US20050051661A1 - Apparatus and method for winding stator teeth - Google Patents
Apparatus and method for winding stator teeth Download PDFInfo
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- US20050051661A1 US20050051661A1 US10/888,564 US88856404A US2005051661A1 US 20050051661 A1 US20050051661 A1 US 20050051661A1 US 88856404 A US88856404 A US 88856404A US 2005051661 A1 US2005051661 A1 US 2005051661A1
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- stator
- stator teeth
- winding
- stator tooth
- tooth
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/08—Forming windings by laying conductors into or around core parts
- H02K15/095—Forming windings by laying conductors into or around core parts by laying conductors around salient poles
Definitions
- the present invention relates generally to electric machinery and in particular to an apparatus and method for winding stator teeth.
- Stators of such electric machinery typically include a series of connected electrical wire coils formed on stator teeth mounted around the internal periphery of a ring.
- the electrical wire coils are wound in alternating orientations on the stator teeth, creating a set of alternating magnetic fields about the internal periphery of the ring when energized by a current.
- the rotor which carries magnets of alternating polarity about its circumference, is rotated within the stator to generate current in the coils as the magnets align with coils.
- the strength of the current is dependent on the strength of the magnets, the speed at which the rotor rotates, and the number of loops in each coil.
- stator teeth supporting the coils leads to more efficient power conversion of the stator.
- access thereto is restricted.
- the stator teeth are placed close to one another, little working space is provided to wind the wire around the individual stator teeth to form coils thereon.
- a number of methods for winding wire around the stator teeth prior to their final positioning in the stator have been considered.
- U.S. Pat. Nos. 6,121,711 and 6,323,571 to Nakahara et al. disclose a method of manufacturing a stator for magnetic disk drive units.
- the stator includes a stator body comprising two or more segments that are hingedly connected, allowing the segments to be positioned into either a generally linear arrangement or a generally circular arrangement.
- Each segment has one or more stator teeth on a side thereof.
- Wire is coiled about the stator teeth when the segments are generally linearly arranged and the wire ends are connected to terminations.
- the segments are then formed into an annulus and secured.
- each segment has more than one stator tooth
- the relative proximity of the stator teeth is limited by the space required to accommodate the winding mechanism used to wind the wire around each stator tooth.
- each segment only has one stator tooth, while the winding of wire around each stator tooth is facilitated by swinging adjacent segments away from the segment having the stator tooth being wound, the increased number of hinge connections between segments increases the cost and complexity of the stator.
- U.S. Published Patent Application No. 2002/0011755 to Shteynberg et al. discloses a method of winding stator teeth that are stacked side-by-side to form a column, with a spacer placed between each adjacent pair of stator teeth, leaving exposed the peripheral edges of the stator teeth about which wire is wound.
- the column of stator teeth is clamped on opposing ends and mounted onto a rotating platform adjacent a wire dispenser.
- the wire dispenser winds wire around each stator tooth, one after another, until all of the stator teeth have coils formed thereon.
- Posts are then inserted into preformed bores around the perimeter of the spacers around which the wire dispenser routes the span of wire.
- the posts are positioned such that the length of the span of wire extending between two adjacent stator teeth is controlled to some extent.
- opposing stator teeth surfaces are equipped with mating features to allow the column of stator teeth to be securely clamped at its two opposing ends without spacers.
- a first set of stator teeth is mounted on a first ring with spaces between the stator teeth equal to the width of a stator tooth. Coils are wound on the stator teeth mounted on the first ring in a first orientation (that is, either clockwise or counter-clockwise).
- a second set of stator teeth is mounted on a second ring that is complementary to the first ring, with spaces between the stator teeth equal to the width of a stator tooth. Coils are then wound on the stator teeth mounted on the second ring in an orientation opposite to the first orientation. The rings are then coupled, interleaving the stator teeth to form a stator having adjacent stator teeth carrying coils wound in opposite orientations.
- Shteynberg et al. stator teeth winding methods address some of the problems associated with conventional stator teeth winding methods, a number of problems still exist with the Shteynberg et al. stator teeth winding methods. For example, forming the column of stator teeth and spacers prior to winding is time-consuming and complicated. Further, the method for controlling the span of wire between the stator teeth is complicated and produces a set number of discrete span lengths, thus limiting the number of stator configurations that can be produced.
- stator teeth winding methodology that overcomes the above disadvantages is desired. It is therefore an object of the present invention to provide a novel apparatus and method for winding stator teeth.
- an apparatus for winding stator teeth comprising:
- the stator teeth holder is rotatable to present each stator tooth to the fly winder.
- the stator tooth retainers are circumferentially spaced about the stator teeth holder and are vertically offset with respect to one another.
- the stator teeth holder is also vertically adjustable to present each stator tooth to the fly winder.
- the fly winder winds each stator tooth in a manner so that the coils on the stator teeth have opposite orientations.
- Each stator tooth retainer includes a channel shaped to accommodate a stator tooth.
- the channel is defined by a clamp assembly accommodated by the stator teeth holder.
- the clamp assembly includes a pair of side clamps for engaging opposite sides of a stator tooth.
- the clamp assembly may further include a biasing member actuable between engaged and disengaged states. In the engaged state, the biasing member biases the stator tooth into engagement with the side clamps.
- the channel may be sized to form a friction fit with the stator tooth.
- the stator teeth holder may include a main body including a pair of cutouts formed therein with each of the cutouts accommodating a respective clamp assembly.
- the main body presents a generally arcuate outer surface bridging the cutouts.
- an apparatus for winding stator teeth comprising:
- the present invention provides advantages in that since the length of the span of wire between two stator teeth is controlled during winding, the stator teeth can be positioned in a stator side-by-side with substantially no excess wire extending therebetween. Also, by vertically offsetting the stator teeth relative to one another during winding, the stator teeth can be positioned further apart, thus facilitating winding, and allowing the length of wire extending between the stator teeth to be more easily controlled. Further, the present invention allows for stator teeth to be wound in alternating orientations while retaining control over the span of wire extending between pairs of stator teeth.
