Method for making armatures for electrodynamic machines

• US 5,522,125 A
• Filed: 09/09/1994
• Issued: 06/04/1996
• Est. Priority Date: 02/03/1992
• Status: Expired due to Term

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Wiedemann, Gustave F., Pierre, David M., Bradtmueller, Lynn E., Smitley, Ronnie G.
• Primary Examiner(s): Hall, Carl E.
• Application Number:
  US08/304,007
• Time in Patent Office: 634 Days
• Field of Search: 29/596-598, 29/732, 29/736, 29/564.1, 29/564.6, 29/564.8
• US Class Current: 29/598
• CPC Class Codes: H02K 13/04 Connections between commutator segments and windings
• CPC Class Codes: H02K 15/064 Windings consisting of separate segments, e.g. hairpin windings H02K15/063 takes precedence
• CPC Class Codes: Y10T 29/49011 Commutator or slip ring assembly
• CPC Class Codes: Y10T 29/49012 Rotor
• CPC Class Codes: Y10T 29/5137 including assembling or disassembling station
• CPC Class Codes: Y10T 29/53161 including deforming means

Abstract

An operator sequentially inserts into an automated system for making armatures for electrodynamic machines loaded magazines containing a required number of hairpin conductors for an armature to be made, an armature core comprising a plurality of substantially aligned laminations preassembled to form the core and a commutator, and removes armatures completed by assembling these components. All the insertion and removal steps are performed from an operator'"'"'s position such that operation of the system embodying the present invention is easily and conveniently performed even though the components and completed armatures can be of substantial weight. The use of a hairpin magazine, including the hairpin conductors required for an armature, permits simultaneous transfer of all the hairpin conductors into upper twist tooling wherein upper ends of the hairpin conductors adjacent end turn portions of the conductors are moved apart relative to one another. The frog leg conductors thus formed are removed from the upper twist tooling and inserted into slots of an armature core which has been earlier inserted into the system. The frog leg conductors are fully pressed through the armature core into lower twist tooling which then is operated to move the ends of the conductors extending beyond the armature core away from one another and into alignment with other conductors for insertion into a commutator for the armature, which commutator was earlier placed into the system. The commutator is properly positioned beneath the armature core which is then pressed onto the commutator. The completed armature is moved to the operator'"'"'s position where the operator removes the completed armature and replaces it with a commutator for the next armature. The operator continues to insert components of armatures into the system and removes completed armatures made up by assembling the components so inserted.

Claims

1. A method of making an armature for a dynamoelectric machine comprising the steps of:

simultaneously moving a defined plurality of hairpin conductors into upper twist tooling;

operating said upper twist tooling to rotate legs of said hairpin conductors adjacent end turns of said hairpin conductors to displace said legs in opposite directions relative to one another by a defined angular displacement corresponding to said upper twist and thereby changing the conductors to frog leg conductors having a spread-legged configuration;

removing said plurality of frog leg conductors from said upper twist tooling;

inserting said frog leg conductors into an armature core defining a plurality of conductor receiving slots corresponding to said defined plurality around the periphery thereof;

driving said frog leg conductors through said armature core to extend into lower twist tooling positioned adjacent said armature core;

operating said lower twist tooling to rotate the distal ends of the legs of said frog leg conductors to displace said legs in opposite directions relative to one another by a defined angular displacement corresponding to said lower twist; and

pressing a commutator onto said armature core to receive the distal ends of the legs of said frog leg conductors.

2. A method of making an armature for a dynamoelectric machine as claimed in claim 1 wherein the step of simultaneously moving a defined plurality of hairpin conductors into upper twist tooling comprises the steps of:

preforming said defined plurality of hairpin conductors;

loading said defined plurality of hairpin conductors into a magazine having a corresponding defined plurality of conductor receiving ports formed into the periphery thereof;

positioning said magazine adjacent said upper twist tooling; and

inserting a defined plurality of stripper blades into the conductor receiving ports of said magazine to move said defined plurality of hairpin conductors into said upper twist tooling.

3. A method of making an armature for a dynamoelectric machine as claimed in claim 2 further comprising the steps of:

engaging said magazine; and

moving said magazine to a return position after said conductors have been removed therefrom.

4. A method of making an armature for a dynamoelectric machine as claimed in claim 3 further comprising the step of moving said magazine away from said upper twist tooling to totally remove said conductors prior to moving said magazine to said return position.

5. A method of making an armature for a dynamoelectric machine as claimed in claim 1 wherein the step of removing said plurality of frog leg conductors from said upper twist tooling comprises the steps of:

inserting a defined plurality of stripper blades into said upper twist tooling to move said defined plurality of conductors out of said upper twist tooling; and

clamping said conductors in conductor engaging fingers, said conductors being supported by said conductor engaging fingers.

6. A method of making an armature for a dynamoelectric machine as claimed in claim 1 further comprising the step of:

inserting the distal ends of said frog leg conductors into alignment means prior to inserting said frog leg conductors into an armature core for forcing the distal ends of said conductors together and into proper alignment for insertion into an armature core.

