US1843592A - Machine for assembling and heating dynamo electric machine elements - Google Patents

Description

Feb. 2, 1932. v. G. APPLE 1,843,592

MACHINE FOR ASSEMBLING AND HEATING DYNAMO ELECTRIC MACHINE ELEMENTS Original Filed June 14, 1928 Patented Feb. 2, 1932 narr res VINCENT G. APPLE,

or DAYTON, onro MACHINE FOR ASSEMBLING AND HEATING DYNAMO ELEOTRIC'MACHINE ELEMENTS Original application filed .Tune 14, 1928, Serial No. 285,363. Divided. and this application filed March 7,

1930. Serial This invention is a division of my copending application Serial Number 285,363, filed June 14th, 1928, and relates to a machine for assembling and cementing together insulation coated core laminae and similarly coated conductor bars, compacting the laminae on the bars and heating them while so compacted to bind the laminae together and to thebars.

The object of the invention is to provide a machine wherein a complete set of the conductor bars, previously heavily coated with a cementitious insulation are held in cylindrical formation within a mold, while the perforated laminae intended to compose the core also previously coated with the insulation are rapidly threaded over the bars, compressed in the mold, held there, heated to harden and unify the mass, then forced by pressure from the mold.

I attain this ob 'ect by the mechanismhereinafter described, reference being had to the drawings, wherein Fig. 1 is a conventional laminated conductor bar of the type herein employed to illustrate my invention.

Fig. 2 is the same conductor bar provided with insulation.

Figs. 3 and 4 are sections on the lines 3-3 and 4:4 of Figs. 1 and 2.

Fig. 5 shows a threading cap in perspective.

Fig. 6 shows a pair of coated conductors placed edge to edge in the relation which they occupy when assembled in the core, and a cap covering one end of the pair to facilitate threading the apertures of the laminae over the bars.

Fig. 7 shows a segmental laminae of a type readily assembled and made into a core by my machine.

Fig. 8 is a vertical. axial section through the machine itself.

Similar numerals refer to similar parts throughout the several views.

To illustrate the operation of my machine I show it as employed in the making of an alternating current stator of relatively large proportions such as maybe used as part of a turbo generator or synchronous motor. To

No. 434,00o;

consist of a mixture of synthetic resin, iron. free silica sand, lime and a flux such as feldspar, fluorspar or sodaash and maybe applied of considerable greater thickness and length than required, in its finished form. The conductors so covered may then be placed in a die to which just enough pressure.

and heat is applied to bring about the reaction of the synthetic resins, and when removed from the die the covering is sufliciently hard, smooth, and accurate for further steps in the process. y

,A conductor so treated and removed from the die is shown at 12, Figs. 2 and 4;, where 13 is the covering of insulation surrounding the laminae 10, 10, etc. "of the conductor and 14 and 14: the ends which are left uncovered to facilitate subsequent connection to form a winding.

In conformity with present practice I use as a core for my stator a plurality of segmental sheet stampings as shown at 15, Fig. 7 a

series of such segments composing a layer and;

a suflicient number of layers the core. Perforations 16 are of a size and form which may contain two covered conductors Fig. 2 placed edge to edge. Perforations shown are known as of the closedtvpe. The stampings may be coated or not as desired but when coated the insulating compound used may preferably be of the same nature as that used onthe con- 9 ductors. v

A hydraulic cylinder 18 having a wide flange 19 and containing a hollow ram 20 is supported on concrete base 21. Extending vertically from flange 19 are columns 22'and supported on the upper end thereof by wide flange 23 is a hydraulic cylinder 24 containing ram 25. Intermediate of flanges 19and 23 and supported by columns 22 is another flange 26 having a downwardly extending ram 27 and an upwardly extending cylinder 28, the ram 27 being fitted to a bore in ram 20 and the cylinder 28 being of outside diameter equal to the bore of the stator being assembled, and of inside diameter suitable to receive another ram 29. Concentric with cylinder 28 and mounted on flange 26 is a cylindrical member 30 having an inside diameter equal to the outside diameter of the stator to be assembled.

