TH13039B - Improved methods for winding electric motor coils? - Google Patents

Abstract

The method for making field windings for electric motors, generators, or alternators involves the process of continuously winding insulated conductors into coils with a first set of windings wound in one direction and a second set of windings wound in a second, opposite direction along the diameter. The windings are then flattened into a flat double filament (138) with the sides of one first set of windings overlapping the sides of the opposite second set of windings along the diameter. Multiphase field windings (24) can be made by winding insulated conductors (38,40,42) to form groups of alternating windings to create elongated coil assemblies. The entire assembly is then flattened to form a flat double filament (138) and wound end-to-end into a cylindrical shape.

Claims (23)

1. A method for making field coils (24) for electric motors (10), generators or alternators, which is characterized by the following steps: winding a continuously insulated conductor around a rotating shaft (58) to obtain a coil in which the first set of individual coils (64,66,68) are wound in the first direction around the shaft and the second set of individual coils (78,80,82) are wound in the second direction around the shaft, closely opposite to the first direction; flattening of the coil to obtain a relatively flat double filament (138) with a first end (124) and a second end (128) such that the circumference of the first set of coils overlaps the circumference of the corresponding second set of coils on the opposite side by diameter; and connecting the first end (124) of the double filament to its second end (128) such that the circumference of the second set of coils overlaps the circumference of the corresponding first set of coils on the opposite side by diameter. 2. The method under claim 1 is characterized by the insertion of the connected filament (138) into the magnetic return path (140). 3. The method under claim 2 is characterized by the insertion of the sheath piece (146) into the connected filament. Such sheath piece contains the internal space within which the rotor assembly (14) may rotate. 4. The method under claim 3 has an additional specific characteristic in that the procedure of extending the spliced fibers radially toward the return path (140) before inserting the sheath piece (146) to compress the spliced fibers radially after the spliced fibers have been inserted toward the return path. 5. The method under either claim 3 or 4 has an additional specific characteristic in the procedure of extending the said casing section (146) radially toward the said return path (140) after the said casing section has been inserted into the said return path. 6. The method under claim 5 is characterized by the expansion of the said sleeve section (146) being accomplished by inserting the expandable arbor (144) into the said sleeve section. 7. Any of the methods under claims 3 through 6 have an additional specific characteristic in the process of heating the stator assembly after the sleeve (146) has been fitted. 8. Methods for making multiphase field windings (24) for an electric motor, generator or assembled alternator: (a) winding at least two insulated conductors together around a common axis with axial spacing in the first winding direction to form a group of at least two adjacent winding units; (b) shifting the insulated conductors relative to the axial winding units by a distance of approximately (n-1) times the axial thickness of the winding unit, where n is the number of the wound conductors; (c) winding a second group of the adjacent winding units given in step (a) together in a second winding direction opposite to the first winding direction, with the second group of winding units adjacent to the first group of winding units; (d) compressing the adjacent winding groups into a relatively flat double filament (138) with a first axial end (124) and a second axial end (128); and (e) winding the flat filament into a field winding (24) by connecting the first axial end to the second axial end. 9. The method under claim 8 is characterized by the fact that the number of conductors wound is equal to 3. 10. Any of the methods under claim 8 or 9, which are characterized by steps (a) and (c) being performed by wrapping an insulated conductor around the same rotating shaft (58). 11. The method under claim 10 is characterized by the fact that the rotating shaft (58) has a polygonal shape to aid in the precise compression of the coil group in step (d). 12. The method according to claim 11 is characterized by the fact that the axis of rotation (58) has a hexagonal shape. 13. Any of the methods under claims 8 through 12 have an additional characteristic in that steps (a), (b), and (c) are repeated one or more times before step (d), thus resulting in more than two groups of contiguous coil units. 14. Any of the methods under claims 8 through 13 is characterized in that step (d) is performed so that the perimeter of each coil unit wound in the first direction overlaps the perimeter of another corresponding coil unit wound in the opposite diameter in the second direction, with the leading perimeter of the first end coil unit and the trailing perimeter of the second end coil unit being exposed as a single filament (126,130) at the first and second axial ends, respectively of a flat second filament (138). 15. The method under claim 14 is characterized by step (c) being composed of connecting the first axial end to the second axial end so that the leading side of the first coil unit overlaps the trailing side of the second coil unit. 16. The method under any of the preceding claims has an additional characteristic in the procedure of securely securing each coil set independently in position relative to other coil sets after the winding process, in order to allow the coil to be removed from the folding stand. 17. The method according to claim 16 is characterized by the procedure of such secure fastening being carried out by placing at least one length of adhesive strip (114,118) horizontally along the outer surface of such coil and perpendicularly along the direction in which such individual coil assembly protrudes. 18. The method under any of the preceding claims has an additional specific characteristic in the step of inserting the non-conductive material (122) inside the coil before the flattening step. 19. The method under claim 18 is characterized by the insertion procedure which involves inserting a non-conductive strip (122) inside the coil. 20. The method under claim 19 is characterized by the fact that the non-conductive strip (122) is incorporated with a reinforced polymer. 21. The method according to claim 8 in which all the coil units are simultaneously rearranged: (1) the radial compression of such coil units into two relatively flat filaments (138), and (2) the axial shifting of one layer of such filaments relative to another layer of such filaments by a distance relatively equal to the axial dimension of one group of such coil units, and where the opposite ends (124,128) of such filaments are joined together to form a cylindrical stator and thus overlap sections of coil units at one end of such filaments and are placed in its first layer on sections of coil units placed at the opposite ends of such filaments and in its second layer, where currents flow in the same direction in each conductor in the overlapping layers of each coil unit, thus creating compatible and mutually reinforcing electromagnetic fields. 22. Field winding (24) for an electric motor, generator or multiphase alternator. Such field winding consists of at least two insulated conductors. Each such insulated conductor makes up one of the first number of adjacent winding units wound in the first direction. Each such conductor also makes up one of the second number of adjacent winding units wound in the second direction opposite to the first direction. Each such winding unit has a first and a second circumference opposite in diameter to its first circumference. The winding units are arranged such that the first circumference of the winding unit wound in the first direction overlaps the second circumference of the winding unit wound in the second direction, and the first circumference of the winding unit wound in the second direction overlaps the second circumference of the winding unit wound in the first direction. 23. Multiphase field winding (24) for use as a grooveless stator in electric motors, generators, or alternators, consisting of two relatively flat filaments (138) with the first axial end (124) connected to the second axial end (128). Such flat filaments consist of a first group of individual winding units constructed of a number of insulated conductors wound in the first winding direction; a second group of individual winding units constructed of such a number of insulated conductors wound in the second winding direction; at least one of the winding units in such second group of individual winding units is adjacent to at least one of the winding units in such first group of individual winding units, where each of the respective winding units in such first and second groups of individual winding units is flattened relative to each other, so that the circumference of each of the respective winding units in such first group of individual winding units overlaps the circumference of the corresponding winding unit opposite in diameter in such second group of individual winding units.