Apparatus for developing winding coils

Abstract

A high speed winding machine for developing or generating coil groups each comprising one or more coils each having one or more turns of winding material. The turns are developed and placed on coil turn receiving means such as coil injection tooling or a coil transfer mechanism with or without auxiliary coil shaping means. The apparatus may be advantageously utilized in the manufacture of wound inductive devices, e.g., dynamoelectric machines such as motors. An illustrated preferred embodiment includes a frame, a coil form support having auxiliary coil shaping means embodied as a coil form mounted thereon for axial movement relative to the frame, and a flyer rotatable about a central axis for developing wire turns on the coil form. In order to prevent rotation of the coil form, located in the vicinity of the central axis, with the rotating flyer and a rotating wire feed tube, a migrating mechanical linkage is provided between the frame and coil form support to prevent rotation of the coil form with the rotating flyer. The illustrated migrating linkage includes a carriage which supports a wobble face gear and is rotatable relative to the gear. The wobble gear is provided with teeth on opposite faces thereof and the teeth on one face of the wobble gear mesh with the stationary gear teeth on the frame while teeth on the other face of the wobble gear engage the gear on the coil form support. The stationary gear teeth and gear teeth on the coil form support are spaced apart and the wobble gear extends between the spaced gears so that portions of the wobble gear spaced 180° apart engage the stationary gear teeth and gear teeth on the coil form, respectively. The wobble gear carriage is canted relative to the central axis and as it rotates it drives succeeding teeth on the faces of the wobble gear into engagement with succeeding ones of the stationary and coil form support gear teeth. As the carriage rotates with the flyer, the wobble gear executes a rotationless wobble motion synchronized with the flyer. This motion results in a moving shutter, synchronized with the flyer, through which wire is fed to the flyer.

What we claim as new and desire to secure by Letters Patent of the United States is: .[. 
     
       1. Apparatus for developing turns of winding material for ultimate assembly with a magnetic core, the apparatus comprising a machine frame; flyer means rotatable about a first axis of rotation for developing winding turns about the first axis or rotation; winding material guiding means directing winding material in a direction generally radially relative to the first axis of rotation; a drive member rotatable about the first axis of rotation and extending longitudinally in the direction of the first axis of rotation for supplying motive power to the flyer means; a first device including coil shaping means about which at least a portion of the flyer means is movable; and meshing means interconnecting said first device and machine frame for locking said coil shaping means against rotation about the first axis of rotation during movement of the flyer means and for establishing an unobstructed generally radially directed shutter passage, continuously movable along a predetermined path in synchronism with the flyer means, through which winding material may be fed generally radially relative to the first axis of rotation; said meshing means including first and second members spaced axially apart along the first axis and wobble means; the first member being secured against rotation relative to the machine frame and having a meshing surface extending around the first axis; the second member being secured against rotation relative to the coil shaping means and having a meshing surface extending around the first axis; and said wobble means meshing continuously with the meshing surfaces of the first and second members and constraining the second member from rotation about the first axis relative to the first member; said wobble means including carrier having first and second bearing parts concentrically disposed about a second axis disposed in non-parallel relation to the first axis of rotation, the first bearing part being locked for rotation with said drive member and the second bearing part being constrained from rotation by the meshing of the wobble means and the first member; rotation of the first bearing part relative to the second bearing part causing the second bearing part to execute a rotationless wobble motion during rotation of the flyer means; said guiding means, wobble means, and flyer means all being movable in synchronism with one another, with the wobble means establishing the unobstructed substantially radially directed shutter passage for winding material being fed generally radially between the axially spaced apart first and second members..]..[. 
     
     
       2. The structure of claim 1 wherein the first and second members each include a gear face comprised of a plurality of gear teeth and the wobble means includes gear teeth meshed with the gear teeth of the first and second members..]..[. 
     
     
       3. The structure of claim 1 wherein the first member comprises a first gear face, the second member comprises a second gear face, and the wobble means comprises at least one pair of gear faces supported by the carrier and interconnected to prevent relative movement there-between, said at least one pair of gear faces comprising third and fourth gear faces; the first and third gear faces each having the same number of teeth and meshing with one another, and the second and fourth gear faces each having the same number of teeth and meshing with one another..]..[. 
     