- FIG. 1 is a side elevation view of an apparatus for winding stator teeth in accordance with the present invention
- FIG. 2 is a perspective view of a portion of the apparatus of FIG. 1 ;
- FIG. 3 is a perspective view of a sub assembly forming part of a stator teeth holding tool
- FIG. 4 is a perspective view of a turret forming part of the stator teeth holding tool
- FIG. 5 is a top plan view of the turret
- FIG. 6 shows two stator teeth in their relative positions when mounted on the turret
- FIG. 7 shows the two stator teeth of FIG. 6 when removed from the turret and positioned side-by-side.
- Apparatus 10 includes a plurality of fly winders 12 and a stator teeth holding tool 14 .
- fly winders 12 For ease of illustration only one fly winder 12 is shown. Also, since fly winders are well known in the art, for ease of illustration, some of the components of the fly winder have been omitted from the figures.
- Each fly winder 12 includes a flyer head 24 having a flyer arm 28 and a counterweight 32 joined by a central body section 34 .
- a nozzle 36 is positioned at the distal end of the flyer arm 28 and is operable to dispense wire to be wound around stator teeth when flyer head 24 is rotated about a central horizontal axis.
- a pair of redirector pulleys 40 and 44 allow wire to be routed to nozzle 36 .
- Pulley 40 is positioned within a channel 46 provided in the flyer arm 28 , adjacent the nozzle 36 , and pulley 44 is positioned on the central body section 34 .
- Flyer head 24 is mounted on a rotating hollow shaft (not shown), providing flyer head 24 with rotational movement in both directions about an axis coaxial with opening 48 in the central body section 34 . Further, the fly winder 12 is operable to move flyer head 24 along the two axes of a horizontal plane. Wire to be dispensed by the fly winder 12 passes over redirector pulley 44 , through channel 46 in the flyer arm 28 , over redirector pulley 40 and through nozzle 36 .
- stator teeth holding tool 14 presents stator teeth to the fly winders 12 to enable the fly winders 12 to wind coils thereon.
- stator teeth holding tool 14 includes a sub assembly 50 supporting a plurality of posts 52 .
- Sub assembly 50 includes a pair of motors 54 and a motor 56 .
- Each motor 54 is associated with a pair of posts 52 and is coupled to the pair of posts by a transmission. In this manner, each motor 54 is operable to rotate each post 52 in its associated pair about the central longitudinal axis of each post 52 .
- Motor 56 is operable to raise and lower the posts 52 .
- a fixturing detail 60 is disposed on the top of each post 52 .
- a turret 62 is slidably received by and rests on each post 52 . Only one turret 62 is shown in the figures for ease of illustration.
- turret 62 includes a pair of pegs 64 around which wire is turned in preparation for termination.
- a stationary tie-off post 66 is positioned on the sub assembly 50 adjacent each post 52 .
- Each turret 62 is associated with one of the fly winders 12 . In conjunction with the two degrees of movement of turret 62 by virtue of the movement of the posts 52 , flyer head 24 of its associated fly winder 12 has five degrees of movement relative to the turret 62 .
- FIGS. 4 and 5 better illustrate one of the turrets 62 .
- the turret 62 includes a main body 70 that is generally cylindrical in shape when viewed in top plan.
- a pair of clamp assemblies 72 are accommodated by cutouts 74 provided in the main body 70 to receive and retain a pair of stator teeth 100 a and 100 b to be wound.
- the cutouts 74 are positioned 90 degrees apart relative to the outer peripheral surface 76 of the turret 62 and are vertically offset.
- the outer peripheral surface 76 of the turret 62 bridging the cutouts 74 is arcuate.
- Each clamp assembly 72 includes a back plate 80 and a pair of side clamps 82 that define a dove-tailed channel 84 accessible from the top and bottom.
- the side clamps 82 are designed to engage a stator tooth 100 to be wound that is inserted into the dove-tailed channel 84 .
- the back plate 80 accommodates a cam-shaped member (not shown).
- the cam-shaped member is actuable between an engaged state wherein the stator tooth 100 is engaged by the side clamps 82 and retained by the clamp assembly 72 and a disengaged state wherein the stator tooth is moveable along the dove-tailed channel 84 .
- the cam-shaped member projects outwardly from the back plate 80 to contact and bias the stator tooth 100 into engagement with the side clamps 82 thereby to retain the stator tooth.
- the main body 70 of the turret only includes structure to engage stator teeth at the desired positions thereby to reduce the weight of the turret. By reducing the weight of turret 62 , less stress is placed on automation machinery that is used to mount and dismount turrets 62 on the posts 52 .
- Each stator tooth 100 includes an outer arc plate 102 , an inner arc plate 104 and a winding core 106 between the plates 102 and 104 about which wire is to be wound.
- the outer arc plate 102 is shaped generally complimentary to the dove-tailed channel 84 to facilitate insertion of the outer arc plate therein.
- stator teeth 100 a and 100 b that have not yet been wound with coils are loaded onto each turret 62 by sliding them into the dove-tailed channels 84 of the clamp assemblies 72 before each turret 62 is secured to a respective post 52 .
- the cam-shaped members within back plates 80 are then actuated to engage and bias stator teeth 100 a and 100 b firmly against side clamps 72 .
- the turrets 62 are then mounted onto the fixturing details 60 disposed on the posts 52 and preferably locked in place to avoid vertical movement of the turrets 62 during winding.
- one stator tooth 100 a is positioned towards a lower end of the turret 62
- the other stator tooth 100 b is positioned towards an upper end of the turret 62 , and spaced 90 degrees about the circumference of the turret 62 .
- the stator teeth 100 a and 100 b are mounted on perpendicular surfaces of each turret 62 , a wire spanning the two stator teeth must undergo a 90 degree change of direction.
- the arcuate outer peripheral surface 76 of the main body 70 spanning the cutouts allows a span of wire to be gradually routed from the top of one of stator tooth to the bottom of the other stator tooth, thus avoiding unnecessary sharp bends in the wire, which can damage the wire enamel and cause downstream rejects in the electric machinery in which the stator teeth 100 a and 100 b are utilized.
- Each post 52 and associated turret 62 are then lowered to present one of the pegs 64 to the flyer head 24 of its associated fly winder 12 .
- a wire extending from stationary tie-off post 66 to the nozzle 36 of the flyer head 24 is turned around the presented peg 64 by moving the flyer head 24 along the two horizontal axes of movement.