7. A method of making an armature for a dynamoelectric machine as claimed in claim 1 wherein the step of inserting said conductors into an armature core comprises the steps of:

engaging the end turns of said conductors; and

applying an inserting force thereto.

8. A method of making an armature for a dynamoelectric machine as claimed in claim 1 wherein the step of inserting said conductors into an armature core comprises the steps of:

engaging the end turns of said conductors;

applying an inserting force thereto to partially insert said conductors into said armature core;

clamping said conductors by clamping fingers at a position spaced from said end turns; and

applying an inserting force to said conductors via said clamping fingers.

9. A method of making an armature for a dynamoelectric machine as claimed in claim 1 wherein the step of operating said upper twist tooling comprises the steps of:

operating said upper twist tooling in a first direction to rotate the legs of said hairpin conductors adjacent end turns thereof to displace said legs in opposite directions relative to one another by an angular displacement exceeding said defined angular displacement corresponding to said upper twist and thereby changing the conductors to a frog leg spread-legged configuration; and

operating said upper twist tooling in a second direction opposite to said first direction to return the legs of said conductors adjacent end turns thereof to said defined angular displacement and thereby stably displace said legs adjacent said end turns by said defined angular displacement corresponding to said upper twist.

10. A method of making an armature for a dynamoelectric machine as claimed in claim 9 wherein the step of operating said upper twist tooling in said first direction is performed to displace said legs by a circumferential distance corresponding to x+1 slots of said armature core;

and, the step of operating said upper twist tooling in said second direction is performed to displace said legs by a circumferential distance corresponding to 1 slot of said armature core, x being equal to the defined angular displacement corresponding to said upper twist in terms of slots of said armature core.

11. A method of making an armature for a dynamoelectric machine as claimed in claim 1 wherein the step of operating said lower twist tooling comprises the steps of:

monitoring the circumferential positioning of said armature core;

operating said lower twist tooling to displace the legs of said conductors adjacent distal ends thereof in opposite directions relative to one another, said armature core being circumferentially displaced by operating said lower twist tooling, and said legs being rotated until said armature core is angularly displaced by a defined circumferential distance;

clamping said armature core; and

operating said lower twist tooling until the legs of said conductors adjacent distal ends thereof are displaced relative to one another by said defined angular displacement corresponding to said lower twist.

12. A method of making an armature for a dynamoelectric machine comprising the steps of:

preforming an armature core defining a plurality of conductor receiving slots around the periphery thereof;

preforming a plurality of hairpin conductors each having two legs interconnected by an end turn;

preforming a commutator adapted to be received by said core;

preforming a magazine having a plurality of conductor receiving ports formed into the periphery thereof;

loading said plurality of hairpin conductors into said magazine;

placing a loaded magazine onto a first position of a turntable at a first operator'"'"'s station of said system, said first position of said turntable including upper twist tooling;

rotating said turntable one position such that said loaded magazine at said first position of said turntable is moved to a second station of said system and a second position of said turntable is moved to said first station of said system;

simultaneously loading said plurality of hairpin conductors into said upper twist tooling from said magazine;

rotating said turntable one position such that said loaded upper twist tooling at said first position of said turntable is moved to a third station of said system, said second position of said turntable is moved to said second station of said system, and a third position of said turntable is moved to said first station of said system, said third position of said turntable including lower twist tooling;

placing said armature core onto said third position of said turntable;

operating said upper twist tooling to rotate the legs of said hairpin conductors adjacent the end turns thereof to displace said legs in opposite directions relative to one another by a defined angular displacement corresponding to said upper twist;

removing said plurality of conductors from said upper twist tooling;

rotating said turntable one position such that said first position of said turntable is moved to a fourth station of said system, said second position of said turntable is moved to said third station of said system, said third position of said turntable is moved to said second station of said system, and a fourth position of said turntable is moved to said first station of said system, said plurality of conductors being retained at said third station of said system;

placing said commutator onto said fourth position of said turntable;

rotating said turntable one position such that said first position of said turntable is moved to said first station of said system, said second position of said turntable is moved to said fourth station of said system, said third position of said turntable is moved to said third station of said system, and said fourth position of said turntable is moved to said second station of said system, said armature core at said third position of said turntable being positioned adjacent said plurality of conductors at said third station of said system;

inserting said plurality of conductors into said armature core;

driving said conductors through said armature core to partially extend into said lower twist tooling positioned adjacent said armature core;

rotating said turntable one position such that said first position of said turntable is moved to said second station of said system, said second position of said turntable is moved to said first station of said system, said third position of said turntable is moved to said fourth station of said system, and said fourth position of said turntable is moved to said third station of said system, said conductors being extended fully through said armature core and fully into said lower twist tooling at said fourth station of said system;

operating said lower twist tooling to rotate the distal ends of the legs of said conductors to displace said legs in opposite directions relative to one another by a defined angular displacement corresponding to said lower twist;