     
       4. The structure of claim 1 wherein the coil shaping means and flyer means are relatively movable in an axial direction..]..[. 
     
     
       5. The structure of claim 1 wherein the first and second bearing parts mutually trap a plurality of antifriction bearing members..]. .[. 
     
     
       6. Apparatus for developing turns of winding material for ultimate assembly with a magnetic core, the apparatus comprising a machine frame; flyer means for developing winding turns about a first axis of rotation; a first mechanism about which a portion of the flyer means is movable; means for locking said first mechanism against angular movement relative to the frame, and for establishing a shutter opening, continuously movable along a predetermined path in synchronism with the flyer means, through which segments of winding material may be fed from a first region proximate to the first axis to a second region spaced a different radial distance from the axis than the first region; a first gear surface carried by the machine frame; a second gear surface carried by the first mechanism; the means for locking including a locking structure comprising a single carriage and at least one pair of gear surfaces comprising third and fourth gear surfaces supported by said carriage; the third gear surface meshing with the first gear surface, and the fourth gear surface meshing with the second gear surface; the flyer means including a flyer drive shaft rotatable about the first axis of rotation, the carriage including a bearing structure having first and second bearing races with the first bearing race secured to the flyer drive shaft, and the third and fourth gear surfaces being fixed together to prevent relative motion therebetween and being supported, in oppositely facing relationship, from the second bearing race; said bearing races being relatively movable about a second axis of rotation disposed at a preselected angle relative to the first axis of rotation, whereby the third and fourth gear surfaces execute a rotationless wobble motion as the flyer drive shaft rotates and whereby winding material may be moved generally axially along the first region and radially away from the first axis and toward the second region along an angularly moving passageway extending between the first mechanism and machine frame..]..[. 
     
     
       7. The structure of claim 6 wherein the first and second bearing races are concentrically supported relative to the second axis of rotation and the first and second bearing races are supported from the flyer drive shaft eccentrically relative to the first axis of rotation..]..[. 
     
     
       8. A winding machine for generating turns of winding material about form means, the machine comprising a frame; winding turn generating means comprising a shaft supported by the frame for rotation about a first axis of rotation, a flyer arm spaced from the shaft a preselected radial distance and rotatable with the shaft in a predetermined path, and a winding material passage for winding material having a first portion extending in a generally axial direction along the shaft and a second portion located axially between a predetermined portion of the frame and the form means, and extending generally radially toward the flyer arm; said form means including a coil form disposed axially beyond the generally radially extending second portion of the passage; and locking means for preventing rotational movement of the form means about the first axis of rotation while establishing an opening, continuously and synchronously movable with the flyer arm, along which a portion of the winding material may extend; said locking means including a first gear surface fastened in stationary relationship with the predetermined portion of the frame, a second gear surface interconnected with said coil form to prevent relative rotation between said second gear and coil form, and other gear means extending between the first and second gear surfaces; said first and second gear surfaces being spaced apart axially along the first axis; said other gear means instantaneously meshing with diametrically oppositely located portions of the axially spaced apart first and second gear surfaces respectively; and eccentric means driven by said shaft for controlling the instantaneous engagement of the other gear means with the first and second gear surfaces, whereby the winding material passage, flyer arm, and eccentric means move in synchronism during every revolution of the flyer arm with an unobstructed winding material passage being maintained between the axially spaced apart first and second gear surfaces..]. .[. 
     
     
       9. The structure of claim 8 wherein the other gear means includes a deformable spline supported for meshing engagement with the first and second gear surfaces..]..[. 
     
     
       10. The structure of claim 8 wherein the eccentric means includes a bearing structure having first and second bearing races with the first bearing race secured to the shaft, the other gear means comprises third and fourth gear surfaces fixed against relative motion and supported in oppositely facing relationship from the second bearing race; said bearing races being relatively movable about a second axis of rotation disposed at a preselected angle relative to the first axis of rotation, whereby the third and fourth gear surfaces execute a rotationless wobble motion as the shaft rotates..]..[. 
     
