Coil winding armatures and arrangement of parallel coils

• US 5,155,403 A
• Filed: 05/24/1991
• Issued: 10/13/1992
• Est. Priority Date: 05/24/1990
• Status: Expired due to Term

• Current Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Gifford, Carl, Dyke, Colin
• Primary Examiner(s): Stephan, Steven L.
• Assistant Examiner(s): HASZKO, DENNIS
• Application Number:
  US07/705,496
• Time in Patent Office: 508 Days
• Field of Search: 310/40 MM, 310/206, 310/208, 310/234, 310/233, 310/264, 310/158, 310/184, 310/179, 310/198, 310/210, 310/204, 310/71, 310/215
• US Class Current: 310/208
• CPC Class Codes: H02K 13/04 Connections between commutator segments and windings
• CPC Class Codes: H02K 15/09 by laying conductors into slotted rotors
• CPC Class Codes: H02K 23/26 characterised by the armature windings

Abstract

A method of winding a motor armature includes providing a sub-assembly comprising a shaft having an armature core and a commutator mounted thereon, the commutator having commutator bars spaced apart about the shaft with each bar having leading and trailing wire connection devices angularly spaced apart with respect to said shaft. A first wire is connected to a leading wire connection device and a second wire is connected to a leading connection device on the other side of the commutator. The successive coils are separately wound on the armature core from the first and second wires with connection of each wire to a different leading connection device between successive coils. Thereafter further successive coils are separately wound on the core from the wires but now with connection of the wires between successive coils to trailing connection devices until the commutator bars have pairs of electrically parallel coils connected thereto. Armatures can be produced having parallel coils of 17 gauge copper wire by continuous winding with end termination only occurring after completion of winding.

Claims

1. An armature, comprising:

an armature core and a commutator supported on a shaft;

said core having an inner set of coils wound thereon and an outer set of coils wound on top of said inner set;

half of said inner set and half of said outer set being formed by a first continuous wire, the remaining half of said inner set and the remaining half of said outer set being formed by a second continuous wire;

said commutator having a plurality of commutator bars each having a pair of wire connecting devices; and

the first and second wires being connected to said bars between coils of said inner set by only one of the wire connecting devices of each said pair of devices, with said wires being connected to said bars between coils of said outer set by only the other of the wire connecting devices of each said pair of devices.

2. The armature of claim 1, wherein said connecting devices are disposed in a circle about said shaft, each said pair of devices having a leading device and a trailing device in a specific direction of rotation of said shaft.

3. The armature of claim 2, wherein said one of each said pair of devices is a said leading device and said other of each said pair of devices is a said trailing device.

4. The armature of claim 1, wherein each said pair of connecting devices comprises a pair of spaced-apart slots in the respective commutator bar.

5. The armature of claim 1, wherein:

said core has a plurality of cavities extending parallel to said shaft;

everyone of the coils of said inner and outer sets of coils being wound through two of said cavities; and

each cavity having therethrough one of said inner set of coils wound from one of said wires and one of said outer set of coils wound from the other of said wires.

6. An armature, comprising:

an armature core and a commutator supported on a shaft;

said core having an inner set of coils wound thereon and an outer set of coils wound on top of said inner set;

one half of said inner set and one half of said outer set all being formed by a first continuous wire, the remaining half of said inner set and the remaining half of said outer set all being formed by a second continuous wire;

said commutator having a plurality of spaced-apart commutator bars each having first and second wire connecting devices;

said first and second wires being connected to said commutator bars between coils of said inner set by only said first wire connecting devices of said pairs of devices;

said first and second wires being connected to said commutator bars between coils of said outer set by only said second wire connecting devices of said pairs of devices;

said armature core having a plurality of cavities extending therethrough;

everyone of the coils of said inner and outer sets of coils being wound through two of said cavities;

each cavity having therethrough one of said inner set of coils wound from one of said wires and one of said outer set of coils wound from the other of said wires; and

said one of said inner set of coils and said one of said outer set of coils being connected between a common pair of commutator bars and being so connected in parallel.

