MXPA96003524A - Systems, methods and apparatus for injecting groups of winding coils for injection stator in a nucleus of this - Google Patents

Abstract

The present invention relates to apparatus for injecting a plurality of groups of coils into the magnetic core of a dynamoelectric machine, each group of coils having one or more coils, the stator having a central hole and a plurality of teeth spaced around the orifice with a slot between adjacent teeth extending radially outwardly of the hole, said injection apparatus comprising a plurality of elongated sheets defining spaces, arranged in a circular form, said sheets being configured to have the groups of coils placed therein so that portions of each of the coils are located in spaces between adjacent sheets and segments of each of the coils extend through the interior of said arrangement of sheets, said apparatus further comprising an axially movable spacer assembly within said circular arrangement of sheets, said separating assembly comprising a first separation or, the first separator comprising a disk having an external diameter smaller than an internal diameter of the circular array, a first surface of said first separator configured to contact, at least, with a segment of at least one coil that is extends through an interior of the circular arrangement of leaves and to move axially, at least one coil, along said sheets without making contact with the portions of the coil in the spaces between said sheets.

Description

SYSTEMS METHODS AND APPARATUS FOR INJECTING GROUPS OF WINDING COILS FOR INJECTION STATOR IN A STATOR NUCLEUS Field of the Invention This invention relates generally to stators for dynamo-electric machines and, more particularly, to methods and apparatuses for injecting groups of winding coils for stators in the grooves of a magnetic core. BACKGROUND OF THE INVENTION The stator of a dynamo-electric machine such as an electric motor or generator, typically includes a core of magnetic material having an orifice extending axially to receive a rotor. The core is typically formed of a plurality of identical laminations that are aligned and arranged in a stack joined by fasteners. Each lamination includes a plurality of teeth that extend radially in the hole. The grooves between each of the teeth extend radially outward from the hole. The ends of the teeth and the open ends of the grooves define the periphery of the hole. A plurality of coils formed of insulated conductive wire are inserted into the selected core grooves with portions of the coils at the ends of the final coil regions. The coils are interconnected to form groups or poles of coils. The conductor wires forming the coils, sometimes referred to as the stator windings, are usually coated with a varnish or enamel so that a hard protective coating is formed, formed around each wire. The coating is required in such a way that each wire is well insulated from other wires. Improvements in, or reduction of damage to, said liner, facilitate improved engine performance, for example by reducing field faults. In order to insert the coils into the stator core grooves, it is known to form coil-shaped coil groups, locate the groups of coils in the coil insertion (or injection) tooling arrangement, and then change the groups of coils of the coil insertion tool, to a stator with portions thereof, located in the stator slots. The coil injection apparatus for inserting the coils into the stator slots is described, for example, in the U. U.A. Patent. No. 3, 949,464. The known tooling for said apparatus normally includes a base having a plurality of radially spaced and disposed blades extending from a top surface of the base. The blades are arranged in a circular arrangement. With known apparatuses, a "separator" having fins is placed inside the hole defined by the circular arrangement of the blades. The fins of the separator are aligned with and extend in the spaces between the adjacent blades. A fin of the separator extends in each of said spaces. The separator includes a top surface, or operative, configured to contact the segments of the coils that lie within the spaces between the adjacent blades and extend in the interior, or in the hole, established by the circular arrangement of blades. A lower surface of the separator is connected to a moving ram, or push rod, which extends through the base of the apparatus and moves the separator axially along the hole of the circular blade arrangement. The separator is usually constructed of a material such as bronze. A single-speed motor usually includes winding groups that establish at least one main winding and an auxiliary winding or start winding. The groups of coils are formed with a winding machine and located on the tooling of the coil insertion tool, in such a way that the coil groups are located in spaces between the blades at a location between the separator and the free ends of the coils. blades The portions of each coil extend through spaces between the blades and segments of each coil section, an inner region of the hole established by the circular arrangement of blades. A stator core is then aligned with, and placed on, the tooling of the coil injection apparatus or device such that at the open end of the circular arrangement of blades, each blade corresponds exactly to a stator tooth and to the stator tooth. this shape the spaces between the adjacent blades coincide with the openings in the stator groove. The driving rod then moves the separator into the circular arrangement of blades and from a retracted position towards the stator core. The fins of the separator are brought into contact with the portions of the coils that lie in the spaces between the adjacent blades. Also, the surface of the separator facing the core is brought into contact with the segments of the coils that extend along the inside of the circular arrangement of the blades. Once the separator is contacted with the coils as described above, and as the separator moves towards the stator core, the separator forces the coils to move along the blades towards the stator core. As the separator begins to move through the hole in the stator core, each flap of the separator that contacts a coil portion in the knife spaces, said coil portion forces respective aligned stator grooves. When the upper surface of the separator has been completely moved through the stator hole, each of said coil portions is completely injected into the stator core grooves. The separator is then retracted to a retracted position and the core of the "injected" stator is removed from the insertion device.

When two coil groups are injected, e.g. , groups of main and auxiliary coils (or start), in a stator core, at least a portion of, at least, the group of lower coils on the blades, directly contact the fins of the separator . Normally, some portions of the uppermost coil group are also in direct contact with some of the fins. During the injection process, the fins of the separator exert sufficient forces against said portions of coils to move the coils axially along the blades and to inject lateral portions of rotation thereof into the slots of the stator. Said forces are generally of sufficient magnitude not only to move the coils along the blades and inside the stator slots, but they are also sufficient to cause the tension and abrasion of the magnetic wire forming the coils. Sometimes, these deformations are called pressure marks. Particularly, pressure markings are problematic since over time, as the wire insulation wears, the insulation may fail and the conductive material may be exposed. Such exposure can lead to an engine field failure. Also, if the magnetic wire is deformed or sufficiently stressed, the operational efficiency for the motor can be reduced, for example, due to the increased resistance of the magnetic wire and possibly also to the short circuit of the wire.