- the wire protruding from the nozzle 36 which was terminated to the stationary tie-off post 66 or clamped at the end of the last wind cycle, is thus wound around peg 64 under tension.
- the post 52 and turret 62 is rotated and raised to present a first stator tooth 100 a to the flyer head 24 for winding.
- stator tooth 100 a it is preferable to position stator tooth 100 a in the axis of rotation of the flyer head 24 so that the wire is distributed evenly about stator tooth and is generally evenly tensioned thereabout.
- Flyer head 24 is then positioned in front of stator tooth 100 a and a pre-set number of loops of wire are coiled around stator tooth in a counter-clockwise direction, with the flyer 24 head moving incrementally further from turret 62 with each loop of wire thereby to evenly distribute the wire about winding core 106 .
- flyer head 24 moves slowly toward turret 62 all while flyer head 24 continues to rotate about the stator tooth 100 a to wind a second set of loops of wire about winding core 106 .
- flyer head 24 is operated in a clockwise direction to wind a first set of loops of wire around stator tooth 100 b , all while flyer head 24 moves incrementally away from turret 62 with each loop.
- flyer head 24 begins to move slowly toward turret 62 to distribute a second set of loops of wire evenly around winding core 106 .
- flyer head 24 Upon completion of the second set of loops, turret 62 is lowered and flyer head 24 is moved through the two horizontal axes to form a set of turns about a second of the pegs 64 . Upon completion of the set of turns, flyer head 24 moves to wind a set of loops of wire around the stationary tie-off post 66 . The wire is then cut between the pegs 64 and the stationary tie-off post 66 .
- turret 62 having two wound stator teeth is removed from post 52 by unsecuring it and lifting it, making room for another turret 62 bearing a set of stator teeth to be wound.
- Completed stator teeth are then removed from turret 62 by actuating the cam-shaped members to allow the completed stator teeth to slide out of the dove-tailed channels 84 .
- FIG. 6 shows a pair of stator teeth 100 a and 100 b having coils 108 formed thereon and joined by the span of wire 110 .
- a terminating wire end 112 extends from each stator tooth for connection in a stator.
- Arrows 114 depict the direction in which stator teeth are moved to arrive at their final relative position side-by-side, as shown in FIG. 7 , wherein span of wire 110 is taut and includes substantially no excess length.
- adjacent stator teeth have coils of opposite orientation; that is, one is wound clockwise and another is wound counter-clockwise.
- stator teeth supports While the present invention has been described with specificity to mounting stator teeth onto a turret that presents the stator teeth to the fly winder for winding, other types of stator teeth supports will occur to those of ordinary skill in the art.
- a plate having a number of positions for securing stator teeth in a similar fashion as employed in the described embodiment can be used.
- the plate can be raised and lowered relative to the fly winder just as the turret, and can be moved relative to the fly winder along a longitudinal axis to present a different stator tooth to the flyer head, simulating the rotation of the turret.
- the positions of the stator teeth on the turret can be made adjustable to allow different dimensioned stator teeth to be coiled using the same turret. Further, the turret can be made expandable, through additional concentric surface layers on its periphery, through the placement of each stator tooth on a separate arcuate plate whose distance from the center of the turret can be adjustable, or through some other means.
- stator teeth are shown as being positioned ninety degrees apart about the circumference of the turret, it is to be appreciated that the stator teeth can be positioned in other configurations.
- the stator teeth can be placed along the circumference of the turret at varying degrees, depending on the circumference of the turret, the relative vertical separation of the stator teeth positions along the vertical length of the turret, and any variation in the radial distance of the stator teeth positions along the surface of the turret.
- the turrets can be equipped with clamps in place of pegs to engage the wire ends during the start and end of the winding process.
- This method of termination is well-suited to work with both a wire which has been previously terminated on a stationary tie-off post, and one which is loosely hanging out of the flyer nozzle, and is especially beneficial for use with heavier gauge wires.
- clamp assemblies are described as including cam-shaped members to bias the stator teeth into engagement with the side clamps, other means of securing the stator teeth to the turrets during the winding process can be used.
- the stator teeth can be frictionally fit into the dove-tailed channels.
- the apparatus is described as including a fly winder associated with each turret, fewer fly winders that are moveable laterally between multiple turret locations can be used.
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Abstract
An apparatus for winding stator teeth includes at least one fly winder for winding wire around stator teeth. At least one stator teeth holder includes stator tooth retainers at spaced locations for retaining stator teeth thereon. The at least one stator tooth holder and fly winder are moveable relative to one another to present each stator tooth to the at least one fly winder for winding a wire coil thereon. The stator tooth retainers are relatively positioned on the at least one stator teeth holder to control a span of wire extending between the stator teeth after the stator teeth have been presented to the at least one fly winder and wound.
Description
- This application claims the benefit of U.S. Provisional Patent Application No. 60/484,649 filed on Jul. 7, 2003.
- The present invention relates generally to electric machinery and in particular to an apparatus and method for winding stator teeth.
- Electric machinery that includes stators accommodating rotors, such as for example electric motors and generators, is well known in the art. Stators of such electric machinery typically include a series of connected electrical wire coils formed on stator teeth mounted around the internal periphery of a ring. The electrical wire coils are wound in alternating orientations on the stator teeth, creating a set of alternating magnetic fields about the internal periphery of the ring when energized by a current.
- In the case of electric generators, the rotor, which carries magnets of alternating polarity about its circumference, is rotated within the stator to generate current in the coils as the magnets align with coils. The strength of the current is dependent on the strength of the magnets, the speed at which the rotor rotates, and the number of loops in each coil.
- Conversely, in the case of electric motors, an alternating current is run through the coils, creating a combination of magnetic attraction and repulsion forces that rotate the magnet-carrying rotor.
- It has been found that close relational placement of the stator teeth supporting the coils leads to more efficient power conversion of the stator. As the stator teeth reside on the inside periphery of the ring, access thereto is restricted. Further, when the stator teeth are placed close to one another, little working space is provided to wind the wire around the individual stator teeth to form coils thereon. As a result, a number of methods for winding wire around the stator teeth prior to their final positioning in the stator have been considered.
