Note: Descriptions are shown in the official language in which they were submitted.
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Case 5077
STREAMLINED PRODUCTION OF ELECTRIC MOTOR
ARMATURES AND STATORS
FIELD OF THE INVENTION
This invention relates to the manufacture of electric
motors, particularly to methods and production lines for
the production of armatures and stators.
~Y~
An electric motor essentially comprises an armature
assembly and a stator assembly both of which are
individually produced on separate production lines after
which the armature and the stator assemblies are
assembled together.
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~; In order to make two lectric motors of different ;sizes
~ for example with armatures of 47mm and 57mm diameter, it
has been the practice to have four separate and distinct
production lines, i.e. two for the armatures and two for
the stators.
Each production line occupies a substantial floor space.
Furthermore, ea h production line has its own independent
equipment and its own staff.
~UMMARY OF rHE INVEN~TON
One asp ct of the present invention, at least in its
pre~erred embodiments, aims to reduce the floor space
oacupied ~y suah production lines by 60 to 70~ and, -at
the same ~ime, reduce staffing levels by 25 to 50~.
Accord;ng to one aspect of the invention there is
provid~ o production Iines for the manufacture of
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armatures or stators for electric motors separated along
at lea~t part of the length thereof by a common
partition. The pair of production lines being designated
for the production of one of the two major subassemblies
of electric motors, i.e. either the armatures or the
stators.
By placing the production lines close together many
operations can be carried out using a common operating
head thereby ~ubstantially red~cing duplication of
operating mechanisms~
; Preferably, one or more shuttles are provided for
transferring~ articles from one production line to the
other and ~vice-versa. Preferably, the shuttles are
disposed one upstream and one downstream of the coil
winding areas.
This has ignificant advantages, particularly where there
a temporary~demand for the increase in production~of
ons type of motor. Thus, for ~xample, if there is a
temporary increased demand~for 47mm armatures, one or
more coil winders~ on the 57mm production line can be
assigned to 47mm winding duty. A number of 47mm
~;` armatures can then be ;transferred to the 57mm production
line by the~shuttle,~wound on ~he conscripted winder and
returned to the 47mm line downstream of the winding`~area.
The armatures and/or stators can be transported on
pallets which are prePerably provided with identifying
means, such as identifying lnserts, which enable them to
be ldentified as they approach an operating station.
When the quaue to the winder on the 57mm production line
3~ .is not ~ull, a signal is sent to a shuttle which diverts
the appropriate number of units from the 47mm production
line. As these units pass through the 57mm winding area
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they are ignored by all the winders with the exception of
the conscripted winder which identifies them and admits
them to its queue. The wound units are similarly
idenkified as they approach the downstream shuttle and
are xeturned to the 47mm production line.
In both armature and stator manufacture, an end member is
first laid on an assembly pallet. The end member is then
covered with a stack of laminations~ The total height of
the stack must be within a prescribed range. Heretofore,
it has been the practice to pick a stack with a height
about the minimum of the range, check the height and, if
nec~ssary, add a further lamination. This requires a
first stacker station, a measuring station and a second
stacker station.
According to another aspect of the present invention,
there is provided a method of obtaining a stack of
armature or stator laminations of a height within a
defined range, which method comprises the steps of
picking a tack close to the maximum height permitted,
checking the height of the stack, and removing a
lamination if the measured height is greater than the
maximum height.
Pre~erably, the height of the stack is measured with a
measuring head and the lamination is removed, if
necessary, with means associated with the measuring head.
Advantageously, the means comprises a vacuum line.
It will be appreciated that by using this techni~ue only
one stacker st~tion is required thereby making useful
~avings both in capital cost and in production line
length. The discarded laminations can, of course, be
reoycled to the stacker.
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Once the windings are completed, it is necessary to make
electrical contact between the magnetic wire used in the
winding and either the commutator ring in the case of the
armature or terminals in the case of the stator. This
may be achieved in several ways.
A further aspect of the present invention provides a
method of ~tripping the ends of magnetic wire on an
armature or a stator, which method comprises the step of
subjecting the ends of the magnetic wire to a laser beam.
Although the magnetic wires could be individually indexed
into position and the laser activated, in the case of an
armature, it i~ preferred to place a mirror between the
main winding and the~ends of the magnetic wire on the
armature and rotate the armature beneath the laser.
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The present invention~also provides buffer storage which
comprises a platform for supporting electric motors or
parts thereof in layersj and means which, as said :
; plat~orm is loaded, lower said platform so that it
remains substantially horizontal at all times.
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Preferably, the buffer storage comprises means ~which
lower the platform at a rate such that when the;platform
i~ covered ~ith a layer of articles thé tops of the
articleB lie in substantially~ the same plane ~as ~the
platform before the artioles were applied~
Advantageously, each end of the platform may be supported
by a reapective belt which passes upwardly and over a
respective wheel and is connected, at the other end
thereo~ to at least ons respective spring. Pre~erably,
the belta are provided with spacer members at vertically
~paced locations to facilitate the loading of the buffer
storage. Advantageously, the wheèls may be provided with
teeth and the belts are provided with teeth which mesh
with the teeth on said wheels. Preferably, the wheels
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are mounted fast with respect to other toothed memb~rs
and 6aid other toothed members are interconnected by a
chain arranged in a figure of eight configuration so that
any vertical movement at one end of the platform is
accompanied by an equal movement at the other end
thereof. Advantageously, the platform may be scalloped
to receive a row of armatures therein.