With respect to known separators, said separators are generally constructed of a soft metal such as bronze in an attempt to limit damage to the insulation and pressure markings on the coils, caused during the coil injection process. The manufacture of bronze dividers, of course, is expensive in terms of both material and labor. In addition, the bronze fins of the separator, usually must be polished at regular intervals to remove notches and avoid sharp edges that penetrate the insulation. Of course, the polishing of said separators is time consuming and expensive. In addition, the fins of a separator are susceptible to damage if, for example, the separator is dropped. If a separator falls, a fin may flake or even break. Said damaged separator may have to be discarded. In addition, with known spacers, as the number of windings forming the groups of coils being injected increases, the probability of joining, or "hooking" of coils, increases. Also, the windings that form the coils can be bent during the injection process, or they can be caught between the separator and one or more of the circular blade arrangements. When this occurs, the separator can be enclosed and the axial movement of the separator can be avoided. U seally, the opportunity to enclose it is reduced by limiting the number of coils, injected in one step, of the separator through the rotor hole. Therefore, with this technique the likelihood of a closing condition with known separators can be reduced. When the separator and the one-step process described above are used, for injecting three or more coil groups into a stator core, the forces exerted by the separator against the coil wires are very high. As a result, the coil wires can be significantly damaged. In addition, although it is highly desirable in some motor applications, eg. , when the inductive reactance effect is significant, have the set of initial winding coils as close as possible to the stator hole to facilitate the magnetic coupling between the fields generated by the initial winding and the rotor, the winding coil wire Initial and isolation usually can not withstand the direct high forces, which must be exerted against the initial winding by the fins of the separator in said one-step injection process. For exampleThe initial winding wire and insulation is usually much thinner than the main winding and insulation wire. Therefore, the initial coils could preferably be located in an injection device in such a way that the fins of the separator do not contact directly with said coils, that is, the separator next to the coils that are in contact with each other. direct with the separator fins, could preferably be main winding coils. As a result, the initial winding coils, usually, after being placed in the slots of the stator core, are located either at a distance remote from the bore, ie at the ends of nearby slots, or at an intermediate slot location between two main windings. To avoid the formation of excessive pressure marks, and reduce the possibility of a closing condition when three or more groups of coils are injected into a stator core, a two step injection process is normally used. For example, a first group of main coils and a group of auxiliary coils are injected into the stator core in a first step. A second group of main coils is then injected into the stator core in a second step. Said two-step, coil injection process allows the use of lower forces compared to the magnitude of forces required for a one-step injection of three groups of coils, using known separators. Although lower forces are used in the two-step injection process, said lower forces are still sufficient to create pressure marks on coil wires. Of course, even higher forces would have to be used to inject three groups of coils in one step, and said higher forces seem to inevitably cause unacceptable damage to the coil wires.

Although a two-step process is effective in reducing damage to coil wires, such a two-step process is more labor-intensive and time-consuming than the known one-step processes used for single-engine motors. speed . By reducing manpower and the time required to inject more than two groups of coils into stator cores, the manufacturing costs for such stators could be reduced. Known attempts have been made to carry out the injection of coils in a step of three or more groups of coils with separators of complex shape. However, the forces needed to inject the coils using known spacers of complex shape are thought to be high, which, as explained a, can result in the fins of the separator forming pressure marks on coil wires. Also, it is thought that separators of complex shape are expensive both in manufacturing and in maintenance. Another known attempt in such a one-step injection has used a structure in which two bronze spacers were stacked, one on top of the other, within the circular arrangement of blades. A post separated the separators. The lower separator used a 4-point star, which, as described below, separated the main coil group and the initial coil group to reduce the forces exerted by the initial coil wires against the initial coil wires during the injection process. However, with this approach, it is thought that the forces necessary to inject the coils with said structure could be undesirably high. Also, two bronze spacers must be manufactured and maintained. As explained a, the manuffacture and maintenance of said brass spacers are expensive.

When a two-part device is used, the groups of initial and main winding coils are first loaded onto the lowermost spacer previously placed. The upper separator is then inserted into the hole of the circular array of blades, the fins of the separator extending into the spaces between the adjacent blades, and lowered to rest on the pole extending upwardly of the lower separator. The coils of the second group of main coils are then loaded into the knife spaces a the fins of the upper separator. Although it is convenient to completely automate the coil injection process, the known automation equipment can not operate consistently within the small dimension tolerances required to align fins of the separator with the spaces between the adjacent fins. Therefore, when a two spacer process is used, a human operator must perform the task of aligning the upper spacer so that each fin of the spacer extends in a space between the adjacent knives and initially placing the upper spacer in the tooling. Of course, any of these functions performed by humans, inevitably increases the costs of the process and slow down the process. Consequently, it may be desirable and advantageous to provide equipment for coloring, in one passage, coils in a stator core of a multiple speed motor, and providing a separator which exerts, against the coil wires, forces less than the forces exerted by the motor. known separators. It could also be desirable and advantageous to provide said separator which is of lower cost, both for manufacturing and maintenance, and which eliminates the need for a human operator to orient the separator within the circular arrangement of blades of the injection device during the manufacturing process. An object of the present invention is to provide a separator to place, in one step, winding coils on a stator for a multi-speed motor. Another objective of the present invention is to provide a separator that is of lower cost and does not have significant requirements or costs for its maintenance. Still another object of the invention is to provide a separator that injects the winding coils into a stator core for a multi-speed motor exerting significantly lower forces against the coil wires, compared to the forces exerted against the coil wires by means of spacers. known. Still another object of the present invention is to provide an improved separator and process that facilitates the complete automation of magnetic wire coil injection processes.

Summary of the Invention These and other objectives can be obtained with methods and apparatus for injecting, in a step, groups of multiple coils, into the stator slots of a stator core. In one embodiment, the apparatus may include a first spacer without fins that damage the wire, an example of which is a nylon injection disk. A fastening member, which may also be constructed of nylon, extends from and perpendicular to the core that looks, or is operative, toward the flat surface of the injection disk. The clamping member includes a post and a handle. A weight extends from a lower flat surface of the injection disk. The weight preferably has a frusto-conical configuration and may be constructed of a fully dense material such as cold rolled steel. The length of the weight member may vary. In some applications, said depth can be selected to be the same as the height of the column of a next stator winding group to be injected into a stator core by a second lower separator. The first separator can be used in connection with known separators and injection devices in many different configurations. For example, in a combination, the first separator can be stacked on a second separator. The second separator, for example, can be a separator such as the separator described in the U.S. Patent. No. 3, 845,548, which is assigned to the present assignee. More particularly, the second separator can have a disk-like configuration with fins formed on its outer periphery and sized to fit in the spaces between the adjacent blades of the injection tool. A push rod is connected to a lower surface of the second separator. In one form of operation, and in a particular injection process for injecting an auxiliary, or initial, four-pole winding, a four-pole main winding, and a six-pole main winding, the second separator is initially retracted within the tooling of injection. Preferably a four-cornered star is located on the operating face of the second separator. An auxiliary winding group can then be loaded onto the blades or tooling in such a way that the segments of the auxiliary coils extending through the interior of the circular arrangement of the blades also extend the face or operating surface of the second separator. The coils of the six-pole main winding group can then be loaded onto the tooling. The lateral coils of the coils of the six-pole main winding group are angularly and axially displaced from the lateral coils of the coils of the auxiliary coil group in such a way that at least some of the coils occupy different spaces of blades .