7. An electric motor armature, comprising:

a shaft defining a rotational axis of the armature;

a laminated core mounted on the shaft and having axially extending coil cavities open radially with respect to the shaft;

a commutator mounted on the shaft and spaced axially from said core, said commutator having a plurality of axially extending commutator bars spaced apart around said axis;

each commutator bar having therein, at an end nearest to said core, a pair of parallel, axially extending slots, in a selected direction of rotation of the armature about said axis each said pair of slots comprising a leading slot and a trailing slot;

a first series of coils formed from a first single wire and disposed in said cavities, each coil of said first series being wound through a different two of said cavities;

a second series of coils formed from a second single wire and disposed in said cavities, each coil of said second series being wound through a different two of said cavities;

said first wire having two ends secured one on top of the other in a leading slot of a first commutator bar, and said second wire having two ends secured one on top of the other in a leading slot of a second commutator bar diametrically opposite said first commutator bar with respect to said axis;

a second half of the coils of said first series being wound on top of a first half of the coils of said second series, and a second half of the coils of said second series being wound on top of a first half of the coils of said first series;

the first wire being looped over on itself and secured in a respective one of said leading slots between coils of said first half of said first series of coils;

the second wire being looped over on itself and secured in a respective one of said leading slots between coils of said first half of said second series of coils;

the first wire being looped over on itself and secured in a respective one of said trailing slots between coils of said second half of said first series of coils;

the second wire being looped over on itself and secured in a respective one of said trailing slots between coils of said second half of said second series of coils; and

each first series coil and second series coil which are wound one on top of the other being connected between a pair of commutator bars with one of these coils being connected to the leading slots of the pair of commutator bars and the other of these coils being connected to the trailing slots of these commutator bars to connect the coils wound on top of each other in parallel.

8. The armature of claim 7, wherein each said coil is formed by three turns of 17 gauge copper wire.

9. An armature, comprising:

a shaft having an armature core and a commutator mounted thereon;

said commutator having a plurality of bars angularly spaced apart about said shaft;

each commutator bar having first and second wire connection devices angularly spaced apart with respect to said shaft;

a first series of coils formed by a first continuous wire, and a second series of coils formed by a second continuous wire;

each said commutator bar having connected thereto four coils;

said four coils providing two pairs of parallel coils with the two coils of each pair of parallel coils being formed by one of said first series of coils and one of said second series of coils;

said four coils also providing two non-parallel coils connected to the first wire connecting device of the respective commutator bar and two non-parallel coils connected to the second wire connection device of that respective commutator bar; and

said first and second continuous wires each having two ends, the two ends of said first wire both being connected to a selected one of said first wire connection devices, the two ends of said second wire both being connected to a selected different one of said first connection devices, and said selected one and different one of said wire connection devices being on different commutator bars.

10. The armature of claim 9, wherein:

said armature core has a plurality of cavities; and

each of said cavities has wound therethrough one coil of said first series of coils and one coil of said second series of coils.

11. The armature of claim 10, wherein the two said one coils wound through a respective cavity comprise a top coil and a bottom coil with the top coil being wound on top of the bottom coil.

12. The armature of claim 11, wherein the two said one coils are parallel coils.

13. The armature of claim 12, wherein half the coils of each of said first and second series of coils are top coils, and half the coils of each of said first and second series of coils are bottom coils.

14. The armature of claim 13, wherein a second half of the coils of said first series of coils are wound on top of a first half of the coils of said second series of coils, and a second half of the coils of said second series of coils are wound on top of a first half of the coils of said first series of coils.

15. The armature of claim 9, wherein said first and second wire connection devices of each commutator bar comprise a pair of parallel slots, each slot containing two portions of the same wire with one portion on top of the other portion.

16. An armature, comprising:

a shaft having an armature core and a commutator mounted thereon;

said commutator having a plurality of bars angularly spaced apart about said shaft;

each commutator bar having first and second wire connection divides angularly spaced apart with respect to said shaft;

a first series of coils formed by a first continuous wire, and a second series of coils formed by a second continuous wire;

said coils being wound through said armature core;

each said commutator bar having connected thereto at least four coils;

said four coils comprising two pairs of parallel coils with the two coils of each pair of parallel coils being formed by one coil of said first series of coils and one coil of said second series of coils;

each such pair of parallel coils having the coils thereof connected to different ones of the wire connection devices of a respective one of said commutator bars;

said first and second series of coils each comprising first and second halves, the second half of the coils of each series being wound after the first half of the coils of the respective series;

the second half of the coils of said first series of coils being wound on top of the first half of the coils of said second series of coils; and

the second half of the coils of said second series of coils being wound on top of the first half of the coils of said first series of coils.

17. The armature of claim 16, wherein said first and second wires are each formed by a single filament copper wire of 17 gauge.