According to another aspect of the present invention,
there is provided a method of simultaneously producing
similar subassemblies for two different motor
specifications, comprising the steps of advancing
subassemblies of first and second specificat:ions along
~;~ two sid~ by side production lines, one for each
specification, and at a winding station transferring some
of the subassemblies from one production line to the
other line and winding coils thereof on the other line,~
and thereafter returning these:~same subassemblies~back to
said one line, whereby the ;rate of production of the~
subassemblies on said one line ls increased.
Other objects, features and :advantages of the~ present
invention will bécome more~ ully apparent ~rom the
: following detailed description o~ the preferred: ;
:~ embodiments, the ~appended claims and the accompanying
,
drawings.
BRI~F ~ESCRIPTION QE-T~ AwIN~
` In the accompanying drawing~: :
~ FIGURE 1 is a block diagram showing the layout o~
: Fi~s. 2A to G;
: FIGURES 2A to G show a schématic layout of a dual
: 30 highway armature production line;
FIGURE 3 is a schematic cross-section of two
elevators taken along line III-III of Fig. 2A;
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FIGURE 4 is a perspective view of an armature
assembly pallet;
FIGURE 5 is a schematic cross-section taken along
line V-V of Fig. 2A;
FIGURE 6 is a schematic plan view of an assembly
pallet awaiting end fibre placement;
FIGURE 7 is a fragmentary cross-section showing part
of an armature provided with a slot liner about
to be cut as the first stage in a cut and tuck
operation:
FIGURE 8 is a view similar to Fig. 7 but showing the
first step of the tuck operation;
~: ~IGURE 9 Qhows the second step of the tuck
~: ~ operation:
FIGURE lO is a schematic side elevation of a~trickle~
: station;
FIGURE 11 is~a~block diagram showing the layout of
: ~ Figs. 12A to C; :~
~; : FIGURES 12A, B~and:C show a schematic layout of a~
dual highway stator production line;
FIGURE 13 is a perspective view of a stator assembly
pallet;
: FIGURE 14: is a plan~ view of:the~ stator assembly
: pallet loaded with a stack of laminations;
25 : FIGURE 15 iB a side elevation of the stator assembly
: pallet ~immediately after winding;
~IGURE 16 i9: ~a perspective view of~a buf~er storage
~or armatures;
FIGURE 17 is a perspective view o~ part of a buffer
storage for gears; and
FIGURE 18 is a plan view showing the buffer storage
. of Fig. 16 in use.
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~AILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of complete armature and 6tator
production lines according to the present invention are
illustrated in Figs. 1 through 18. For ~ase of
understanding, various sQctions or aspects of these
production lines will be separately described with the
use o~ appropriate subheadings.
DUAL HIGHWAY ARMATURE PRODUCTI~N LTNE
Referring to Figs. 2A to 2G there is shown a dual highway
armature production line which is generally identified by
reference numeral 1. Figs. 2A to 2G should be taken ln
se~uence together as a single drawing as schematically
indicated in Fig. 1.
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The dual highway armature production line 1 comprises two
conveyors 2 and 3 which are separated by a stationary
partition 4. The conveyors 2 and 3 are driven at the
same speed by separate and distinct variable speed motors
(not shown).
EL~VATOR
Two elevator 5 and 6 are arranged at the beginning of the
production line to raise armature assembly~pallets to the~
level o~ conveyors 2 and 3, respectively. Each elevator
has a plurallty of trays 7 (Fig. 3) which can each
aacommodate two armature assembly pallets. The elevators
5 and 6 are independently controllable and can together
raise 3600 armature assembly pallets per hour to the
level of the conveyor~ 2 and 3. The armature assembly
pallets are transferred to the conveyors 2 and 3 by
plungers ~not shown).
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ARMATURE ASSEMBLY PALLETS
Fig. 4 shows an armature assembly pallet which is
generally identified by reference numeral 8. The
armature assembly pallet is made of mild steel and
comprises a base 9 which is approximately 63mm wide, 75mm
long and 25mm deep. The top of the base is provided with
two upward~y extending pins lO and ll which are relieved
adjacent the base 9. The pins lO and ll are disposed to
either side of a counterbored hole 12. A similar
counkerbored hole 13 is disposed adjacent the
countexbored hole 12. One side of the base 9 is provided
wlth a 610t 14 which accommodates an identifying insert
; 15. The base is provided with a positioning arrangement
which comprises a horizontally extending bore 16~and a~
cut-ou~ 17.