After the group of auxiliary coils and the group of six-pole main coils are loaded on the circular arrangement of blades as described above, the first separator will be changed to the internal tooling such that a central axis of the separator is substantially coaxial with the axis of the hole, and in such a way that the lower surface of the weight member rests on the second separator. The working disk of the first separator will be axially separated from the coils of the auxiliary coil group and the six-pole main coil group. The main group of four-pole coils will then be loaded onto the tooling above the first separator. After the groups of coils have been loaded into the injection tool, the tooling and the stator core are relatively aligned so that each tooling blade coincides with a stator tooth. The driving rod then exerts a force directly against the second separator and forces both the first and second spacers towards the stator core. As the first separator moves axially through the stator hole, the segments of four-pole coils are forced into the stator slots aligned with the spaces in which the segments were originally confined. The first separator is pushed completely through the stator hole so that the group of four-pole coils is completely injected into the stator slots.

The wire segments of the four-pole coils trapped in the spaces between adjacent blades are not coupled by any wire or insulation damaging the fins of the separator during the injection process. As the first separator is pushed through the tooling, the four-cornered star follows and contacts the segments of the six-pole main coil group located within the tooling hole, and the next surface of the second separator is contacts the segments of the auxiliary coil group located inside the tooling hole. The separator fins of the first separator are also contacted with, and push the wire segments of the six pole coil group and the auxiliary coil group, which are trapped in the spaces between the adjacent tooling blades. The second separator and star move the auxiliary coil group and the six pole main coil group to the stator core and in the stator slots and the star and the second separator move towards the stator hole. As a result of the operations described above, the group of four-pole main coils is placed within the stator slots at a location farther from the stator hole, i.e., adjacent to the closed ends of the stator holes. The group of auxiliary winding coils is positioned radially within the slots at a location closer to, or adjacent to, the slot openings in the stator hole. The group of six-pole main coils is positioned radially in a radial location of intermediate slots between the outer four-pole main coil group and the internal auxiliary coil group. An injection process, as described above, is a one-step coil injection process, for injecting, for example, multiple groups of coils into a stator core for a multi-speed motor. This can be done using significantly lower forces. As a result, it is thought that the number and degree of pressure markings formed on the coil wires is significantly reduced. Also, since the first spacer has no fins, it is thought that the possibility of wires enclosing the tooling spaces is significantly reduced. In addition, the group of auxiliary coils can withstand the direct forces exerted by the second separator, including the fins of the second separator, without being significantly damaged because the insertion forces associated with the first separator are not transmitted through the wire in the groups of auxiliary coils. Therefore, the magnitude of said forces is sufficiently low such that the relatively thin auxiliary coil wires and insulation are not significantly damaged by direct contact with the fins of the separator. Using said lower forces, the groups of auxiliary coils can be placed adjacent to the stator hole, which in turn, provides operational advantages as explained above. In embodiments in which the first separator comprises an injection disk made of nylon, the first separator is relatively inexpensive to manufacture compared to the manufacturing cost associated with known bronze separators. Also when the coil contact portion of the first separator is an injection disk formed of nylon, the maintenance costs for said separator are greatly reduced. Also, it seems that a nylon injection disk is actually rougher than known bronze fin dividers. Furthermore, it will be appreciated by those skilled in the art, that since the first spacer can be placed within the circular arrangement of blades literally with any angular orientation relative to the tooling, an automated robot arm can be used, to place the first separator inside the tooling. As explained above, said automated handling is not thought to be possible with known separators having fins.

Brief Description of the Drawings Figures 1 A and 1 B are perspective and plan views, respectively, of a known separator and a four-cornered star, known, and Figure 1 C, is a perspective view of a section of a stator orifice. . Figures 2A and 2B are plan perspective views, respectively, of the separator shown in Figures 1A and 1B, with a six-pointed star, known. Figure 3 is a perspective view of a mode of a separator useful for carrying out my invention in a preferred form. Figure 4 is an elevation, with parts removed and separated, of the coil injection apparatus, which modalizes aspects of the invention. Figure 5 is a schematic representation of engine parts and windings, and includes a retracted retractor with a four-cornered star, and three groups of coils. Figure 6 is a view similar to Figure 5, but of a separator in which the star has been omitted. Figure 7 is a description of the block diagram of an automatic coil injection system for injecting injection stator coils into the stator cores for multi-speed motors. Figures 8A and 8B are force-distance diagrams for a known injection process and for an injection process using the arrangement illustrated in Figure 5. Figure 9 is a perspective view of an alternative embodiment of a separator .

Figure 10 is a perspective view of an engine stator including a stator core and coils.

Detailed description Figure 1 A is a perspective view of a known spacer 20 having a known four-pointed star 22 secured therein by a bolt 24. The spacer 20 has a generally circular configuration with fins 26 formed therein. external periphery. A first or operative surface 28 of the separator 20, and a first or operative surface 30 of the star 22, is brought into contact with the stator windings placed on the blades of the injection tool (not shown) during a process of injection. The fins 26 extend in the spaces between adjacent blades of the circular arrangement of the blades of the injection device not shown. As best seen in Figure 1 B, the concave portions 32 of the star 22 define regions of the surface 28 of the separator 20, which makes direct contact with a first group of coils during the injection process. The first surface 30 of the star 22 is brought into contact with the portions of a second group of coils during the injection process. When the separator 20 and the star 22 are used to inject a group of four-pole main winding coils, and a group of four-pole initial winding coils into a stator core, the separator 20 and the star 22, are located initially in a retracted position in the lower part of the circular arrangement of the injection tool blades, as suggested in Figure 4. The groups of coils, are produced with winding equipment, and placed on the blades of insertion equipment of coils, such that the windings of the coil groups are located on blades at a location axially above the separator 20, and the star 22 (as suggested in Figures 5 and 6). Normally, the lowermost group of coils is the four-pole star coil group, and the uppermost coil group is the four-pole main coil group. The portions for each coil extend through the spaces between the blades and the segments of each coil that extends or unfolds through an interior region of the circular arrangement of blades that form the coil injection tool. A stator core (see Figure 10) is then aligned with, and placed on, the injection tool in such a way that each blade coincides with a stator tooth and the spaces between the adjacent blades coincide with the stator slots between the adjacent teeth of the stator, in order to inject the coils, a driving rod moves the separator 20 and the star 22 in a direction to push the lateral spirals of the groups of coils into the stator slots.