In the space between cylinder 28 and member 30 is a cylindrical ring 31 the outside and inside diameters of which are equal to those of the stator to be assembled. The upper side of ring 31 contains a series of pockets 32 equal in number to the apertures 16 of the core to be assembled, a pocket 32 being of such size that conductors paired edge to edge as in Fig. 6 may have the ends 14, 14 entered therein and a portion of the insulated part 13. 13 as well, the depth of the pocketsbeing such that the portion of the conductors which are to extend beyond the core will be entirely contained in the pockets. Fastened to and extending downwardly from ring 31 through openings in flange 26, rods 33 connect to flange 34 of ram 20 so that when valve admits fluid underv pressure through pipe 36, ring 31 is moved upwardly by ram 20 through rods 33 and when valve 37 admits fluid under pressure through pipe 38. ring 31 is returned downwardly by ram 20 through rods 33.

At the lower end of ram 25 is a sleeve 39 flanged inwardly at the bottom end as at 40 the flange having through-perforations of a number and size corresponding to the apertures 16 of the core being assembled. Cables 41 fastened to lugs 42 and passing over sheaves 43 supported by lugs 44 of cylinder 24 connect to a motor hoist not shown by means of which flange 40 maybe rapidly raised or lowered when no hydraulic effect is being applied to ram 25. A high frequency coil 45 made of rectangular copper tubing surrounds part 30 for the purpose of generating heatin the metal masses within by eddy current effect so that the mold and product becomes in effect a high frequency induction furnace. Insulation 46 serves to confine the heat and prevent short circuits between the coils.

To carry forward my method by means of the above described press I first raise sleeve 39 well above the top of member 30 then I stand vertically in each pocket of ring 31 a pair of conductors assembled edge to edge as shown in Fig. 6. each pair comprisingone long inner layer conductor and a relatively shorter outer layer conducton and placing on the upper end of each pair a spear-shaped cap 47. The cap 47 is separately and more clearly shown in Fi 5. I now place suificient stampings 15 for one layer of the core over caps 47, then sufficient stampings for another lay ,r oyer caps 47 in such a way that the joints between successive stampings of one layer will be intermediate the joints of the other layer After a number ot layers have been so placed over the caps 47 the sleeve 39 may be rapic ly let down by the motor hoist until the perforated flange 40 drives the stainpings downward over the con ductors 12 against ring 31 when the sleeve may be returned to its upper limit of travel and more stampings threaded on. This process is repeated until sufficient stampings have been placed to complete the core. The sleeve 39 is then brought down against the stampings and valve 48 is opened allowing liquid under pressure to flow through pipe 49 into hydraulic cylinder 24 and acting through ram 25 against sleeve 39 applying great pres sure to the assembled structure. High trequency current is then turned into coil 45 to heat the structure under pressure and it the stampings have been coated the heat thus gen erated fluxes the insulating compound between them and the maintained pressure on sleeve 39 evenly distributes the insulating material between them forcing the excess material into the minute spaces between the conductors and core apertures so that the conductors will be so firmly bound in the core to effectively prevent any subsequent shitting of their relative positions. 7

Since any mixture applied to the'stampings should be of similar material to that previousy applied to the conductors the gradually rising heat first brings about the reaction of the synthetic resins bringing the mixture on the stampings to a state equal to that on the conductors but as a considerablyhigher'heat is obtainable with. the high frequency coil and as the mixture as previously stated may contain also iron tree silica sand, lime feldspar, fluorspar, soda ash or other flux the heat is carried higher and the synthetic resins are converted. to carbon which as the yitritying state of the mixture is reached combines with the silica forming silica-carbide as the insulating material. The lime content may in such proportion as will by its effect of causing expansion of the mixture as it reaches its final state, assist in binding the conductors tightly in the core apertures. and the flux in such. proportion as is needed to control. the vitritying temperature.

While I have herein suggested for insulating; one mixture suitable to my precess any other mixture may be used which may be brought to a vitreous sta e by degree ct he at lower than that which would permanently injure the copper in the conductors.

After the insulating compound has been brought to the desired state the current in ins coil 45 is shut off and valve 48 is closed, the liquid in cylinder 24 by-passed and valve 50 opened so that liquid admitted through pipe 51 acts hydraulically against ram 29 raising same until it carries with it sleeve 39 thus stripping flanged end 40 from the ends of the conductors. After flange ID has been stripped from the conductors ram 29 is returned and the motor hoist is employed to return sleeve 39 to its upper position. Valve 35 is next opened so that ram 20 through rods 33 raises ring 31 to strip the core from the die. In order to loosen the ends of the conductors from the pockets 32 of ring 31 the core is first raised a short distance only by ram 20. By then opening valve 37 ram 20 is returned thus stripping pockets 32 from the ends of the conductors. By repeating this operation several times the ends will be loose enough in the pockets so that when the core is raised clear of the die it may be held by other means and the ring 31 returned to its lower position.