removing said conductors from said lower twist tooling;

rotating said turntable one position such that said first position of said turntable is moved to said third station of said system, said second position of said turntable is moved to said second station of said system, said third position of said turntable is moved to said first station of said system, and said fourth position of said turntable is moved to said fourth station of said system, said commutator being positioned adjacent said armature at said fourth station of said system;

pressing said commutator onto said armature core to receive the distal ends of the legs of said plurality of conductors and thereby complete said armature;

rotating said turntable one position such that said first position of said turntable is moved to said fourth station of said system, said second position of said turntable is moved to said third station of said system, said third position of said turntable is moved to said second station of said system, and said fourth position of said turntable is moved to said first station of said system; and

removing said completed armature from said system at said first operator'"'"'s station.

13. A method of making an armature for a dynamoelectric machine as claimed in claim 12 wherein said second position of said turntable comprises alignment means for forcing the distal ends of said conductors together and into proper alignment for insertion into said armature core, and said method further comprises the step of inserting distal ends of said conductors into said alignment means prior to inserting said conductors into said armature core.

14. A method of making an armature for a dynamoelectric machine as claimed in claim 12 further comprising the steps of:

engaging said magazine; and

moving said magazine to a return position after said conductors have been removed therefrom.

15. A method of making an armature for a dynamoelectric machine as claimed in claim 14 further comprising the step of moving said magazine away from said upper twist tooling to totally remove said conductors prior to moving said magazine to said return position.

16. A method of making an armature for a dynamoelectric machine as claimed in claim 12 wherein the step of removing said plurality of conductors from said upper twist tooling comprises the steps of:

inserting a plurality of stripper blades into said upper twist tooling to move said plurality of conductors out of said upper twist tooling; and

clamping said conductors in conductor engaging fingers, said conductors being supported by said conductor engaging fingers.

17. A method of making an armature for a dynamoelectric machine as claimed in claim 12 wherein the step of inserting conductors into an armature core comprises the steps of:

engaging the end turns of said conductors; and

applying an inserting force thereto.

18. A method of making an armature for a dynamoelectric machine as claimed in claim 12 wherein the step of inserting conductors into an armature core comprises the steps of:

engaging the end turns of said conductors;

applying an inserting force thereto to partially insert said conductors into said armature core;

clamping said conductors by clamping fingers at a position spaced from said end turns; and

applying an inserting force to said conductors via said clamping fingers.

19. A method of making an armature for a dynamoelectric machine as claimed in claim 12 wherein the step of operating said upper twist tooling comprises the steps of:

operating said upper twist tooling in a first direction to rotate the legs of said hairpin conductors adjacent end turns thereof to displace said legs in opposite directions relative to one another by an angular displacement exceeding said defined angular displacement corresponding to said upper twist; and

operating said upper twist tooling in a second direction opposite to said first direction to return the legs of said conductors adjacent end turns thereof to said defined angular displacement corresponding to said upper twist and thereby stably displace said legs adjacent said end turns by said defined angular displacement corresponding to said upper twist.

20. A method of making an armature for a dynamoelectric machine as claimed in claim 19 wherein the step of operating said upper twist tooling in said first direction is performed to displace said legs by a circumferential distance corresponding to x+1 slots of said armature core;

and, the step of operating said upper twist tooling in said second direction is performed to displace said legs by a circumferential distance corresponding to 1 slot of said armature core, x being equal to the defined angular displacement corresponding to said upper twist in terms of slots of said armature core.

21. A method of making an armature for a dynamoelectric machine as claimed in claim 12 wherein the step of operating said lower twist tooling comprises the steps of:

monitoring the circumferential positioning of said armature core;

operating said lower twist tooling to displace the legs of said conductors adjacent distal ends thereof in opposite directions relative to one another, said armature core being circumferentially displaced by operating said lower twist tooling, and said legs being rotated until said armature core is angularly displaced by a defined circumferential distance;

clamping said armature core; and

operating said lower twist tooling until the legs of said conductors adjacent distal ends thereof are displaced relative to one another by said defined angular displacement corresponding to said lower twist.

22. A method of making an armature for a dynamoelectric machine comprising the steps of:

simultaneously confining a preselected number of hairpin conductors in first tooling;

operating said first tooling to reconfigure legs of said hairpin conductors adjacent end turns of said hairpin conductors and displace said legs in opposite directions relative to one another by a defined angular displacement thereby to transform each hairpin conductor into a frog leg spread-legged conductor;

transferring the plurality of transformed conductors from said first tooling into an armature core defining a plurality of conductor receiving slots corresponding to said preselected number around the periphery thereof;

driving the legs of said transformed conductors through said armature core to extend into second tooling positioned adjacent said armature core;

operating said second tooling to reconfigure the distal ends of the legs of said transformed conductors and to displace said legs in opposite directions relative to one another by a defined angular displacement; and

pressing a commutator onto said armature core to receive the distal ends of the legs of said transformed conductors.