The fins 26 of the separator 20 are provided to contact the side scroll portions of the coils of the coil groups, which lie in the spaces between adjacent blades. Also, the regions of the separator surface 28, defined by concave portions 32, of the star 22, are brought into contact with the segments of the coils of the initial coil group, which lie within the inner part of the circular arrangement of the coils. The blades The first surface 30 of the star 22 is brought into contact with the segments of the coils of the main group of coils, which lies on the inside of the circular arrangement of the blades. When the separator 20 and the star 22 come into contact with the coils described above, and as the separator and the star continue to move, the separator and the star force the coils to move along the knife spaces towards the Stator core. As the separator 20 begins to move through the stator hole of the stator core, the fins 26 of the spacer 22 continue to contact the coil portions in the knife spaces and force said portions of coils into the slots of the stator. stator When the coil portions are injected completely into the stator core, the separator 20 and the star 22 are retracted and the "loaded" or "wound" stator core is removed from the tooling. Figure 1 C illustrates a stator core 34 having portions of magnetic wires 36A, 36B and 36C injected into slots 38A, 38B, and 38C, respectively. The pressure markings, such as the markings generally indicated at 40A, 40B and 40C, are thought to be formed in or laid on the magnetic wires 36A, 36B and 36C by the fins 26 of the spacer 20. Of course, it should be understood that Different operating conditions and separators can create pressure marks having other appearances. Figure 2A is a perspective view of the separator 20 having a six-pointed star 42, secured thereto by a bolt 44. The six-pointed star 42 includes a first surface 46, which is brought into contact with the segments of a coil group during the coil injection process. Figure 2B is a top plan view of the separator 20 and the star 34 of six peaks. As best shown in Figure 2 B, the six-pointed star 42 includes the concave portions 48. The concave potions 48 define areas of first surface 28 of the separator 20 that makes direct contact with a coil group during the injection process. of coil The four-cornered star 22 illustrated in Figures 1 A and 1 B is used when a group of coils having four coils is the last group that will be injected, in one step, into the stator slots. On the other hand, the star 38 of six peaks, is used when the last group of coils that will be injected, by separator 20, has six coils.

The separator 20 with the star 22 or 34, has been widely used by the injection coils in stator cores for single-speed motors. Normally, and as explained above, two groups of coils are injected in one step, using the separator 20 and the star 22 of four peaks or the star 42 of six peaks. Although the pressure markings appear to be invariably formed on the wires of the coil groups during said injection, the number and degree of said pressure markings and the damage to the wire associated therewith, are usually within acceptable limits. Attempts have been made to use the spacer 20 and the star 22 to inject, in one step, three or more groups of coils into a stator core for a multi-speed motor. However, the forces required to inject such groups of coils into the stator slots are extremely high and result in unacceptable damage to the windings. As a result, a two step injection process, as described above, is normally used for the injection of more than two groups of coils. The separator 50 shown in Figure 3 overcomes many disadvantages and drawbacks of known separators, particularly with respect to the one-step injection of more than two groups of coils into the stator slots of a stator core. The separator 50 includes an injection disk 52 having a first operating surface 54, defining a shoulder 55 of the curved Injection, around its outer perimeter. A handle 56 extends from the surface 54 and includes a post 58 and a clamping member 60. A weight member 62 extends from a second surface 64 of the disc 52. The weight member 62 can have many geometric shapes but can it shows generally with a frusto-conical configuration. The disc 52, and the handle 56, can be constructed of any suitable material, such as, for example, plastic, bronze, wood, metal, etc. The disc 52, preferably, although perhaps not necessarily, is formed of a material that is softer than the isolation of the magnetic wire that will be injected by the disc 52. In the preferred embodiment, the disc 52 and the handle 56 are formed of nylon and machined using a lathe. The disc 52 and handle 56, alternatively, could be formed using a molding process. The weight member 62 can have many other shapes and can be constructed of various materials. In the preferred embodiment, the weight member 62 is formed of cold rolled steel. The handle 56 and the weight member 62 are attached to the disc 52 by a bolt 66, which extends through aligned openings in the handle 56, the disc 52, and the weight member 62. Alternatively, it could be used an adhesive to form a bond. In Figure 4, an injection device 68 is illustrated, with some parts separated. The device 68 includes a lower housing member 70. The coil injection tooling in the form of elongated blades 72 extends from the upper part 74 of the housing 70. The blades 72 are formed in a circular arrangement. Spaces 76 are defined between adjacent blades 72. Additional details with respect to device 68 are set forth, for example, in the U.S. Patent. No. 3, 949,464, the entire description of which is incorporated herein by reference. In Figure 4, some blades 72 are removed in order to better illustrate a spacer assembly 78. Also, in Figure 4, groups of coils are not shown. The spacer assembly 78 includes the first spacer 50.