As s~hown in Fig. 5, the bottoms of the bases 9~of the~ -
armature assembly pallets rest on their respective~;~
~` conveyors 2 and 3, while the ~ides are confined~between ~ ;
~ide members 18 and beam l9 which supports the 6tationary
20 ; partition 4. The~instal1ation shown is intended for the~
simultaneous production of armatures having; a nominal
diameter of 57mm~;and 47mm. The;identifying~inserts 15 on
the armature assembly pallets are appropriately coded~and
the armature assembly pallets intended for the production
of 57mm armatures pass along conveyor 2, whi~le those~
intended for the production of 47mm armatures pass along
aonveyor 3.
ND FIBRE PLACEMENT
Th~ ~irst stage in making an armature is the construction
30 of the armature core assembly. As the empty armature
assembly pallets are carried down the dual highway
~armature production line l by conveyors 2 and~ 3 they ~ !
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enter station 20 (Fiy. 2A). The followiny events then
occur on the armature assembly pallet 8 on conveyor 2.
As the armature assembly pallet enters the station 20 it
engages a 8top 21 (Fiy. 6) which projects across the path
of the conveyor 2. When engagement is sensed, an arm 22
i moved to the right so that a shot pin 23 enters the
horizontally extending bore 16 in the armature assembly
pallet 8 and urges it against the stationary partition 4.
Once the armature assem~ly pallet 8 is in position, a
moulded end ~ibre is lowered onto the armature assembly
pallet 8 with a low vertical pressure slide (not shown).
The moulded end fibre is made of plastics material and
comprises a hub with outwardly projecting spokes which
are correctly orientated with respect to the armature
1~ assembly pallet 8 by the slide. An escapement
alternately holds ~ack and releases the moulded end fibre
in correct timing with the slide so that a moulded end
~ fibre can be pressed onto an armature assembly pallet~8
: ~ as soon as it is correctly loca~ed. Once the moulded end
fibre i8 in position the~arm 22 is withdrawn to allow the
armature assembly pallet 8 to continue its journey. The
arm 22 is then advanced so that the stop 2~ is ready to
sense the next armature assembly pallet.
While this is happening, conventional end fibre placement
25 iB per~ormed on the armature assembly pallet on conveyor
- 3. The total time taken ~or armature assembly pallet
trans~er and placement o~ the end fibre is about 2.25
seconda.
S~AC~ER STATION
~0 The ar~ature assembly pallets pass to a stacker station
24 where they are~ sensed and detained in pairs to each
side of the stationary partition 4. A dispenser 25 is
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disposed to each side of the production line. Each
dispenser contains a plurality of stacks 26 of armature
laminations 27 (Fig. 2A~. Each stack 26 is biased
upwardly again6t retaining fingers by a damped piston and
cylinder arrangement (not shown). In use a common
operating head moves ~our universal grippers into a
position ~uch that two universal grippers are positioned
over two stacks 26 of one dispenser 25 and two universal
grippers are positioned over two stacks 26 of the other
dispenser 25. As the universal grippers move into
position they displace the retaining fingers thereby
allowing the armature laminations 27 to rise into the
universal grippers. The grippers are then raisecl until
they reach an air cylinder stop which determines the
height of the stack to be removed. This height is set at
the maximum height in the acceptable range of heights~.
The grippers and the gripped stacks are ~then removed
upwardly sufficiently rapidly to enable the retaining
Pingers to move into place above the remaining armature
laminations without displacing ~urther laminations.~
The stacks of armature laminations are placed on the
armature as~embly pallets between~the pins lO and 11 and
over the counterbored hole 12~ Once the ~tacks of
armature laminations are correctly positioned, the
armature assembly pallets are released and continue down
the pro~uctlon line.
SPLIT $TACK S~ATIOM
The assembly pallets then enter a split stack station 28
~Fig. 2A) where they are sensed and detained in pairs to
each side of the etationary partition 4. A common
operating head having two bars pivotally mounted thereon
and having a gripper at both ends thereof descends onto
the stacks so that the grippers on each ba~ grip the top
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75% of armature laminations on successive armature
assa~bly pallets. ~he common operating head is then
raised and the bars are rotated through 180 degrees by a
common chain drive. The common operating head is then
lowered and the armature laminations released. The
common operating head is then raised by a small distance
and the grippers actuated so that the grippers on each
bar grip the top 25% of the armature laminations on
successive armature assembly pallets. The operating head
is then raised, the bars rotated through a further 180
degrees and the armature laminations replaced. As a
result of this operation inaccuracies in the manufacture
of the armature laminations tend to be balanced out.
MEASURING STACK
The armature assembly pallets then pass to a measuring
station 29 (Fig. 2A) where they are sensed and detained
individually to each side of the stationary partition 4.
A common operating head with individually adjusted
~easuring heads descends onto the stacks. If a stack
exceeds the maximum height permissible a vacuum line
leading to the pertinent measuring head is actuated and
an armature lamination removed fxom the relevant stack.
~he removed armature lamination is then returned ko the
~tacker station for re-use.