- For example, U.S. Pat. Nos. 6,121,711 and 6,323,571 to Nakahara et al. disclose a method of manufacturing a stator for magnetic disk drive units. The stator includes a stator body comprising two or more segments that are hingedly connected, allowing the segments to be positioned into either a generally linear arrangement or a generally circular arrangement. Each segment has one or more stator teeth on a side thereof. Wire is coiled about the stator teeth when the segments are generally linearly arranged and the wire ends are connected to terminations. The segments are then formed into an annulus and secured. Unfortunately, a number of problems exist with this stator teeth winding approach. In situations where each segment has more than one stator tooth, the relative proximity of the stator teeth is limited by the space required to accommodate the winding mechanism used to wind the wire around each stator tooth. In situations where each segment only has one stator tooth, while the winding of wire around each stator tooth is facilitated by swinging adjacent segments away from the segment having the stator tooth being wound, the increased number of hinge connections between segments increases the cost and complexity of the stator.
- U.S. Published Patent Application No. 2002/0011755 to Shteynberg et al. discloses a method of winding stator teeth that are stacked side-by-side to form a column, with a spacer placed between each adjacent pair of stator teeth, leaving exposed the peripheral edges of the stator teeth about which wire is wound. The column of stator teeth is clamped on opposing ends and mounted onto a rotating platform adjacent a wire dispenser. As the column of stator teeth is rotated, the wire dispenser winds wire around each stator tooth, one after another, until all of the stator teeth have coils formed thereon. As the wire dispenser moves from stator tooth to stator tooth, a span of wire is extended between them. Posts are then inserted into preformed bores around the perimeter of the spacers around which the wire dispenser routes the span of wire. The posts are positioned such that the length of the span of wire extending between two adjacent stator teeth is controlled to some extent. In an alternative embodiment, opposing stator teeth surfaces are equipped with mating features to allow the column of stator teeth to be securely clamped at its two opposing ends without spacers. In a further embodiment, a first set of stator teeth is mounted on a first ring with spaces between the stator teeth equal to the width of a stator tooth. Coils are wound on the stator teeth mounted on the first ring in a first orientation (that is, either clockwise or counter-clockwise). Likewise, a second set of stator teeth is mounted on a second ring that is complementary to the first ring, with spaces between the stator teeth equal to the width of a stator tooth. Coils are then wound on the stator teeth mounted on the second ring in an orientation opposite to the first orientation. The rings are then coupled, interleaving the stator teeth to form a stator having adjacent stator teeth carrying coils wound in opposite orientations.
- While the Shteynberg et al. stator teeth winding methods address some of the problems associated with conventional stator teeth winding methods, a number of problems still exist with the Shteynberg et al. stator teeth winding methods. For example, forming the column of stator teeth and spacers prior to winding is time-consuming and complicated. Further, the method for controlling the span of wire between the stator teeth is complicated and produces a set number of discrete span lengths, thus limiting the number of stator configurations that can be produced.
- As will be appreciated, an improved stator teeth winding methodology that overcomes the above disadvantages is desired. It is therefore an object of the present invention to provide a novel apparatus and method for winding stator teeth.
- Accordingly, in one aspect of the present invention, there is provided an apparatus for winding stator teeth, comprising:
-
- at least one fly winder for winding wire around stator teeth; and
- at least one stator teeth holder including stator tooth retainers at spaced locations for retaining stator teeth thereon, said at least one stator tooth holder and fly winder being moveable relative to one another to present each stator tooth to said at least one fly winder for winding a wire coil thereon, wherein said stator tooth retainers are relatively positioned on said at least one stator teeth holder to control a span of wire extending between said stator teeth after said stator teeth have been presented to said at least one fly winder and wound.
- In one embodiment, the stator teeth holder is rotatable to present each stator tooth to the fly winder. The stator tooth retainers are circumferentially spaced about the stator teeth holder and are vertically offset with respect to one another. The stator teeth holder is also vertically adjustable to present each stator tooth to the fly winder. In the case where the stator teeth holder includes a pair of stator tooth retainers each for retaining a single stator tooth, the fly winder winds each stator tooth in a manner so that the coils on the stator teeth have opposite orientations.
- Each stator tooth retainer includes a channel shaped to accommodate a stator tooth. The channel is defined by a clamp assembly accommodated by the stator teeth holder. The clamp assembly includes a pair of side clamps for engaging opposite sides of a stator tooth. The clamp assembly may further include a biasing member actuable between engaged and disengaged states. In the engaged state, the biasing member biases the stator tooth into engagement with the side clamps. Alternatively, the channel may be sized to form a friction fit with the stator tooth.
- The stator teeth holder may include a main body including a pair of cutouts formed therein with each of the cutouts accommodating a respective clamp assembly. The main body presents a generally arcuate outer surface bridging the cutouts.
- According to another aspect of the present invention, there is provided an apparatus for winding stator teeth, comprising:
-
- a fly winder for winding wire around stator teeth; and
- a stator teeth holder including a rotatable turret having a main body and stator tooth retainers at spaced locations on said main body for retaining stator teeth, said turret being rotatable to present each stator tooth to said fly winder for winding a wire coil thereon, wherein said stator tooth retainers are relatively positioned on said turret in a manner such that after said stator teeth have been wound by said fly winder to include coils of opposite orientation, removed from said turret and placed side-by-side, the span of wire extending between said stator teeth includes substantially no excess length.
- According to yet another aspect of the present invention there is provided a method of winding stator teeth, comprising:
-
- mounting a first stator tooth and a second stator tooth at spaced locations on a tool;
- presenting said first stator tooth to a winding device and winding a coil having a first orientation thereon;
- biasing said tool to present said second stator tooth to said winding device; and
- winding a coil on said second stator tooth having an orientation opposite that of the coil wound on said first stator tooth, wherein the relative locations of said first stator tooth and said second stator tooth on said tool are such that the span of wire extending from said first stator tooth to said second stator tooth includes substantially no excess length when said first stator tooth and second stator tooth are positioned side-by-side.
- The present invention provides advantages in that since the length of the span of wire between two stator teeth is controlled during winding, the stator teeth can be positioned in a stator side-by-side with substantially no excess wire extending therebetween. Also, by vertically offsetting the stator teeth relative to one another during winding, the stator teeth can be positioned further apart, thus facilitating winding, and allowing the length of wire extending between the stator teeth to be more easily controlled. Further, the present invention allows for stator teeth to be wound in alternating orientations while retaining control over the span of wire extending between pairs of stator teeth.