In the preferred embodiment, the space or tolerance between the outer periphery of the disk 54 of the first separator 50 and the periphery of the circular arrangement of the blades 72, preferably is not more than about half the diameter of the wire with smaller diameter, which will be injected by the first separator 50. The separator assembly 78, includes a four-peaked star 80, and a second separator 82. The four-peaked star 80, and the second separator 82, are identical to the separator 20 and the star 22 illustrated in Figs. 1 A and 1 B. It will be appreciated that the second spacer 82 includes fins 84 extending in spaces 76 between adjacent blades 72. The second separator 82 also includes a first operative surface 86. The star 80 and the second separator 82 are secured to one another by the bolt 88. A second lower surface 90 of the weight member 62 rests on the star 80. A spacer (not shown) could be positioned between the star 80 and the weight member 62. A fastener 92, shown in dotted lines, forms part of an automated spike and positioning machine (not shown). The fastener 92 includes first and second arms 94A and 94B, respectively. The arms 94A and 94B are configured to hold the handle gripping member 60, as described above in greater detail. Figure 5 is useful to explain the process of injecting coil groups with the coil assembly 78, and the device 68, and shows the first, second and third coil groups 96, 98 and 100, loaded on the blades 72 of the device 68. The first group of coils 96 is positioned adjacent to the first surface 54 of the first separator 50. The second group of coils 98 is positioned adjacent to the first surface 102 of the four-peaked star 80. The third group of coils 100, is positioned adjacent to the regions of the first surface 86 of the second separator 82 defined by the concave portions 104 of the star 80. The first group of coils 96, may have four main winding coils, the second group of coils 98, it may have six main winding coils, and the third group of coils 100, may have four initial or auxiliary winding coils. It will be understood by those skilled in the art, and observing Figure 5, that the third group of coils 100 is first loaded on the blades 72 in such a way that the segments of the coils of the third group 100, are extended or deployed through the inner of the circular arrangement of the blades 72. Said segments are also either wrapped in, or aligned for, the contact with the upper or operative surface 86, of the second separator 82. The second group of coils 98, is then loaded into the blades 72. The coils of the second group 98, are displaced angularly and axially from the coils of the third group 100. Normally, the spaces of the blades occupied by the third group of coils 100, are not occupied by the second (or first) groups of coils 98 (or 96) and vice versa. The segments of the coils of the second group 98, extend or deploy through the interior of the circular arrangement of the blades 72. Said segments are also aligned for contact with the upper surface 102 of the star 80. After the third group of coils 100 and the second group of coils 98 are loaded in the circular arrangement of the blades 72 as described above, the first separator 50 is lowered in the circular arrangement of the blades 72 in such a way that the vertical axis of the disk Nylon injection 52 is substantially coaxial with the vertical axis of the circular arrangement of the blades 72. The weight member 62 of the first separator 50 rests on the upper surface 102 of the four-peaked star 80. The injection disk 52 of the first separator 50, is axially above the coils of the coil groups 98 and 100. The first group of coils 96, is then loaded on the free ends of the blades 72. In order to inject coil groups 96, 98 and 100. , in the stator core (not shown), a core of the stator is aligned with the injection device 68 such that each blade 72 coincides with a stator tooth, and the spaces 76 coincide with the stator slots. A pushrod (not shown) extends through the housing member 70, and engages the second spacer 82, and forces the spacer assembly 78 in one direction to place the group of spools 96 on the stator core. As the spacer 50 moves axially within the blades 72, the shoulder 55 and the surface 54 of the disc 52 come into contact with the segments of the first group 96 of coils, which extend and unfold through the interior of the circular arrangement of the blades 72. The injection disk 50 forces the first group of coils 96 to move along the lengths of the blades 72 towards the stator core. The injection disk 52 does not physically contact those portions of the coils of the first group of coils 96 that lie in the spaces 76 of the adjacent blades 72. As the injection disk 52 moves through the rotor orifice of the stator core, the coil portions of the first group of coils 96, in the spaces 76, are forced into the respective aligned stator slots. The injection disk 52, of the first separator 50, is pushed completely through the hole of the stator in such a way that the first group of coils 96 is injected completely into the stator slots. As the first separator 50 moves along the arrangement of the blades 72, as described above, the four-cornered star 80 and second separator 82 also move along the blades. The four-cornered star 80 moves the segments of the second group of coils 98 and the upper surface 86 of the second separator 82 moves the segments of the third group of coils 100. The fins 84 of the second separator 82 are brought into contact with and move the portions of the second and third groups of coils 98 and 100, which lie in the spaces 76. The second separator 82 and the star 80, cause the second and third groups of coils 98 and 100, to move axially along the blades 72 towards the stator core. The second and third groups 98 and 100 are injected into the stator slots as the star 80 and second separator 82 move through the rotor orifice. As a result of the injection operation described above, the first group of main coils 96 is placed on the stator core, within the stator grooves at a radial location farther from the rotor bore, ie at the bottom or closed end of the stator slot. The third group of coils 100 will be placed within the stator slots at the location radially closest to, or adjacent to, the stator hole. The second group of coils 98 is positioned within the stator slots at an intermediate location between the first group of main coils 96 and the third group of coils 100. The injection process of the one-stage coil group, described above, it can be carried out using significantly lower forces, at least, compared to the forces required with a particular known injection separator assembly. Due to said lower forces, the number and degree of pressure markings formed on the coil wires due to the fins 84 can be significantly reduced. Also, since the injection disk 52 has no fin, not only pressure marks are virtually eliminated, but also the possibility of closing between the injection disk 52 and the coils of the first group of main coils 96 are thought to be eliminated. injected by said disks 52, it is significantly reduced, if not eliminated entirely. It is also a somewhat surprising and unexpected advantage, since significantly lower forces are used. The advantage is that the third group of coils 100 can be the group of initial winding coils since the risk of damaging the wires has been overcome, caused by excessive injection forces. Particularly, as described above, the third group of coils 100 is placed within the stator slots at a radial location closer to, or adjacent to, the stator hole. The placement of the initial winding coils adjacent to the rotor orifice provides certain operational advantages as discussed above. Since only lower forces are required to inject said groups of coils, the wire and insulation formed by the initial winding coils can withstand the direct forces exerted during the injection in a single step by the second separator 82, including the second fins of the coil. separator 84, without being significantly damaged. Further, when the injection disk 52 is constructed of nylon, the disk 52 is relatively inexpensive to manufacture compared to the manufacturing cost associated with known brass spacers. Also, the maintenance costs for said injection disk 52 are reduced, and a nylon injection disk unexpectedly appears to have longer and rougher life compared to the bronze separator 20 having fins 26. Of course, the star 80 it does not necessarily have to be used in relation to the separator assembly 78. For example, the six-pointed star 34, illustrated in Figures 2A and B, could be used in place of the four-cornered star 80. Also, as shown in Figure 6, no star could be used. Figure 6 illustrates a coil injection assembly 104, which includes the first separator 50, and the second separator 82. Compared to the assembly 78 illustrated in Figure 5, in the assembly 104, the star 80 of four has been removed peaks A spacer (not shown) can be placed between the weight member 62 and the spacer 82. With the assembly 104, the second spool group 98 rests on the third group 100 of the spools, instead of being separated from the spool. third group of coils 100 by the star 80. This configuration can be used in some injection processes where it is acceptable to have the third group of coils 100 exerting some additional forces against the second group of coils 98 during the coil injection process. With the different configurations discussed above, since the first