     
       11. The structure of claim 10 wherein the eccentric means includes first and second bearing races concentrically supported relative to a second axis of rotation and the first and second bearing races are supported from the shaft eccentrically relative to the first axis of rotation..]. .Iadd. 12. In apparatus for the winding of wire coils which can be drawn axially into a stator of an electric machine, the apparatus having form means onto which wire turns can be wound and from which wire turns can be transferred to a coil receiver; a rotatable flyer for winding wire about said form means; a coil receiver having at least one part thereof relatively movable axially into interfitting relation with said form means and onto which turns of wire can be transferred from the form means; means for effecting relative axial movement of the flyer and form means, and relative axial movement of at least part of the form means and coil receiver in a direction so that the coil receiver and form means relatively move axially toward one another with the coil receiver interfitting axially along the form means during movement of said flyer, and hence during the winding process; a rotatable hollow drive shaft for the flyer; and shaft means associated with the form means and disposed within the hollow shaft and inerconnected with the form means, the improvement comprising: annular gear means mounted eccentrically about the hollow shaft by at least one bearing, a first circumferentially extending gear, concentric with the axis of rotation for the hollow drive shaft, mounted non-rotatably on the apparatus and meshing with said annular gear means; a second circumferentially extending gear mounted non-rotatably relative to said form means and meshing with the annular gear means; and means connecting the hollow drive shaft and the flyer; said annular gear means preventing relative rotation of the form means and coil receiver while wire is being wound about the form means by the flyer, and yet permitting movement of wire to the flyer. .Iaddend..Iadd. 13. Apparatus for developing turns of winding material for ultimate assembly with a magnetic core, the apparatus including a machine frame; coil turn accommodating means; a device including shaping means, locked against rotation relative to the turn accommodating means for at least assisting in the formation of winding turns; a flyer mechanism rotatable about the shaping means about a first axis of rotation for developing winding turns about the first axis of rotation; at least one winding material guide means for at least assisting in directing winding material from a first region to a second region spaced a different radial distance from the first axis than the first region; at least one nonrotating locking member; at least one movable locking mechanism interconnecting said nonrotating locking member and said device so that said device is locked against rotation about the first axis of rotation during movement of the flyer mechanism and for establishing an unobstructed passage, continuously movable along a predetermined path in synchronism with the flyer means, through which winding material may be fed from the first region to the second region; said locking mechanism including first and second gear surfaces spaced axially apart along the first axis of rotation; said mechanism providing a first wire path extending generally axially along the direction of the first axis and a second wire path extending from the first region to the second region; said shaping means having a portion for developing, in co-operation with the flyer means, a number of winding turns; said shaping means being movable axially relative to the turn accommodating means and to the nonrotating locking member; and means for effecting axial movement of the shaping means relative to the turn accommodating means during rotation of the flyer mechanism. .Iaddend. .Iadd. 14. Apparatus for developing turns of winding material; the apparatus comprising: a machine frame; coil receiving means; winding turn placing means including a rotatable flyer assembly having a wire guiding portion rotatable in a predetermined path about a first axis for feeding winding material from a first region to a second region spaced a different radial distance from the first axis than the first region; form means movable axially relative to the flyer assembly during rotation thereof, and including a portion located axially beyond the second region; locking means for preventing rotation of the form means and permitting movement of winding material from the first region to the second region; said locking means including a first gear surface adapted to be held against rotation, a second gear surface interconnected with said coil form, and interconnected gear means extending a predetermined axial distance between the first and second gear surfaces; said first and second gear surfaces being spaced apart axially approximately the same distance as the predetermined axial distance, and the interconnected gear means instantaneously meshing with portions of the first and second gear surfaces; and means for causing axial movement of the form means relative to the flyer assembly, locking means, and coil receiving means, so that successively formed winding turns are moved successively into the receiving means during rotation of the wire guiding portion of the flyer assembly. .Iaddend. .Iadd. 15. The invention of claim 14 