OTHE~ END FIBRE PLACEMENT
The armature assembly pallets then pass to station 30
(Fig. 2B) where they are sensed and detained in pairs to
each ~ida of the stationary partition 4. End ~ibres are
then placed over the upper end of each armature in a
manner ~i~ilar to that described with reference to
8tation 20~
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SHAFT INSULATION PLACEMENT STATION
The armature assembly pallets then pass to station 31
(Fig. 2B) where they are sensed and detained individually
to each side of the stationary partition 4. A tube 32 is
fed horizontally toward each armature assembly pallet,
cut to length and then moved into a vertical position.
Each tube is then pressed through the top end fibre, the
stack o~ armature laminations and the bottom end fibre by
a common operating head. The tube 32 comes to rest in
the counterbore portion oP the counterbored hole 12
(Fig. 4) in the respective pallet.
SHAFT P~I~CEMENT STATION
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The armature assembly palle~s then pass to station 33
(Fi~. 2B~ where they are sensed and detained in pairs to
each side of the stationary partition 4. ~ A common
operating head simultaneously presses a sha~t through
each shaft insulation tube. The shafts come to rest
adjacent the bottom of the counterbored holes 12. The
shafts are arranged in plastic chain carriers which align
~; 20 the ~hafts with the shaft insulation tubes. ~ The
operating head then presses the sha~ts out of the
carrier, through a guide member into~the shaft insulation~
tube.
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The armature assembly pallets then pass to a slot lining
~takion 34 (~ig. 2B) where the outer periphery of the
a~a~ure laminations is provided with an insulating
lining. This can be aahieved conventionally (as shown)
or ~y transferring the~assembly in counterbored hole 12
to ~unterbored hole 13 ~(Fig. 4) and inserting pre-
pun~i! ; lot liners into the slots either individually or
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in pairs on opposite sides of the armature.
COMMUTATOR PLACEMENT STATION
The armature assembly pallets then pass to station 35
(Fig. 2C) where ~hey are sensed and detained individually
to each side of the stationary partition 4. A common
operating head descends and the armature assemblies are
indexed to an appropriate position. A commutator ring i6
then placed on the upper end of each armature assembly.
The commutator rings are supplied ~rom two vessels both
disposed to one and the same side of the production line.
Thïs ha~ the advantage of increasing access to the
production line on the opposite side to the vessels.
The completed armature core assemblies then pasa to a ;
buffer zone 36 (Fig. 2C) where the cores are removed ~rom
the armature assembly pallets which are returned~to the
elevators 5 and 6 (Fig. 2A~.
WINDING AREA
The completed armature core assemblies are transferred~
from the buffer zone 36 to winding pallets and pass to a
winding area 37 (Fig. 20) which comprises a multiplicity
of "flow through" dual winders 38. The windlng pallets
enter a winder 38 with the armatures substantially
vertiaal and their commutator rings uppermost. An
overhead chuck descends and grips the armature which is
fed into the winding loop. The armature core assembly is
then wound with magnetic wire in the conventional manner.
Th2 wound armature is removed from the winding loop and
is returned to the conveyor 3' which is about 1 metre
higher than the input conveyor. ~ The ends of each wire
are wound~around respective tangs on the commutator ring
during the~winding operation.
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SHUTTLE S~ATIONS
Shuttle stations 71 and 72 are provided both upstream and
downstream of the winding area 37. Each shuttle station
71, 72 functions to transfer selected winding pallets
from one production highway to the other, the pallets so
transferred passing through gaps 4a in the dividing
partition 4. The selected pallets are pushed
transversely from one side of the partition to the other
by air cylinders, each pallet so transferred engaging
against a stop when the trans~er is completed.~ Endless
belt cross conveyors may be employed in place of the air
cylinders. Winding of the armature coils at the winders
38 is the slowest operation in the production line, and
for that reason multiple winders 38 are employed. Should
one of the dual production lines have a heavier winding~
load than the other, then a parcentage of the armatures~
on the production line ha~ing~this heavier winding load
can be transferred by the upstream shuttle 71 to the
;~ other production line and the coils of the transferred
armatures wound~ on one of the~ winders of the other
; production ~line.~ After winding, these transferred
a~natures are then returned to their original production
line by the downstream shuttle 72. The winder of~ the
other production line 80 used can be changed in winding
specification should this be necessary. Identification
inserts in the pallets are used to enable the conscripted
winder to identify transferred armatures, and also for
the downstream shuttle 72 to select these transferred
armatures for return to their original production line.
The upstr2am shuttle 71 can eelect the armatures to be
transferred on a numerical basis, e.q. every tenth
armakure. More than one winder 38 can be so conscripted
if production conditions or requirement would benefit
from thi~. For example, in an extre-ne situation when all
the winders for one production line ~ere inoperative,~or
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example by failure of a common drive, then temporarily
half the winders o~ the other production line could be
conscripted to keep both production lines operating, but
at a reduced rate.
Similar pairs of shuttle stations can be provided
upstream and downstream of any other operational stations
in the production lines to provide similar versatility of
production with these stations~
INSULATION REMOVAL STATION
l~ The winding pallets then pass to an insulation removal
station 39 (Fig. 20) where they are sensed and detained
individually to each side of the stationàry partition 4.