spacer 50 can be placed in an angular orientation within the bore defined by the circular arrangement of the knives 72, an automated robotic arm can be used to place the first spacer 50 within the orifice. As explained above, and with the known spacers having fins, it is not thought that such automated placement will be possible later on. However, the first spacer 50 has no fins and does not have to be oriented within the circular arrangement of blades in any particular angular orientation. Therefore, the use of the first separator 50 allows the complete automation of a coil injection process using double separators, even when more than two coils are injected into a stator core. Figure 7 illustrates one embodiment of an automated coil injection system in the form of a block diagram. The system 150 includes a first conveyor 152 which extends between a first pallet 154 for stator cores (not shown) and a second pallet 156 for storing "loaded" or "winding" stator cores subsequent to the coil injection. The laminations forming the core are compressed in a core compression station 158, to ensure that there are no gaps between the laminations forming said cores. A station 160 is provided to review and reject the kernel, in order to make sure that the grooves and teeth of each core are properly aligned. The core insulation is loaded in the stator slots in a groove insulation injection station 62. The insulation is then checked at a station 164 for revision and rejection of slot insulation. The coils are injected into the stator core in a coil injection station 166. Once the coil groups are injected into the core, the core of the "loaded" stator travels along the conveyor 152 to a second vane 156. , wherein the "loaded" stator cores are removed from the conveyor 152 on a second pallet 156. A closed loop conveyor 168 is provided to supply injection devices to the station 166. The conveyor 168 operates to move injection devices in one direction generally in a clockwise direction. The winding stations 170A-D are located at separate locations along the closed loop conveyor 168. A wedge former 172 is also provided along the closed loop conveyor 168, just before the injection station 166. Winding stations 170A-D and wedge former 172 are well known in the art and are commercially available, for example, from "Advance Machine and Tool Corp.", Fort Wayne, Indiana and "Statomat Special Machines Inc." , Cahrlotte, North Carolina. A guide channel 174 extends from injection station 166 to a location between winding stations 170C and 170 D. Channel 174 has a substantially u-shaped cross-sectional configuration with the open end of the channel 174 looking up. The "pick and place" machines (not shown), which are well known, are located at both ends of the channel 172 of the separator guide. With respect to the processes for loading the injection device 68, with the groups of coils, and with initial reference for the injection station 166, a tool 68 travels on the closed loop conveyor 168, for the first winding station 170A of coils The second separator 80 is contained within the lower section of the circular arrangement of the blades 72. However, the first separator 50 is located in the channel 174 between the winding stations 170C and 170D. The first group of coils 100 is formed in the winding station 170A and loaded in the blades 72 of the injection tool. The injection device 68 then travels on the conveyor 168 to the winding stations 170B or 170C. The second groups of coils 98, are formed in stations 170B or 170C, and are loaded on the blades 72 of the coil injection device, but axially above the second separator 82. Both stations 170B and 170C, are used to form seconds. coil groups in order to reduce the overall time required to load a series of injection devices 68. After the second group of coils 98 has been loaded on the blades 72, the separator 50 is loaded on the tooling. More specifically, a conventional pick-and-place machine (not shown), first picks up the separator 50 from the separator guide channel 174 and places the separator 50 inside the blades 72, on top of the second separator 82, as described above. The weight member 62 helps assure that the spacer 50 will vertically depend on the clip to pick up and place, and, in effect, "falls" into the tooling. The length of the weight number 62 is at least equal to the height of the column of the second and third groups 98 and 100 of coils, such that the injection disk 52 is axially above said groups of coils. For ease of use, make sure that the disc 52 is axially above the coil groups, as described above, and before loading the separator 50 in the tooling, the second and third groups of coils 98 and 100, can be compressed in the second separator 82, in a compressor station (not shown). For example, the compressor station may include a compression disc having a diameter smaller than the diameter of the hole defined by the circular arrangement of the blades 72. The compression disc may be inserted, and the compression station, within the tool hole, and presses the second and third coil groups axially downward to the second separator 82. The compression disc, can then be removed from the hole, and the injection device 68, is now ready to be loaded on the same the separator 50, as described above. The injection device 68, then proceeds, on the conveyor 168, to the winding station 170D, where the first group of coils 96, is loaded on the blades 72 and axially above the coil injection disk 52, of the first 50. The injection device 68 then moves on the conveyor 168 towards the wedge former 172, where the groove-tight sealing wedges are loaded on the device 68. The injection device 68 then travels on the conveyor 168 to the injection station 166. In the injection station 166, the injection device 68 is aligned with a stator core, and the groups of coils 96, 98 and 100, are injected into the stator core in the way as described above. Once the coils are injected completely into the stator core, the handle of a first separator protrudes above the top of the stator core, from which a pick-and-place machine (not shown), holds the handle of the first separator 50 and removes the first separator 50 from the stator and the injection device 60. The first separator 50, is then placed by the pick-and-place machine, in the guide channel of the separator 174, and the first separator 50 slides towards down the guide channel 174, at the end of the channel 174 between the stations 170C and 170D, conveniently placed in another group of injection tooling. Specifically with respect to the forces required to inject the groups of coils into a stator core, Figures 8A and 8B are force-distance plots that illustrate the forces exerted by the push rod when injecting coil groups with a known separation assembly and with the separation assembly 78 (Figure 4), respectively. Particularly, Figure 8A illustrates the forces exerted by the driving rod to move a separator assembly having a spacer 20 and four-pointed stars 22 as shown in Figure 1 A. The configuration was as follows: the separator 20, the group of four-pole initial coils, the four-pointed star 22, the six-pole main coil group, the first 50 separator, and the four-pole main coil group, as shown in Figure 8B, the magnitude of the The force required to inject the groups of coils into the core of the stator has a maximum at less than 317.8 kg. This is less than 20 percent as much as, at least five times less than the force of maximum magnitude required to inject the coil groups configured identically using the known spacer assembly referenced in relation to Figure 8A. Said reduction in force is particularly significant with respect to the injection capacity in one step of more than two groups of coils in a stator core. In addition, such reduction in force can reduce the number and degree of pressure marks formed on the coil wires. As explained before, by reducing the number and degree of said pressure marks, the probability of field failures is reduced. Figure 9 illustrates an alternative mode of a separator 200. For example, the spacer 200 could be used in a set 78 instead of the second spacer 82 and the star 80. The spacer 200 could also be used by itself to inject one, two or even more sets of spools into a core of stator The separator 200 includes an injection disk 202, and a generally cylindrical portion 204. The disk 202 is secured to the portion 204 by the bolts 206A-C. The fins 208 are formed in the inferred section of the cylindrical portion 204. The fins 208 are substantially reduced in axial length compared to the axial length of the fins 26 in the separator 20 illustrated in Figure 1 A. The fins 208 have less surface of contact to contact the blades 72 of the injection device 68. By reducing said contact surfaces, the amount of friction between the fins 206 and the blades 72 is thought to be substantially reduced. Such a configuration helps further by reducing the amount of force required to inject coils into a stator core. In operation, and as the separator 200 moves through the hole of the injection device towards the stator core, the upper surface of the injection disk 202 is brought into contact with the segments of the coil groups extending through of the hole of the circular arrangement of the blades. The shoulder 201 engages the wire segments as they exit the spaces between the blades 72. The fins 208 come into contact with the portions of the coil groups that extend through the spaces 76 of adjacent blades 72. .

