wedge maker of a known type
such as disclosed in the hereinabove referenced Arnold et al
U.S. patent 3,579,818 by, for example, varying the location
of either pivot point 74 or pivot point 94 shown in FIG. 2
of the referenced patent. r~he linkage position is controlled
by cylinder 444 which has its cylinder rod 446 connected
to the linkage and switch vane 448 by way bar 450. r~he
vane which is slideably mounted on rod 452 causes actuation
of magnetic switch 454 slideably mounted on rods 45~ and
3Q connected to the adjustment cable 430.
- 36 -
~ 3~ 3D-Do-4946
The operation of the wedge adjustment arrangement
will be described in reference to FIGS. 22 and 23. Rotation
of the adjustment wheel 424 (see FIG. 20) causes the cable
430 to adjust the relative position of the magnetic switch 454
on tha rods 456. The cylinder 444 is then energized in order
to adjust the position of the wedge linkage 442 so that
insulating wedges will be fabricated in accordance with the
stator height as set by the adjustment wheel. The wedge lin];age
is moved by the cylinder until the vane 448 causes actuation of
the magnetic switch. In order to assure more accurate and
repeatable adjustments, the cylinder rod is initially retracted
and then extended so that the vane approaches the switch in the
same direction each time an adjustment is performed.
The cable 432 of FIG. 20 is connected to a wedge
adjustment arrangement at thesecond wedge making station with
the adjustment arrangement and operation being the same as that
described above for the first wedge making station. -~
As mentioned previously, the injection mechanism 374
(see FIG l9) is also adjusted in accordance with the axial
length of the stator core. Adjustment cable or linkage 428 of
FIG. 20 is connected to the injection adjustment arrangement
illustrated in FIGS. 24 and 25 for accomplishing the adjustment
of the injection mechanism.
Referring to FIG. l9, the travel distance of the wedge
pushers 392 during the coil injection operation is determined
by the distance between the wedge adjust flange 384 and the
push plate 386. For example, for a 3/4 inch core stack height
or axial length~ the desired distance between the flange and
pusher plate i5 5/8 inch for the illustrated injection mechanism.
On the other hand, it is desired to have a distance of 3-3/8
- 31 -
"~
3~
inches between the flange and pusher plate where the aY.ial
length of the core is 3-1/2 inches. In addition, the travel
distance of the blades 110 of the injection tooling 56 is
also varied in accordance with the axial length of the stator
core 52 with this travel distance being determined by the
distance between the pusher support rin~ 396 and the frame
member 398. For example, it is desired to have this distance
equal zero for a 3/4 inch stac~ height and 2-3/4 inches for a
3-1/2 inch stack height or axial length.
The adjustment of the travel distances of the wedge
pushers 392 and the injection tooling blades 110 is accomplished
by rotation of the injection rod 3S0 by ~ay of the adjustment
gear 382 attached thereto. As the injection rod is rotated, the
wedge adjustment flange 384 which is threadably en~aged with the
rod is moved along the rod, thus varying the distance between
the wedge adjustment flange and the push plate 386. By varying
this distance, the travel distance of the wedge pushers is
adjusted in accordance with the axial length of the core.
Rotation of the injection rod 380 also causes the
travel distance of the injection tooling blades 110 to vary.
The injection rod is provided with a vertically extending groove
(not shown) in the outer surface thereo~. The sleeve 390 is
provided with a pin (not shown) mounted therein so that the pin
rides in the groove of the rod. Thus, the injection rod is
allowed to move vertically within the sleeve. Ilowever, rotation
of the injection rod also causes rotation of the sleeve having
the pusher ring 39~ threadably attached thereto. Thus, as the
sleeve rotates, the distance between the pusller ring and the
frame member 39O is varied. ~y varyinc~ this distance, the travel
of the injection tooling blades during coil injection is varied
in accordance with the axial length of the stator core.