A mirror is placed immediately over the end of the
armature windings and the wound armature is rotated
through 360 degrees beneath a low power pulsed laser. As
the laser hits the insulated magnetic wire the insulation
vaporises leaving a cleanly stripped wire in the vicinity
of the tangs. A hood is provided to extract the fumes.
The mirror protects the ends of the armature windings.
CRIMPING STAn'ION
The winding pallets then pass to a crimping station 40
~Fig. 20) where they are sensed and detained individually
to each side of the stationary partition 4. A common
operating head descends and the tangs of each commutator
rlngs are then crimped to their respective uninsula~ed
wires by crimping tools which each comprise a plurality
of crimping heads which are electrically insulated from
one another. This enables the armature windings to be
electrically tested during the crimping operation.
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As an alternative to crimpingl the wires may be fused to
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16
their respective tangs. For this purpose the winding
pallet is correctly positioned. The wound armature is
then raised so that the c~mmutator ring is disposed
between two horizontally opposed weld heads. The wound
armature is then indexed and the weld heads activated to
fuse two wires to their respective tangs. The armature
is then reindexed and the process repeated until all the
wires have been fused to their respective tangs.
Finally, the armature is returned to its winding pallet.
SLOT LINING FINISHING - CUT AND TUCK
The wind~ng pallets then pass to a slot lining ~inishing
station 41 (Fiq. 2E~ where they are sensed and detained
individually to each side of the stationary partition 4.
A common operating head descends and the following
operations are performed on ea~h lining. As indicated in
Fig. 7, the slot liner 42 initially extends around the
entire peripheral surface of the armature.
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In the first stage a pair of ~aws 43, 44 descend and
~ever the slot line 42 at locations 45 and 46. The ends
of the 810t liner spring outwardly under their own
resiIience. The jaw 4~ then moves to the left and i5
biased towards the centre of the armature. The jaw 43
enters the opening 48 of the slot 49. As it moves from
its initial position the jAW 43 displaces the cut portion
of the ~lot liner 42 to the position shown in Fig. 8.
The ~aw 43 i then retracted and jaw 4~ is moved to the
right and biase~ into the opening 48 as shown in Fig. 9.
Jaw 44 is then retracted leaving slot 49 completely
lined. The armature is then indexed and the procedure
repeated for all the slots. ~t will be noted from Fig. 7
that a ~mall portion of the slot liner 42 lying between
jaw 43 and 44' (the position of jaw 44 after reindexing)
is not used. This is simply blown away and disposed of.
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~290~144L
TRICKLE STATIQN
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The winding pallets then pass to the trickle station 50
(Figs~ 2E and 10) where the wound armatures are removed
from the winding pallets which are returned to the
beginning of the winding area.
The wound armatures are moved outwardly to a pick and
place robot ~1 which orientates the armatures
horizontally. The armatures are presented to the
respective robot 51 two at a time as indicated in Fig.
2E. The robots 51 place the armatures in chucks on
conv~yor belts 52, as indicated by the arrows 51a.
Should either conveyor 52 be full, then the respective
robot 51 places the armatures in a buffer outside the
full conveyor 52, as indicated by ~he arrows 51b. The
robots~ 51 wil1 draw from these buffers when no armatures
are~béing supplied to the robots. ; At ~the end; of the
trickle station is a vertical cooling tower 56 (Fig. 2F).
~ter cooling, the armatures are transferred to walking
bQam c:onveyors 58. : ~
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~ The trickle station 50 and cooling tower 56 are~ further
il}ustrated diagrammatlcally 1n Fig. 10 which is a side
view taken from the left side of Figs. 2E and 2F.;~The
armatures, carried in chucks 52a, are first moved by the
conveyor 52 downwards and then through a preheating oven
53 in which they are preheated. Next they pass through
trickle zune 54 where drops of molten insulating resin
are trickled onto the armatures~ The res,in pe~neates the
~tructure by capillary action. Then the armatures~are
pas~ed by the conveyor 52 through a curing zone 55. ~he
armature are then transferred to a vertically extending
conveyor in the coo}ing tower 56. After being cooled,
the armatures are unloaded at location 57 onto the
walking beam conYeyor 58. ~ ~
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COMMUTATOR TURN
Returning to Fig. 2F, the armatures are next fed by the
conveyor 58 into a commutator turn station 60 where they
are rotated while a brush is applied to the commutator
5 ring.
FAN PLACEMENT
The armatures then pass to a fan placement station 61
~Fig. 2F) where they are sensed and detained individually
to each ~ide of the stationary partition 4. A common
operating head then places t~e fans on the armature
shaft~ on the respective lines.
The armatures are then transferred by a pick and place
unit 62 (Fig. 2F~ to a measuring station 63. The
armatures are then transferred to balance line pallets
which enter an elevator 64 (Fig. 2G). The balance line
pallets leaving elevator 64 enter a halancing station 65
(Fig. 2G). The balance is ~irst ohecked at station 66
and any corrective action written to a magnetic memory on
the balance line pallet. The armature then pa~ses to an
indexing station where the armature is indexed prior to
enterlng a milling station 67 where material is removed
~rom the circumference of the rotor. Finally, the
balance of the armature and the electrical connections
are tested at station 68 (Fig. 2G).