Figure 10 is a perspective view of a stator 220, which includes a stator core 222, formed of a plurality of laminations held together by pins 224 (only one pin 224 is visible in Figure 10). The groups of coils 226A-C have been injected into the core 222. More particularly, the teeth 228 of the core 222 extend radially and define a hole 230. The grooves 232 between adjacent teeth 228, and the open ends of the grooves 232 , define the periphery of the orifice 230. The groups of coils 226A-C, are inserted in the selected slots 232. From the preceding description of various embodiments of the present invention, it is clear that the objectives of the invention are obtained. Although the invention has been described and illustrated in detail, it should be clearly understood that it is intended as an illustration and example only and should not be taken as a limitation. Consequently, the spirit and scope of the inventions will be limited only by the terms of the appended claims.

Claims (55)

1. REVIVAL NAME IS 1 . Apparatus for injecting a plurality of groups of coils into the magnetic core of a dynamoelectric machine, each group of coils having one or more coils, the stator having a central hole and a plurality of teeth spaced around the hole with a slot between adjacent teeth extending radially outwardly of the orifice, said injection apparatus comprising a plurality of elongated blades defining spaces, arranged in a circular arrangement, said blades configured to have the groups of coils placed therein, such that the portions of each of the coils are located in spaces between the blades and adjacent segments of each of the coils extending through the interior of said circular arrangement of blades, said apparatus further comprising an axially movable separator assembly within said circular array of blades, said first separator a disk having a diameter smaller than the diameter of said circular array of blades, a first surface of said first separator configured to contact the segment of at least one of the coils extending through the said circular array of blades and to move the coil axially along said blades without contacting the portions of the coil in the spaces between such blades.
2. 2. An injection apparatus according to the claim 1, wherein said first separator further comprises a weight member, a first surface of said weight member, being substantially adjacent to a second surface of said disk, said second surface of said disk, being opposite said first surface of said disk.
3. 3. An injection device according to the claim 2, in which said first and second surfaces of said disk, of said first separator, are substantially planar.
4. 4. An injection device according to the claim 1, wherein said first separator further comprises a holding member extending from said first surface of said first separator.
5. An injection apparatus according to claim 4, wherein said holding member of said first separator, comprises a handle configured to be held by a fastener of a machine for picking and placing, automatic.
6. 6. An injection apparatus according to claim 1, wherein said disc of said first separator is formed of nylon.
7. An injection apparatus according to claim 1, wherein the outer periphery of said disc and the internal periphery of said circular arrangement of blades are separated by less than about half the diameter of the wire forming the coils.
8. 8. An injection apparatus according to claim 1, wherein said spacer assembly further comprises a second spacer, the second spacer having a generally circular cross-sectional shape, said second spacer comprising a plurality of fins spaced radially in a circumference external of said second separator, each of said fins extending in one of the spaces between adjacent fingers.
9. An injection apparatus according to claim 8, wherein said second separator includes a frusto-conical shaped surface configured to contact a segment of at least one coil extending through the inner part of said circular arrangement of blades, and to move the coil axially along said blades, said fins of said second separator, coming into contact with the portions of the coil in the spaces between said blades.
10. 10. An injection apparatus according to claim 8, wherein said second separator is formed of bronze. eleven .
11. An injection apparatus according to claim 8, wherein said second separator comprises a first surface configured to contact a segment of at least one coil extending through the inside of said circular array of blades.
12. An injection apparatus according to claim 1, wherein said first separator further comprises a weight member, a first surface of said weight member being substantially adjacent to a second surface of said disk, said second surface of said disc, being opposite said first surface of said disc.
13. 13. An injection device according to the claim 12, in which a second surface of said weight member is substantially adjacent said first surface of said second separator.
14. 14. An injection apparatus according to claim 12, wherein a coil insertion star is mounted on said second separator on said first surface thereof, and a second surface of said weight member is substantially adjacent to said coil. a first surface of such a coil insertion star.
15. 15. An injection apparatus according to the claim 14, in which said coil insertion star has four peaks.
16. 16. An injection apparatus according to claim 14, wherein said coil insertion star has six peaks.
17. 17. An injection apparatus according to the claim 8, wherein said second separator has an axial length and each of said fins extends substantially the entire axial length of said second separator.
18. 18. An injection apparatus according to claim 8, wherein said second separator has an axial length and each of said fins has an axial length substantially smaller than the axial length of said second separator.
19. 19. A separator for injecting, from an injection device, a plurality of groups of coils into a stator core, of a dynamoelectric machine, the injection device having a plurality of elongated blades defining spaces, arranged in a circular arrangement, the blades configured to have the groups of coils placed on them, in such a way that the first portions of each of the coils are received in respective spaces between the blades and segments of each of the coils extend through the inner part of the circular arrangement of blades, said separator comprising a disk having a diameter smaller than the diameter of said circular arrangement of blades, a first surface of said separator configured to contact at least one part of the segment of , at least, one of the coils that extends through the inner part of the arrangement circular of the blades and to move the coil axially along the blades without coming into contact with the first portions of the coil, located in the spaces between the blades.
20. A spacer according to claim 19, further comprising a weight member, a first surface of said weight member, being substantially adjacent to a second surface of said disk, said second surface of said disk, being opposite said first one. surface of said disk.
21. 21. A spacer according to claim 20, wherein said first and second surfaces of said disc are substantially planar.
22. 22. A spacer according to claim 19, further comprising a clamping member extending from said first surface.
23. A spacer according to claim 22, wherein said clamping member comprises a handle configured to be held by a fastener of an automatic pick-and-place machine.
24. 24. A separator according to claim 19, wherein said disc of said first separator is formed of nylon.
25. A separator according to claim 19, wherein the outer periphery of said disc and the internal periphery of said circular arrangement of the blades, are separated by less than about half the diameter of the wire forming the coils to be injected by said separator.
26. 26. A separator assembly for injecting, from an injection device, a plurality of groups of coils into a stator core of a dynamoelectric machine, the injection device having a plurality of elongated blades defining spaces, arranged in a circular arrangement, the blades configured to have the groups of coils placed on the same, in such a way that the first portions of each of the coils are received in respective spaces between the blades and segments of each of the coils extend to Through the inner part of the circular arrangement of blades, said first separator comprising a disk having a smaller diameter than the diameter of said circular blade arrangement, a first surface of said separator configured to contact each other. with a segment of at least one of the coils extending through the inner part of the circular arrangement of the blades and to move the coil axially along the blades without coming into contact with the first portions of the coil in the spaces between said blades.
27. 27. A spacer assembly according to claim 26, wherein said first spacer further comprises a weight member, a first surface of said weight member, being substantially adjacent to a second surface of said disc, such second part. surface of said disc, being opposite said first surface of said disc.