- An embodiment of the present invention will now be described, more fully with reference to the accompanying drawings in which:
-
FIG. 1 is a side elevation view of an apparatus for winding stator teeth in accordance with the present invention; -
FIG. 2 is a perspective view of a portion of the apparatus ofFIG. 1 ; -
FIG. 3 is a perspective view of a sub assembly forming part of a stator teeth holding tool; -
FIG. 4 is a perspective view of a turret forming part of the stator teeth holding tool; -
FIG. 5 is a top plan view of the turret; -
FIG. 6 shows two stator teeth in their relative positions when mounted on the turret; and -
FIG. 7 shows the two stator teeth ofFIG. 6 when removed from the turret and positioned side-by-side. - Turning now to FIGS. 1 to 3, an apparatus for winding stator teeth in accordance with the present invention is shown and is generally identified by
reference numeral 10.Apparatus 10 includes a plurality offly winders 12 and a statorteeth holding tool 14. For ease of illustration only onefly winder 12 is shown. Also, since fly winders are well known in the art, for ease of illustration, some of the components of the fly winder have been omitted from the figures. Eachfly winder 12 includes aflyer head 24 having aflyer arm 28 and acounterweight 32 joined by acentral body section 34. Anozzle 36 is positioned at the distal end of theflyer arm 28 and is operable to dispense wire to be wound around stator teeth whenflyer head 24 is rotated about a central horizontal axis. A pair of redirector pulleys 40 and 44 allow wire to be routed tonozzle 36.Pulley 40 is positioned within achannel 46 provided in theflyer arm 28, adjacent thenozzle 36, andpulley 44 is positioned on thecentral body section 34.Flyer head 24 is mounted on a rotating hollow shaft (not shown), providingflyer head 24 with rotational movement in both directions about an axis coaxial with opening 48 in thecentral body section 34. Further, thefly winder 12 is operable to moveflyer head 24 along the two axes of a horizontal plane. Wire to be dispensed by thefly winder 12 passes overredirector pulley 44, throughchannel 46 in theflyer arm 28, overredirector pulley 40 and throughnozzle 36. - The stator
teeth holding tool 14 presents stator teeth to thefly winders 12 to enable thefly winders 12 to wind coils thereon. As shown inFIG. 3 , statorteeth holding tool 14 includes asub assembly 50 supporting a plurality ofposts 52.Sub assembly 50 includes a pair ofmotors 54 and amotor 56. Eachmotor 54 is associated with a pair ofposts 52 and is coupled to the pair of posts by a transmission. In this manner, eachmotor 54 is operable to rotate eachpost 52 in its associated pair about the central longitudinal axis of eachpost 52.Motor 56 is operable to raise and lower theposts 52. - A
fixturing detail 60 is disposed on the top of eachpost 52. Aturret 62 is slidably received by and rests on eachpost 52. Only oneturret 62 is shown in the figures for ease of illustration. In this embodiment,turret 62 includes a pair ofpegs 64 around which wire is turned in preparation for termination. A stationary tie-off post 66 is positioned on thesub assembly 50 adjacent eachpost 52. Eachturret 62 is associated with one of thefly winders 12. In conjunction with the two degrees of movement ofturret 62 by virtue of the movement of theposts 52,flyer head 24 of its associatedfly winder 12 has five degrees of movement relative to theturret 62. -
FIGS. 4 and 5 better illustrate one of theturrets 62. As can be seen, theturret 62 includes amain body 70 that is generally cylindrical in shape when viewed in top plan. A pair ofclamp assemblies 72 are accommodated bycutouts 74 provided in themain body 70 to receive and retain a pair ofstator teeth cutouts 74 are positioned 90 degrees apart relative to the outerperipheral surface 76 of theturret 62 and are vertically offset. The outerperipheral surface 76 of theturret 62 bridging thecutouts 74 is arcuate. - Each
clamp assembly 72 includes aback plate 80 and a pair of side clamps 82 that define a dove-tailed channel 84 accessible from the top and bottom. The side clamps 82 are designed to engage a stator tooth 100 to be wound that is inserted into the dove-tailed channel 84. In order to enable the side clamps 82 to engage the stator tooth, theback plate 80 accommodates a cam-shaped member (not shown). The cam-shaped member is actuable between an engaged state wherein the stator tooth 100 is engaged by the side clamps 82 and retained by theclamp assembly 72 and a disengaged state wherein the stator tooth is moveable along the dove-tailed channel 84. In the engaged state, the cam-shaped member projects outwardly from theback plate 80 to contact and bias the stator tooth 100 into engagement with the side clamps 82 thereby to retain the stator tooth. - Since the
turret 62 is designed to support only two stator teeth 100, themain body 70 of the turret only includes structure to engage stator teeth at the desired positions thereby to reduce the weight of the turret. By reducing the weight ofturret 62, less stress is placed on automation machinery that is used to mount anddismount turrets 62 on theposts 52. - Each stator tooth 100 includes an
outer arc plate 102, aninner arc plate 104 and a windingcore 106 between theplates outer arc plate 102 is shaped generally complimentary to the dove-tailed channel 84 to facilitate insertion of the outer arc plate therein. - During operation, two
stator teeth turret 62 by sliding them into the dove-tailed channels 84 of theclamp assemblies 72 before eachturret 62 is secured to arespective post 52. The cam-shaped members withinback plates 80 are then actuated to engage andbias stator teeth turrets 62 are then mounted onto the fixturing details 60 disposed on theposts 52 and preferably locked in place to avoid vertical movement of theturrets 62 during winding. In this condition for eachturret 62, onestator tooth 100 a is positioned towards a lower end of theturret 62, whereas theother stator tooth 100 b is positioned towards an upper end of theturret 62, and spaced 90 degrees about the circumference of theturret 62. As thestator teeth turret 62, a wire spanning the two stator teeth must undergo a 90 degree change of direction. The arcuate outerperipheral surface 76 of themain body 70 spanning the cutouts allows a span of wire to be gradually routed from the top of one of stator tooth to the bottom of the other stator tooth, thus avoiding unnecessary sharp bends in the wire, which can damage the wire enamel and cause downstream rejects in the electric machinery in which thestator teeth - Each
