Dynamo-electric machine component winding methods and apparatus

Abstract

Stator designs have wide-mouth slots between adjacent poles. Wire coils with high slot fill conductivity are formed around the poles. In some designs, the wire coils are wave wound around the poles. Thick bar conductors can be used for making the wire coils. The wire coils may be inserted using nozzle dispensers or transferred from a pre-form mandrel. In other designs, the wire coils are pre-formed on transferable pockets that are then mounted on the poles. Optional pole extensions or shoes can be attached to the stator poles after the wire coils are formed around the poles.

1 . A dynamo-electric machine component comprising:
 poles that are geometrically defined by slot passages in a casing, wherein the slot passages have openings between adjoining poles and wherein the openings have widths that are substantially comparable to the widths of the slot passages over their depths; and   wire coils placed around the poles, from directions that are generally along the radii of the dynamo-electric machine component.   
     
     
         2 . The component of  claim 1  wherein the wire coils comprise conductors having cross sections that are comparable to the widths of the slot passages. 
     
     
         3 . The component of  claim 1  wherein the wire coils comprise coils pre-formed on pockets that are transferred onto the poles and attached to the casing. 
     
     
         4 . The component of  claim 1  wherein the wire coils comprise a conductor wound in a wave configuration. 
     
     
         5 . The component of  claim 1  further comprising slot covers that have pole extension sections. 
     
     
         6 . The component of  claim 5  wherein a slot cover further comprises an intervening insulating section between two pole extension sections, and wherein the two pole extension sections respectively abut the poles adjoining a slot passage. 
     
     
         7 . The component of  claim 5  wherein the adjoining poles comprise seats for holding the slot cover by its edges. 
     
     
         8 . The component of  claim 5  further comprising a ring for holding the slot covers by their ends, wherein the ring is attachable to an axial face of the stator. 
     
     
         9 . The component of  claim 1  further comprising a cover structure having alternating insulating sections and pole extension sections, wherein the cover structure is disposed in the casing such that alternating sections are respectively over the slot passages and the poles. 
     
     
         10 . The component of  claim 9  wherein surfaces of the pole extension sections that are disposed over the poles are in mechanical contact with surfaces of the later, and wherein the mechanically contacting surfaces are conformably shaped. 
     
     
         11 - 23 . (canceled) 
     
     
         24 . A method for the assembly of a dynamo-electric machine component comprising:
 providing a casing having poles;   placing wire coils around the poles; and,   then placing pole extensions next to the poles.   
     
     
         25 . The method of  claim 24  wherein placing a wire coil around the poles comprises:
 winding wire coils on movable pockets; and, 
 moving the movable pockets onto the poles. 
 
     
     
         26 - 33 . (canceled)