After the assembled core and conductor structure is removed from the machine the bare ends 14 of the conductors may be joined in pairs by end connectors of any of the conventional designs usually employed for this purpose but which, forming no part of the present invention, are not herein shown, and while I have shown my machine as employed in the making of a stator unit, it is obvious that dynamo electric machine rotor units may be produced with equal facility, and while I have shown conductors of laminar structure, solid conductors may be used if desirable, and while the laminae employed have completely closed apertures, semiclosed or open apertures may be employed.

Having described my invention, I claim 1. As part of a machine for entering insulation covered conductor bars placed edge to edge in pairs, with bare ends, into winding apertures of dynamo electric machine core laminae, an outwardly tapering cap having inside dimensions adapted to fit over the bare ends and outside dimensions equal to the insulation covered portion of the pair.

2. As part of a machine for entering insulation covered conductor bars placed edge to edge in pairs, the one bar of a pair being longer than the other bar and the ends of the bars being bare of insulation, into winding apertures of dynamo electric machine core laminae, an outwardly tapering cap having inside dimensions adapted to fit over the bare ends of the bar, outside dimensions equal to the insulation covered portion of the pair, and an offset inner end to compensate for the difference in length between the two bars.

3. In a machine for assembling insulation covered conductors and core laminm of a dynamic electric machine element, the combination of a cylinder having outside diameter corresponding to the inside diameter of the core, a ring recessed in its side to receive such part of the ends of the bars as is to extend beyond the end of the core, means to press the laminae over the conductors and around the cylinder, and heating means surrounding said core.

4. In a machine for assembling insulation covered conductors and core laminae of a dynamo electric machine element, the combination of a member having an opening corresponding to the outside dimensions of the finished core, a ring recess-ed in its side to receive such part of the ends of the bars as is intended toextend beyond the end of the core, means to press the laminae over the conductors and into the said opening and heating means surrounding the said opening.

5. In a machine for assembling core laminae over insulation coated conductors of a dynamo electric machine element, the combination of a cylinder having an outside diameter corresponding to the inside diameter of the core, a ring surrounding said cylinder having a plurality of pockets corresponding to the part of the bars which is to extend beyond the end of the core, means to press the laminae over the conductors and around the said cylinder and means to move said ring axially over said cylinder.

6. In a machine for assembling core laminm over insulation covered conductors of a dynamo electric machine element, the combination of a cylinder having an outside diameter corresponding to the inside diameter of the core, a member surrounding said cylinder having an inside diameter conforming to the outside of said core,a narrow ring adapted to fill the space between said cylinder and said member at one end, said narrow ring having a plurality of pockets corresponding to the part of the bars which is to extend beyond the end of the core, a wide ring adapted to fill the space between said. cylinder and said member at the other end, said wide ring being recessed to receive the bars for the greater part of their length, means to move the wide ring axially in one direction to compact the several laminae of the core, and means to move the narrow ring axially in the other direction to eject the core from between the said cylinder and the said member, after it is compacted therebetween.

7. In a machine for assembling core laminae over insulation covered conductors 'of a dynamo electric machine element, the combination of a cylinder corresponding in outside diameter to the bore of the core, a cylindrical member corresponding in outside diameter to the outside diameter of the element, a ring and a sleeve'each having inner and outer diameters corresponding to the outer and inner diameters of the cylinder and cylindrical member respectively, and means to move said ring and said sleeve axially betWeen said cylinder and said cylindrical member.

8. In a machine for assembling the laminm of a core over insulation covered conductors of a dynamo electric machine element, the combination of means to hold the conductors at one end and in the arrangement required in the finished element means to press the laminae over the other end of the conductors While so held, means to align the laminae in concentric relation one to the other as they are assembled, and means to strip the completed structure from the aligning means.

In testimony whereof I aflix my signature.

VINCENT G. APPLE.

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