post 52 and associatedturret 62 are then lowered to present one of thepegs 64 to theflyer head 24 of its associatedfly winder 12. For each turret and fly winder pair, a wire extending from stationary tie-off post 66 to thenozzle 36 of theflyer head 24 is turned around the presentedpeg 64 by moving theflyer head 24 along the two horizontal axes of movement. The wire protruding from thenozzle 36, which was terminated to the stationary tie-off post 66 or clamped at the end of the last wind cycle, is thus wound around peg 64 under tension. Next, thepost 52 andturret 62 is rotated and raised to present afirst stator tooth 100 a to theflyer head 24 for winding. It is preferable to positionstator tooth 100 a in the axis of rotation of theflyer head 24 so that the wire is distributed evenly about stator tooth and is generally evenly tensioned thereabout.Flyer head 24 is then positioned in front ofstator tooth 100 a and a pre-set number of loops of wire are coiled around stator tooth in a counter-clockwise direction, with theflyer 24 head moving incrementally further fromturret 62 with each loop of wire thereby to evenly distribute the wire about windingcore 106. Once a first set of loops has been wound around the windingcore 106,flyer head 24 moves slowly towardturret 62 all whileflyer head 24 continues to rotate about thestator tooth 100 a to wind a second set of loops of wire about windingcore 106. - Once the second set of loops is complete,
turret 62 is rotated and lowered to present thesecond stator tooth 100 b toflyer head 24 for winding. As this is done, a span ofwire 110 is extended from the top of thefirst stator tooth 100 a to the bottom of thesecond stator tooth 100 b. At this point,flyer head 24 is operated in a clockwise direction to wind a first set of loops of wire aroundstator tooth 100 b, all whileflyer head 24 moves incrementally away fromturret 62 with each loop. Once the first set of loops is complete,flyer head 24 begins to move slowly towardturret 62 to distribute a second set of loops of wire evenly around windingcore 106. - Upon completion of the second set of loops,
turret 62 is lowered andflyer head 24 is moved through the two horizontal axes to form a set of turns about a second of thepegs 64. Upon completion of the set of turns,flyer head 24 moves to wind a set of loops of wire around the stationary tie-off post 66. The wire is then cut between thepegs 64 and the stationary tie-off post 66. - At this point,
turret 62 having two wound stator teeth is removed frompost 52 by unsecuring it and lifting it, making room for anotherturret 62 bearing a set of stator teeth to be wound. Completed stator teeth are then removed fromturret 62 by actuating the cam-shaped members to allow the completed stator teeth to slide out of the dove-tailed channels 84. -
FIG. 6 shows a pair ofstator teeth coils 108 formed thereon and joined by the span ofwire 110. A terminatingwire end 112 extends from each stator tooth for connection in a stator.Arrows 114 depict the direction in which stator teeth are moved to arrive at their final relative position side-by-side, as shown inFIG. 7 , wherein span ofwire 110 is taut and includes substantially no excess length. As will be appreciated, in this final position, adjacent stator teeth have coils of opposite orientation; that is, one is wound clockwise and another is wound counter-clockwise. - While the present invention has been described with specificity to mounting stator teeth onto a turret that presents the stator teeth to the fly winder for winding, other types of stator teeth supports will occur to those of ordinary skill in the art. For example, a plate having a number of positions for securing stator teeth in a similar fashion as employed in the described embodiment can be used. The plate can be raised and lowered relative to the fly winder just as the turret, and can be moved relative to the fly winder along a longitudinal axis to present a different stator tooth to the flyer head, simulating the rotation of the turret.
- The positions of the stator teeth on the turret can be made adjustable to allow different dimensioned stator teeth to be coiled using the same turret. Further, the turret can be made expandable, through additional concentric surface layers on its periphery, through the placement of each stator tooth on a separate arcuate plate whose distance from the center of the turret can be adjustable, or through some other means.
- Although the stator teeth are shown as being positioned ninety degrees apart about the circumference of the turret, it is to be appreciated that the stator teeth can be positioned in other configurations. For instance, the stator teeth can be placed along the circumference of the turret at varying degrees, depending on the circumference of the turret, the relative vertical separation of the stator teeth positions along the vertical length of the turret, and any variation in the radial distance of the stator teeth positions along the surface of the turret.
- While specific reference is made to the posts upon which the turrets are mounted being controlled by a set of motors, other methods of controlling the posts will occur to those skilled in the art. For example, pneumatic or hydraulic means can be alternatively employed to control movement of the posts.
- The turrets can be equipped with clamps in place of pegs to engage the wire ends during the start and end of the winding process. This method of termination is well-suited to work with both a wire which has been previously terminated on a stationary tie-off post, and one which is loosely hanging out of the flyer nozzle, and is especially beneficial for use with heavier gauge wires.
- Although the clamp assemblies are described as including cam-shaped members to bias the stator teeth into engagement with the side clamps, other means of securing the stator teeth to the turrets during the winding process can be used. For example, the stator teeth can be frictionally fit into the dove-tailed channels.
- Also, although the apparatus is described as including a fly winder associated with each turret, fewer fly winders that are moveable laterally between multiple turret locations can be used.
- Although embodiments of the present invention have been described, those of skill in the art will appreciate that the variations and modifications may be made without departing from the spirit and scope thereof as defined by the appended claims.
Claims (37)
1. An apparatus for winding stator teeth, comprising:
at least one fly winder for winding wire around stator teeth; and
at least one stator teeth holder including stator tooth retainers at spaced locations for retaining stator teeth thereon, said at least one stator tooth holder and fly winder being moveable relative to one another to present each stator tooth to said at least one fly winder for winding a wire coil thereon, wherein said stator tooth retainers are relatively positioned on said at least one stator teeth holder to control a span of wire extending between said stator teeth after said stator teeth have been presented to said at least one fly winder and wound.
2. An apparatus for winding stator teeth according to claim 1 wherein said stator teeth holder is rotatable to present each stator tooth to said fly winder.
3. An apparatus for winding stator teeth according to claim 2 wherein said stator tooth retainers are circumferentially spaced about said stator teeth holder.