Reject units are marked and are automatically diverted to
the side at diverter station 69 (Fig. 2G). Where further
balancing is required the reject unit is returned -to
~tation 66 (Fig. 2G). Where there is an electrical
fault, the units can be checked manually and repaired
where practical.
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~29~)14~
The completed armatures are unloaded by robots at the end
(Fig. 2G) of the dual highway production line
apparatus, and the empty balance line pallets returned
for further use.
The arrangement thus far described has significant
advantages over the prior art. In particular, each
highway may be dedicated to the production of an armature
of a specific size or specification. However, many
operations may be carried out in unison on both
production lines using the same operating head.
Furthermore, considerable capital expenditure is saved in
the area o~ the trickle station where the cost of a large
single tricXle station servicing both production lines is
very much less than the cost of two separate trickle~
tatione as previously required.
Further, although each highway may be dediGated to a
speci~ic armature specification, when one highway is
working at a higher production rate than the other, some
of the armatures o~ the higher production rate highway
can be transferred to the lower production rate highway
for one or more operations to be performed, and then
returned to their ori~inal highway. In this way, the
overall production rate of the dual highway can be
increased when more of one specification of the~armature
is require than another specification. The same approach
is al~o used in stator assembly production as will be
describe~ later.
Where~r po6~ible, equipment ~or performing operations on
the armatures o~ both production lines should be placed
; 30 to one side o~ the dual highway, thereby maximising
operator access from the other side of the dual highway.
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While the arrangement thus far described has significant
advantages over the prior art in steady 6tate operation,
its main advantage comes when there is a ~sudden demand
for one or other of the two armatures. Normally the
bottlenec~ in any armature production line is the winding
area. If there is a sudden demand then this can only be
met within the capacity of the winding area. In the
arrangement described, when a high demand, for example
for 47mm armatures arises, a winder normally on the 57mm
production line i5 assigned for winding 47mm armatures.
When this winder is ready, a signal is sent to the
shuttle 71 which taXes armatures from the 47mm production
line until the queue to the winder is full. Thereafter
the queue is replenished to keep the winder queue full.
The winder recognises the 47mm armatures by virtue of
their identity inserts. Conse~uently, 57mm armatures are
not admitted to the winder queue. The wound 47mm
armatures pass down the 57mm production line until th y
approach the shuttle 72 where they are identified and
returned to the 47mm line.
Similarly, armatures can be shuttled from the 57mm
production line to the 47mm production line and back
again if required.
The production of stators according to the invention will
now be described.
DUAL H~G~RY STATOR PRODUCTION LINE
Referring to Figs. 12A to C, there is shown a dual
highway stator production line which is generally
ident$fied by reference numeral 101. The dual highway
30stator production line 101 comprises two conveyors 102
and 103 which are separated by a stationary partition
104. The conveyors 102 and 103 are driven at the same
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speed by separate and distinct variable speed motors ~not
shown).
ELEVATOR
Two elevators 105 and 106 ~Fig. 12A) are arranged to
raise stator assembly pallets to the level of conveyors
102 and 103 respectively. The elevators 105 and 106 are
similar to the elevators 5 and 6 in Figs. 2A and 3.
STATOR ASSEMBLY PALLETS
. .
Fig. 13 shows a stator assembly pallet which is generally
identified by referen~e numeral 108. The stator assembly
pallet is made of mild steel and compri~ses a base 1os
which is approximately 75mm wide and 75mm 1ong. The~top~
~: : of the base los is provided with two upwardly extending~
lamination locators 110 and lll~which~are~disposed::to:;:
either 6ide o~ a bore 112. The top of::the base~ lO9 is;~
~ also provided with four upwardly extend:ing wire:clips ~: :
; ~ 113a, b, c and d. One side of the base 109 is provided
with a:slot 114 which accommodates an identifying insert
115. : The bottom of the ~base is provided ~with a
ao positioning arrangement which comprises a vertically
extending bore 116. : ~ ~ :
:
BOTTOM END RING ~LACEME~T
The ~lr~t stage in making the stator i5 bottom end ring
placement which occurs at station 120 (Fig. 12A). As
each ~tator pallet on each conveyor 102, 103 enters the
: station 120 it is identified and held Past by a locator
: ~ pin entering vertically extending bore 116. A common
: : operating head moves into position and the bottom~end:
~: ~ rings are then placed over the ~respective holes 112~and
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the stator assembly pallets released.
STACKER STATION
The stator assembly pallets pass to a stacker station 124
(Fig. 12A) where they are sensed and detained in pairs to
each side of the stationary partition 104. A dispenser
125 is disposed to each side of the production line.
Each dispenser contains a plurality of stacks 126 of
stator laminations 127. The stator laminations are
loaded onto the stator assembly pallets in a manner
analogous to the operation of the stacker station on the
armature production line described hereinbefore.