3~
~.~3~3~
PIGS. 24 and 25 illustrate details of the injection
Mechanism adjustment arrangement for causing rotation of the
adjustment gear 382 which accomplishes the above-~escribed
adjustment of the injection mechanism. As illustrated, the
adjus~lent gear is engaged by motor gear 458 OL adjustment
mo-tor ~60. The mo-tor gear also engages screw gear a62 having
threaded member 464 attached thereto. The threaded member has
vane 466 moun-ted thereon so that ro~ation of the screw gear
causes ver-tical movement of the vane. The vane actuates
magnetic switch 468 attached to rods a70 with the relative
position of the switch on -the rods being controlled by the cable
or linkage 42~ connected at the other end thereof for movement
by the adjustment wheel 424 (see FIG. 20).
The adjustment of the injection mechanism 374 (see
FIG. 19) is accomplished by rotating the adjustment wheel
which by way of the cable 428 adjusts the position of the maqnetic
switch 468. The adjustment motor 460 is then energized to cause
rotation of the adjustment gear 382 until the vane a66 attached
to the screw gear 462 causes actuation of the magnetic switchi
thus, the injection mechanism is adjusted in accordance wi-th the
axial length of the core. In order to assure consistent and
repeatable adjustments,.the adjustment motor initially moves the
vane away from the switch and then causes the vane to approach
the switch in the same direction each time an adjustment is
performed.
~fter the respective winding turns ~4 located on the
injection tooling as shown in FIG. 17, have been inserted into
the core slots and the injection rod 380 (see FIG. 19) of the
injection mechanism has been retracted, the core lifti.ng arm
342 is moved upwardly away from the injection tooling and then
39
~3~
rotated back to its home position where the arm is again
lowered so as to position the respective stator core 52
retained in the core holder 33 over end turn separator ~54
shown in FIG. 17. ~fter the windincJ turns have been inserted
into the core slots, the end turns o the winding turns extend
across the bore of the core; thus, in order to allow for
subsequent operations such as mounting of a rotor within the
bore, the end turns must be moved away from the bore.
FIGS. 17 and 13 illustrate details of the end turn
separator 354 which is used to move end turns away from the
bore. I~hen the arm having the loaded core is lowered, arm
locking pin 472 is received within aperture 474 (also illustrated
in ~IG. 12) to prevent lateral movement of the arm. Separator
cylinder 476 is actuated causing separator plug 47~ having a
cone shaped tip 480 to move upwardly through the bore of the
core. The end turns are moved along the cone shaped tip and
away from the bore allowing subsequent assembly of a rotor within
the bore. The upward travel distance or extension of the plug
is controll~d by pressure switch 482 illustrated in FIG. 18 with
the pressure switch causing the cylinder to retract the plug
after i~ has moved a sufficient distance to move the end turns
away from the bore at both faces of the core. Limit switch 44
is actuated by the plug during its downward movement to indicate
that the cylinder has been fully retracted. Of course, the arm
of the core transfer assembly has two core holders, as discussed
previously; thus winding turns contained on ano-ther injection
tool can be inser-ted into another core retained in the oppositely
disposed core holder simultaneous with the operation of the end
turn separator.
~10
~3~3;~
~fter the end turns have been moved away from the
bore of the loaded core, the core 52 is unclamped by activating
the respective clamping cylinder 356 and removed from the core
holder allowing placement of another core.
I;lhile the previously discussed loaded core was being
transferred by the core transfer arm back to a home position
for operation upon by the end turn separator, the index table
94 was rotated an additional 90 c1egrees, thus, moving the empty
injection tooling to an unloading station 48G illustrated in
FIG. 12 which in this embodiment is at the same location the
toolina was initially loaded onto the inde~in~ table. The
tooling transfer assembly arm 260 picks up the empty tooling and
then rotates to place the tooling upon one of the shuttle trays
54 positioned at the transfer station S6.
The shuttle tray with empty tooling thereon is moved
away from the transfer station toward the selection station 50
(see FIG. 1) where another one of the stator cores 52 is loaded
onto the tray for repeating the above-described operations.
IThile the invention has been described in terms of
particular embodiments thereof, it should now be apparent that
changes may be made without departing from the invention. It
is, therefore, intended by the following claims to cover all
such variations which are within the true spirit and scope of
this invention.
~1