4. An apparatus for winding stator teeth according to claim 3 wherein said stator tooth retainers are vertically offset with respect to one another, said stator teeth holder also being vertically adjustable to present each stator tooth to said fly winder.
5. An apparatus for winding stator teeth according to claim 4 wherein said stator teeth holder includes a pair of stator tooth retainers, each for retaining a single stator tooth.
6. An apparatus for winding stator teeth according to claim 5 wherein said fly winder winds each stator tooth in a manner so that the coils on said stator teeth have opposite orientations.
7. An apparatus for winding stator teeth according to claim 6 wherein each stator tooth retainer includes a channel shaped to accommodate a stator tooth.
8. An apparatus for winding stator teeth according to claim 7 wherein said channel is defined by a clamp assembly accommodated by said stator teeth holder.
9. An apparatus for winding stator teeth according to claim 8 wherein said clamp assembly includes a pair of side clamps for engaging opposite sides of a stator tooth.
10. An apparatus for winding stator teeth according to claim 9 wherein said clamp assembly further includes a biasing member actuable between engaged and disengaged states, in said engaged state said biasing member biasing said stator tooth into engagement with said side clamps.
11. An apparatus for winding stator teeth according to claim 9 wherein said channel is sized to form a friction fit with said stator tooth.
12. An apparatus for winding stator teeth according to claim 8 wherein said stator teeth holder includes a main body including a pair of cutouts formed therein, each of said cutouts accommodating a respective clamp assembly, said main body presenting a generally arcuate outer surface bridging said cutouts.
13. An apparatus for winding stator teeth according to claim 12 wherein said clamp assembly includes a pair of side clamps for engaging opposite sides of a stator tooth.
14. An apparatus for winding stator teeth according to claim 13 wherein said clamp assembly further includes a biasing member actuable between engaged and disengaged states, in said engaged state said biasing member biasing said stator tooth into engagement with said side clamps.
15. An apparatus for winding stator teeth according to claim 13 wherein said channel is sized to form a friction fit with said stator tooth.
16. An apparatus for winding stator teeth according to claim 1 including a plurality of stator teeth holders, each of said stator teeth holders being moveable to present each stator tooth held thereby to said at least one fly winder for winding a wire coil thereon.
17. An apparatus for winding stator teeth according to claim 16 wherein each stator teeth holder is rotatable to present each stator tooth held thereby to said fly winder.
18. An apparatus for winding stator teeth according to claim 17 wherein the stator tooth retainers on each of said stator teeth holders are circumferentially spaced about said stator teeth holding tool.
19. An apparatus for winding stator teeth according to claim 18 wherein said stator tooth retainers on each of said stator teeth holders are vertically offset with respect to one another, each stator teeth holder also being vertically adjustable to present each stator tooth held thereby to said fly winder.
20. An apparatus for winding stator teeth according to claim 19 wherein each stator teeth holder includes a pair of stator tooth retainers, each for retaining a single stator tooth.
21. An apparatus for winding stator teeth according to claim 20 wherein said fly winder winds each stator tooth in a manner so that the coils on said stator teeth have opposite orientations.
22. An apparatus for winding stator teeth according to claim 1 including a plurality of stator teeth holders and fly winder pairs, each stator teeth holder being moveable to present each stator tooth held thereby to its associated fly winder for winding a wire coil thereon.
23. An apparatus for winding stator teeth according to claim 22 wherein each stator teeth holder is rotatable to present each stator tooth held thereby to its associated fly winder.
24. An apparatus for winding stator teeth according to claim 23 wherein said stator tooth retainers on each stator teeth holder are circumferentially spaced about said stator teeth holder.
25. An apparatus for winding stator teeth according to claim 24 wherein said stator tooth retainers on each stator teeth holder are vertically offset with respect to one another, each stator teeth holder also being vertically adjustable to present each stator tooth held thereby to its associated fly winder.
26. An apparatus for winding stator teeth according to claim 25 wherein each stator teeth holder includes a pair of stator tooth retainers, each for retaining a single stator tooth.
27. An apparatus for winding stator teeth according to claim 26 wherein each fly winder winds each stator tooth in a manner so that the coils on said stator teeth have opposite orientations.
28. An apparatus for winding stator teeth, comprising:
a fly winder for winding wire around stator teeth; and
a stator teeth holder including a rotatable turret having a main body and stator tooth retainers at spaced locations on said main body for retaining stator teeth, said turret being rotatable to present each stator tooth to said fly winder for winding a wire coil thereon, wherein said stator tooth retainers are relatively positioned on said turret in a manner such that after said stator teeth have been wound by said fly winder to include coils of opposite orientation, removed from said turret and placed side-by-side, the span of wire extending between said stator teeth includes substantially no excess length.
29. An apparatus for winding stator teeth according to claim 28 wherein said stator tooth retainers are vertically offset with respect to one another, said turret also being vertically adjustable to present each stator tooth to said fly winder.
30. An apparatus for winding stator teeth according to claim 29 wherein said turret includes a pair of stator tooth retainers, each for retaining a single stator tooth.
31. An apparatus for winding stator teeth according to claim 30 wherein each stator tooth retainer includes a channel shaped to accommodate a stator tooth.
32. An apparatus for winding stator teeth according to claim 31 wherein said channel is defined by a clamp assembly accommodated by said main body.
33. An apparatus for winding stator teeth according to claim 32 wherein said clamp assembly includes a pair of side clamps for engaging opposite sides of a stator tooth.
34. An apparatus for winding stator teeth according to claim 33 wherein said clamp assembly further includes a biasing member actuable between engaged and disengaged states, in said engaged state said biasing member biasing said stator tooth into engagement with said side clamps.
35. An apparatus for winding stator teeth according to claim 33 wherein said channel is sized to form a friction fit with said stator tooth.
36. An apparatus for winding stator teeth according to claim 32 wherein said main body includes a pair of cutouts formed therein, each of said cutouts accommodating a respective clamp assembly, said main body presenting a generally arcuate outer surface bridging said cutouts.