SPLIT STACK STATION
The stator assembly pallets then enter a split st~c~
;~ ~ station 128 (Fig. 12A)~where the stacks are treated in~a~
~ manner similar to the armature laminations in `~the
armature split stack station 28 (Fig. 2A).; Fig. 14 is~a
plan view of the stator assembly pallet immediately after
this operation.
MEASURING STATION
:~ :
20 ~ The ~stator; assemb~ly pallets then pass to a measuring~
~tation 129 (Fig. 12A) where the height of each stack is
measured and, i~ necessary, one lamination removed by a
vacuum head.
SLOT LINER PLACEMENT
~`~ 25 The stator assembly pallets then pass to slot insulation
; placement stations 130 (Fig. 12A) where they are sensed
a~d detained. A placement head is lowered onto each
stack and injects the slot liners after the pallet has
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1290~44
23
been indexed into position.
OP END RING PLACEMEMT
:
The stator assembly pallets then pass to station 131
(~ig. 128) where they are ~ensed and detained in pairs to
each ~ide of the stationary partition 104. A common
operating head moves downwardly and ~places the top end
xing assemblies on the tops o~ the ætacks.
WINDING A~A
: The ~tator assembly pallet~ then pass to winding area 137
(FigO 12B~ where the field windings are applied in the
~anner ~et out in United States Patent No. 4,6:12,702
issued Septem~er 23, 1986 to the a~signee herein.
'
; Essentially, once each ~tator assembly pallet~i- in the
~winding position a pair of clamps descend to hold it
; ~irmly in place. A pair of ~.ollow needles: 138 (Fig. 153
conta$ning ~agnetic wire rise upwardly through the bore
112 in the ~tator ~ssembly pallet 109 and through the:
entre of the ~tack of~tator laminations. The needles
:~ ~ 20 138 pause at the:top o~ their travel while tooIing
6ecures the ends of the magne ic wire to wire clips 113a
: and 113b. ~he needles ~38, which are ~ccentrically
o~fset with respect to the longitudinal central axis of
the stator, then proceed ~o move upwards and downwards,
2S pivoting alt~rnately in a olockwise and ~n anti-clockwise
~ense at the end of each movement to create the field
winding~ without ~he employment oP temporarily positioned
winding forms. At the end of this process, the needles
138 ag~in pause at~the top of their travel while tooling
~ecures the other ~nd of the wires to the-reamining wire
clips:ll3c And 113d. : : : :
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24
COIL LEAD ASSEMBLY
The ~tator assembly pallets then pass to a coil lead
assembly ~tation 140 (Fig~ 12B~ where a tool grasps the
start and end lead portions of the magnetic wire, removes
them from the wire clips, loops them over strain reliefs
in the top end ring, and turns them around terminal hooks
thereon. Excess wire is then cut off and removed.
TERMINAL FUSE STATION
The ~tator assemblies on the 47mm production line then
pass to a station 141 (Fig. 12B) where the wires are
fused to the terminals. For this purpose the stator
assembly pallet is correctly positioned. The stator is
then raised so that the terminals are disposed between
two horizontally opposed weld heads~ The stator is then
indexed and the weld heads activated to fuse two wires to
their respective terminals. The armature is then
reindexed and the process repeated. Finally, the stator
is returned to its pallet.
CRIMPING STATION
The etator assembly pallets on the 57mm production line
pass into a crimping station 142 (Fig. 12B~ where the
terminals are crimped around the magnetic wires and a
aontlnuity aheck made.
BONDING STATION
The stator assembly pallets then pass into a bonding
station 143 (Fig. 12C) where the terminals are connected
to a source of electricity. As the windings heat they
melt an adhesive coating applied to the stator
laminations~ When the current is switched off the
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adhesive hardens thereby bonding the stator lami~ations
together.
TEST
Finally, the completed stator is tested at station 144
(Fig. 12C). The stators which pass the test are unloaded
by robots and the stator assembly pallets returned to the
start of the stator production line. A load leveler
storage maga~.ine 145 containing tested stators is shown
being loaded by a robot arm 146. Standby empty magazines
147 are al60 shown. When loaded, the storage magazines
are then transferred to a storage area.
SHUTTLE STATIONS
:
As with the armature production line, shut~les 171 and
1~2 (Fig. 12B) are provided immediately upstream and
downstream of the winding area 137 so that production o~
one type of stator can be increased a~ the expens~ of the
other. Thus, to increase the production of 57mm stators,
a wind~r on the 47mm production line may be allocated for
57mm winding duty. The winder has its own internal
queue. When the queue is not fuIl a signal is sent to
the shuttle 171 which transfPrs a palle~ ~rom the~57mm
production line, past the highway dividing partition 104
through a gap 104a therein, to the 47mm production line.
When the stator assembly pallet carrying the 57mm stator
body arrives, it is identified by its identity insert and
admitted to the aonscripted winder. When the wound
stator approaches the downstream shuttle 172, it is
recogniced and re~urned across the partition 104 through
a gap therein to the 57mm production line.