wherein: the interconnected gear means comprises third and fourth gear surfaces interconnected together to prevent relative rotation therebetween; said first and second gear surfaces comprise first and second gears that extend circumferentially around the first axis, with the first axis passing through the geometric center for the first and second gears; said third and fourth gear surfaces are disposed circumferentially about a second axis; and wherein the second axis and first axis are oriented relative to one another so as to be noncoincident. .Iaddend..Iadd. 16. The invention of claim 14 wherein the interconnected gear means comprise third and fourth gear surfaces interconnected together to prevent relative rotation therebetween; said first and second gear surfaces extend circumferentially around the first axis, with the first axis centrally located relative to the first and second gear surfaces; said third and fourth gear surfaces are both disposed circumferentially about a second axis; and said third and fourth gear surfaces are supported in eccentric relation to the first axis. .Iaddend..Iadd. 17. The invention of claim 16 wherein the third and fourth gear surfaces move relative to the first axis as the flyer rotates. .Iaddend..Iadd. 18. The invention of claim 17 wherein the third and fourth gear surfaces are interconnected with the wire guiding portion of the flyer assembly, and move relative to the first axis as the flyer rotates. .Iaddend. .Iadd. 19. The invention of claim 18 further including eccentric means movable in synchronism with the flyer, and wherein the location of interengagement of the third and fourth gear surfaces with the first and second gear surfaces, respectively, is controlled by the eccentric means. .Iaddend..Iadd. 20. In apparatus for the winding of wire coils which can be drawn axially into a stator of an electric machine, the apparatus having form means about which wire turns can be wound and from which wire turns can be transferred to a coil receiver; a rotatable flyer for winding wire about said form means; a coil receiver having at least one part thereof relatively movable axially relative to at least part of said form means and along which receiver at least some turns of wire of a given coil can be moved while at least one other turn of the same given coil is being formed about the form means; means for effecting relative axial movement of the flyer and the at least part of the form means, and for effecting relative axial movement of the at least part of the form means and the coil receiver in a direction so that the coil receiver and the at least part of the form means relatively move axially toward one another during movement of said flyer and hence during the winding process; and a drive shaft for the flyer rotatable about a first axis, the improvement comprising: gear means extending circumferentially about the first axis; a circumferentially extending gear mounted non-rotatably on the apparatus, concentric about the first axis, and meshing with said gear means; means interconnecting the gear means to said form means to prevent relative rotation therebetween; means interconnecting the drive shaft and the flyer; and eccentric means driven by the drive shaft for causing at least a portion of the gear means to engage the circumferentially extending gear; said gear means preventing relative rotation of the form means and coil receiver during relative axial movement of the coil receiver and at least part of the form means and while wire is being wound about the form means by the flyer, and yet permitting movement of wire to the flyer. .Iaddend..Iadd. 21. Apparatus for developing turns of winding material for ultimate assembly with a magnetic core, the apparatus including a machine frame, coil turn accommodating means, a device, including shaping means, locked against rotation relative to the turn accommodating means for at least assisting in the formation of winding turns; flyer means rotatable about the shaping means and about a first axis of rotation for developing winding turns about the shaping means; at least one winding material path along which winding material may move from a first region to a second region spaced a different radial distance from the first axis than the first region; at least one nonrotating locking member; movable locking means for establishing an unobstructed passage, continuously movable along a predetermined path in synchronism with the flyer means, through which winding material may be fed from the first region to the second region; said movable locking means interconnecting said nonrotating locking member and said shaping means so that said shaping means is locked against rotation about the first axis of rotation during movement of the flyer mechanism; said apparatus further including eccentric means, and said locking means including at least one locking surface movable under the influence of the eccentric means; said locking means establishing a movable opening for the winding material path; said shaping means having a portion for developing, in co-operation with the flyer means, a number of winding turns; said shaping means having at least a portion thereof movable axially relative to the turn accommodating means and to the nonrotating locking member; and means for effecting axial movement of the at least a portion of the shaping means relative to the turn accommodating means during rotation of the flyer mechanism.