37. A method of winding stator teeth, comprising:
mounting a first stator tooth and a second stator tooth at spaced locations on a tool;
presenting said first stator tooth to a winding device and winding a coil having a first orientation thereon;
biasing said tool to present said second stator tooth to said winding device; and
winding a coil on said second stator tooth having an orientation opposite that of the coil wound on said first stator tooth, wherein the relative locations of said first stator tooth and said second stator tooth on said tool are such that the span of wire extending from said first stator tooth to said second stator tooth includes substantially no excess length when said first stator tooth and second stator tooth are positioned side-by-side.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US10/888,564 US20050051661A1 (en) | 2003-07-07 | 2004-07-07 | Apparatus and method for winding stator teeth |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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US48464903P | 2003-07-07 | 2003-07-07 | |
US10/888,564 US20050051661A1 (en) | 2003-07-07 | 2004-07-07 | Apparatus and method for winding stator teeth |
Publications (1)
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US20050051661A1 true US20050051661A1 (en) | 2005-03-10 |
Family
ID=33564013
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US10/888,564 Abandoned US20050051661A1 (en) | 2003-07-07 | 2004-07-07 | Apparatus and method for winding stator teeth |
Country Status (3)
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US (1) | US20050051661A1 (en) |
CA (1) | CA2473186A1 (en) |
WO (1) | WO2005004311A1 (en) |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2011010281A1 (en) | 2009-07-22 | 2011-01-27 | Control Techniques Dynamics Limited | Electric device stator and methods for winding |
ITPI20130052A1 (en) * | 2013-06-11 | 2014-12-12 | Atop Spa | EQUIPMENT AND METHOD TO POSITION AND WRAP ELEMENTS OF POLE OF DYNAMIC ELECTRIC MACHINES |
CN114785069A (en) * | 2022-05-16 | 2022-07-22 | 江苏润杨精密制造有限公司 | Winding device for motor stator production and processing |
US11851221B2 (en) | 2022-04-21 | 2023-12-26 | Curium Us Llc | Systems and methods for producing a radioactive drug product using a dispensing unit |
Families Citing this family (3)
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DE112012006426T5 (en) * | 2012-05-28 | 2015-02-26 | Mitsubishi Electric Corporation | Winding device, winding method and method of manufacturing an armature |
DE102014218602A1 (en) * | 2014-09-16 | 2016-03-17 | Continental Automotive Gmbh | Method for winding a plurality of bobbins and segmented spindle |
JP6629366B2 (en) * | 2018-02-23 | 2020-01-15 | 本田技研工業株式会社 | Collecting device |
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US6070826A (en) * | 1997-09-25 | 2000-06-06 | Axis Usa, Inc. | Armature winder shroud changing apparatuses and methods |
US20030098628A1 (en) * | 2001-11-29 | 2003-05-29 | Yuuji Enomoto | Electric motor |
US6941644B2 (en) * | 1999-09-27 | 2005-09-13 | Reliance Electric Technologies, Llc | Method for winding segments of a segmented wound member of an electromechanical device |
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JP3190511B2 (en) * | 1994-03-02 | 2001-07-23 | 三菱電機株式会社 | Rotary motor and method of manufacturing the same |
JP3017085B2 (en) * | 1995-11-02 | 2000-03-06 | 三菱電機株式会社 | Rotating electric machine and method of manufacturing the same |
JP3432452B2 (en) * | 1999-05-10 | 2003-08-04 | 三菱電機株式会社 | Winding machine |
JP4262378B2 (en) * | 1999-11-19 | 2009-05-13 | 本田技研工業株式会社 | Stator winding device |
JP4514171B2 (en) * | 2000-07-14 | 2010-07-28 | 株式会社小田原エンジニアリング | Stator manufacturing method and manufacturing apparatus |
-
2004
- 2004-07-07 US US10/888,564 patent/US20050051661A1/en not_active Abandoned
- 2004-07-07 WO PCT/CA2004/000982 patent/WO2005004311A1/en active Application Filing
- 2004-07-07 CA CA002473186A patent/CA2473186A1/en not_active Abandoned
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US6070826A (en) * | 1997-09-25 | 2000-06-06 | Axis Usa, Inc. | Armature winder shroud changing apparatuses and methods |
US6941644B2 (en) * | 1999-09-27 | 2005-09-13 | Reliance Electric Technologies, Llc | Method for winding segments of a segmented wound member of an electromechanical device |
US20030098628A1 (en) * | 2001-11-29 | 2003-05-29 | Yuuji Enomoto | Electric motor |
US7011266B2 (en) * | 2002-08-08 | 2006-03-14 | Aisin Aw Co., Ltd. | Coil forming device and coil forming method |
Cited By (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2011010281A1 (en) | 2009-07-22 | 2011-01-27 | Control Techniques Dynamics Limited | Electric device stator and methods for winding |
US10530200B2 (en) | 2009-07-22 | 2020-01-07 | Control Techniques Dynamics Limited | Electric device stator and methods for winding |
ITPI20130052A1 (en) * | 2013-06-11 | 2014-12-12 | Atop Spa | EQUIPMENT AND METHOD TO POSITION AND WRAP ELEMENTS OF POLE OF DYNAMIC ELECTRIC MACHINES |
WO2014198561A3 (en) * | 2013-06-11 | 2015-03-26 | Atop S.P.A. | Apparatus and method for positioning and winding pole members of dynamo electric machines |
KR20160019063A (en) * | 2013-06-11 | 2016-02-18 | 어탑 에스.피.에이. | Apparatus and method for positioning and winding pole members of dynamo electric machines |
US10418888B2 (en) | 2013-06-11 | 2019-09-17 | Atop S.P.A. | Apparatus and method for positioning and winding pole members of dynamo electric machines |
KR102294969B1 (en) * | 2013-06-11 | 2021-08-27 | 어탑 에스.피.에이. | Apparatus and method for positioning and winding pole members of dynamo electric machines |
US11851221B2 (en) | 2022-04-21 | 2023-12-26 | Curium Us Llc | Systems and methods for producing a radioactive drug product using a dispensing unit |
CN114785069A (en) * | 2022-05-16 | 2022-07-22 | 江苏润杨精密制造有限公司 | Winding device for motor stator production and processing |
Also Published As
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WO2005004311A1 (en) | 2005-01-13 |
CA2473186A1 (en) | 2005-01-07 |
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