28. 28. A separator assembly according to claim 27, wherein said first and second surfaces of said disk of said first separator are substantially flat.
29. 29. A separator assembly according to claim 26, wherein said first separator further com- prises a clamping member extending from said first surface of said first separator.
30. 30. A separator assembly according to claim 29, wherein said securing member of said first separator comprises a handle configured to be held by a fastener of an automatic pick-and-place machine.
31. 31 A separator assembly according to claim 26, wherein said disc of said first separator is formed of nylon.
32. 32. A separator assembly according to claim 26, wherein the outer periphery of said disc and the internal periphery of said circular arrangement of the blades are separated by less than about half the diameter of the wire forming the coils. .
33. A spacer assembly according to claim 26, further comprising a second spacer, said second spacer having a generally circular cross-sectional shape, said second spacer comprising a plurality of radially spaced fins on an outer circumference of said second spacer , each of said fins extending in one of the spaces between adjacent fingers.
34. 34. A separator assembly according to claim 33, wherein said second separator includes a frusto-conical shaped surface configured to contact a segment of at least one coil extending through the inner part of said circular arrangement of blades, and to move the coil axially along the lengths of said blades, said fins of said second separator, coming into contact with the portions of the coil in the spaces between said blades.
35. 35. A separator assembly according to claim 33, wherein said second separator is formed of bronze.
36. 36. A spacer assembly according to claim 26, wherein said second spacer comprises a first surface configured to contact a segment of at least one spool extending through the interior portion of said spacer. circular arrangement of said fingers.
37. 37. A separation assembly according to claim 36, wherein said first separator further comprises a weight member, a first surface of said weight member being substantially adjacent to a second surface of said disk, said second surface of said weight. disk, being opposite to said first surface of said disc.
38. 38. A separation assembly according to claim 36, wherein a second surface of said weight member is substantially adjacent to said first surface of said second separator.
39. 39. A separation assembly according to claim 36, wherein a coil insertion star is mounted on said second separator on said first surface thereof, and a second surface of said weight member is substantially adjacent to a coil insert. first surface of such a coil insertion star.
40. 40. A separation assembly according to claim 39, wherein said coil insertion star has four peaks.
41. 41 A separation assembly according to claim 39, wherein said coil insertion star has six peaks.
42. 42. A separation assembly according to claim 33, wherein said second separator has an axial length and each of said fins extends substantially the entire axial length of said second separator.
43. 43. A separator assembly according to claim 33, wherein said second separator has an axial length and each of said fins has an axial length substantially smaller than the axial length of said second separator.
44. 44. A separator for injecting, from an injection device, a plurality of groups of coils into a stator core of a dynamo electric machine, the injection device having a plurality of elongated blades establishing spaces, arranged in a circular arrangement, the blades configured to have the groups of coils placed on them, in such a way that the portions of each of the coils is received in the spaces between the blades and segments of each of the coils that extend through the interior of the coils. the circular arrangement of blades, said separator comprising an injection disk and a generally cylindrical portion, said separator further comprising a wire thrust shoulder located within the blade arrangement and a plurality of radially spaced fins, the axial length of said portion cylindrical, being greater than the axial length of said fins.
45. 45. A spacer according to claim 44, wherein the diameter of said disc and the diameter of said cylindrical portion are substantially equal.
46. 46. A spacer according to claim 45, wherein the outer periphery of said disc and the internal periphery of said circular arrangement of the blades are separated by less than about half the diameter of the wire forming the coils.
47. 47. A spacer according to claim 44, wherein a first surface of said disc is configured to contact the segment of at least one of the coils extending through the inner part of the disc. the circular arrangement of the blades and to move the reel axially along the blades without coming into contact with the coil portions in the spaces between the blades.
48. 48. A separator according to claim 47, wherein said first surface of said disk is substantially planar.
49. 49. A spacer according to claim 44, wherein said disc is formed of nylon.
50. 50. A spacer according to claim 44, wherein said fins are formed of bronze.
51. 51 A method for injecting, from an injection device, a plurality of groups of coils into the core of a dynamo-electric machine, each group of coils having one or more coils, the core having a central hole and a plurality of teeth spaced around the hole with a slot between adjacent teeth extending radially out of the hole, the injection device comprising a plurality of elongated blades defining spaces, arranged in a circular arrangement, the blades configured to have the groups of coils placed thereon, in such a way that the portions of each of the coils are received in respective spaces between the blades and segments of each of the coils that extend through the interior of the circular arrangement of the blades, the device further comprising a separator assembly that moves axially within the circular arrangement of the blades, the separator assembly comprising a first separator, the first separator comprising a disk having a smaller diameter than the diameter of the circular arrangement of said separators. blades, a first surface of the first separator configured to contact the segment of at least one of the coils, extending through the interior of the circular arrangement of said blades, the separator assembly further comprising a second separator, the second separator including a first top surface, and a plurality of radially spaced fins, each of the fins configured to extend in one of the spaces between adjacent blades, the method comprising the steps of: inserting the first separator within the circular arrangement of blades; and loading at least a first group of coils on the blades of the injection device at a location axially above the disc of the first separator.
52. 52. A method according to claim 51, wherein said method further comprises the steps of aligning each of the blades to coincide with a respective stator tooth and aligning each of the spaces to coincide with a respective stator slot. .
53. 53. A method according to claim 51, further comprising the step of moving the spacer assembly axially within the circular arrangement of the knives such that the first spacer moves the first spool group axially along the knives. without contacting the portions of the coils of the first group of coils in the spaces between the blades.
54. 54. A method according to claim 53, wherein after the disc of the first separator moves through the hole of the stator core, said method further comprises the step of removing the first separator from within and in alignment with the circular arrangement of the blades.
55. 55. A method for placing windings on the magnetic core of an engine, the method comprising the steps of loading a wire separator having a circumferentially extending continuous shoulder into a bore injection tool hole in a relative random angular orientation to said tooling; place wire spirals in the spaces established by the tooling; placing a grooved magnetic core on the tooling with core grooves aligned with tooling spaces; move the spacer and apply selected portions of the wire spirals with the continuous shoulder inside the hole of the tooling and axially moving the wire spirals along the tooling and into core grooves by engaging the spacer with unique portions of the wire spirals placed inside the hole of the tooling. SUMMARY An apparatus for injecting a plurality of groups of coils into a stator core of a dynamo-electric machine is disclosed. The injection apparatus includes, in one embodiment, a separator assembly including a first separator. The first separator includes an injection disk, which, in one embodiment, is formed of nylon. A first surface of the injection disk is configured to contact a segment of at least one of the coils to move the coil axially along the blades of the injection apparatus without coming into contact with portions of the injection apparatus. the coil in spaces between the blades.