Although the shuttles~ have been placed upstream and
downstream of the winding areas they could additionally
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12910~4qL
26
or alternately be placed in other locations. The
shuttles i71 and 172 are the same as the shuttle 71 and
72 in the armature production line.
The armature and ~tator production lines described above
~ave an estimated 60 to 70% of the floor space occupied
by separa~e production lines used in the prior art.
Furthermore, labour can be reduced by between 25 and 50%
since one machine minder can watch the production of two
different armatures or two different stators
simultaneously.
BUFFER STORAGE
Referring to Fig. 16 there is shown a buffer storage
whi~h i~ generally identified by reference numeral 200.
The bu~fer StQrage 200 comprises a trolley 201 arranged
to run on rails 202. The trolley 201 is provided with
two platforms 203 and 204 which are arranged side by
side. The platform 203 is supported by two belts 205,
206, the longitudinal edges of which are providecl with
toothed strips 207, 208; 209 and 210 respectively. The
toothed strips 207, 208 pass over toothed wheels 211, 212
which are secured fast on a shaft 213. Similarly, the
toothed strips 209, 210 pass over toothed wheels 214, 215
which are secured fast on a parallel shaft 216. A gear
wheel 217 is mounted fast on the end o~ the shaft 2:L3 and
i8 connected to a gaar wheel 218, fast on shaft 216, by a
chain 219 which i5 arranged in the shape of a ~igure
ei~ht. The free end of the belt 205 is connected to ~he
~ase of the trolley 201 by means of a pair of wires 223,
224 vhich pass around puIleys 225, 226 and pulleys 227,
228 attached to springs 221 and 222. Similarly, the free
end 229 of the belt 206 is connected to the ~ase of the
trolley by means of a pair of wires 232, 233 which pass
around pulleys 234, 235 and pulleys 236, 237 attached to
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1290~.44
springs 234, 231. Platform 204 is supported by a
mechanism similar to platform 203. Both platforms 203
and 204 are scalloped as shown to receive a plurality of
armatures. The lengths o~ the support wires are adjusted
so that the platforms 203 and 204 are substantially level
with the top of the inset portion 201A of the trolley 201
when the trolley 201 is unladen.
In use, armatures are progressively loaded onto the
scalloped platforms 203, 204 and, as the weight of th~
load increases, so the respective platform lowers. By
the time the platform has one complete row of armatures
thereon, the platform has descended by an amount such
that the tops of the armatures thPreon are now
approximately level with the inset portion 201A of the
trolley 201. Another layer of armatures can then bs
placed on the first layer and so on until the buffer
storage 200 is full, each platform being loaded
independently. As armatures are removed from the buffer
storage 200, the respective platform 203, 204 rises, so
that at any given time an automatic pick and place unit
will have no difficulty in gripping in sequence the next
armature.
.
Spacers (not shown) are mounted at spaced~ vertical
intervals on the belts 205, 206 to facilitate placement
f armatures, bearing in mind that alternate rows are
o~fset from one another by one half the diameter of the
armature. The platPorm 203 is kept horizontal by the
ahain 219 which ensures that any rotation of toothed
wheels 214 and 215 is matched by~ an equal and opposite
rotation o~ toothed wheels 211 and 212. The springs 22~,
222, 230 and 231 are, of course, chosen to give the
de~ired load~extension ratlo required.
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28
The trolley arrangement shown in Fig. 17 is generally
similar to ~hat shown in Fig. 16, except that four pins
244 are mounted fast with respect to the base of the
trolley and extend through holes 245 in a platform. This
arrangement is primarily intended for the storage of
gears and the like which are stacked on the platform with
the pins extending upwardly through the centers of the
stacks.
Fig. 18 shows the buffer storage 200 of Fig. 16 in use in
an armature production line. In particular, the trolley
201 ls rolled into place on rails 202 beneath a robot
246. In steady state operation, the robot 246 simply
transfers armature core assemblies from armature assembly
pallets in line 247 to winding pallets in line 248. If
the winding line 248 is fully uccupied, the robot 246
transfers armature core assemblies ~rom the assembly
pallets in line 247 to the buffer storagë 200. For this
purpose the robot 246 has intelligent ~'X" and "Y" axls
movement and can consequently progressively load the
buffer storage 200. If the winding line becomes free
when no armature core assemblies are available on line
247, then the robot 246 takes an armature from the buf~er
6torage 200. The robot's memory may be programmed so
that it carries a complete inventory o~ the buffer
storage 200. By extending the travel of the robot 246,
single robot 246 may service three winding lines in
addition to a single armatura assembly line.
Tha bu~fer storage for gears shown in Fig. 17 can
similarly be incorporated in the armature production line
at a station for mountlng gears on the armature shafts.
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~290~4
The above described embodiments, of course, are not to be
construed as limiting the breadth of the present
inven~ion. Modifications, and other alternative construc-
tions, will be apparent which are within the ~pirit and
scope of the invention as defined in the appended claims.
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