U.S. patent number 3,599,680 [Application Number 04/814,421] was granted by the patent office on 1971-08-17 for machine for making wire-wound disc armatures.
This patent grant is currently assigned to Photo-Circuits Corporation. Invention is credited to Robert Page Burr.
United States Patent |
3,599,680 |
Burr |
August 17, 1971 |
MACHINE FOR MAKING WIRE-WOUND DISC ARMATURES
Abstract
A machine for making wire-wound disc armatures. The machine is
comprised of a spindle section and a turret section which operate
in synchronization to wind insulated conductor wire into an
armature for use in electric machines.
Inventors: |
Burr; Robert Page (Huntington,
NY) |
Assignee: |
Photo-Circuits Corporation
(Glen Cove, NY)
|
Family
ID: |
25215009 |
Appl.
No.: |
04/814,421 |
Filed: |
April 8, 1969 |
Current U.S.
Class: |
140/92.2; 29/732;
242/441; 29/605; 140/93R |
Current CPC
Class: |
H02K
3/00 (20130101); Y10T 29/53143 (20150115); Y10T
29/49071 (20150115) |
Current International
Class: |
H02K
3/00 (20060101); B21f 003/00 () |
Field of
Search: |
;140/92.1,92.2,93
;29/205,605 ;242/5,7.04,7.15,7.16 ;72/127,133 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Lanham; Charles W.
Assistant Examiner: Keenan; Michael J.
Claims
What I claim is:
1. An apparatus for making wire-wound disc armatures
comprising:
a rotatable pin jig support shaft;
a turret spider fixedly mounted on the rotatable pin jig support
shaft;
a pin jig;
means for mounting the pin jig on the turret spider;
a wire dispensing reciprocating mechanism adapted for substantially
radical movement with respect to the pin jig;
a stylus mounted on the leading edge of the reciprocating mechanism
through which the insulated wire is adapted to pass;
means to drive the reciprocating mechanism such that the stylus
moves radially into and out of the pin jig area;
means to rotate the pin jig as the stylus is travelling radially
into and out of the pin jig; and
means to synchronize the rotation of the pin jig and reciprocation
of the reciprocating mechanism;
whereby the insulated wire is drawn from the reciprocating stylus
by the pins on the pin jig as the pin jig rotates to arrange the
insulated wire on the pin jig in the form of a wire-wound disc
armature.
2. An apparatus for making wire-wound disc armatures
comprising:
a rotatably mounted pin jig on which to wind insulated conductor
wire into a disc armature;
a wire dispensing reciprocating mechanism adapted for substantially
radial movement with respect to the pin jig for delivering the
insulated wire to the pin jig;
means to drive the reciprocating mechanism; and a mechanical power
transmission assembly driven by the means to drive the
reciprocating mechanism and arranged to rotate the pin jig to
thereby provide synchronization of the rotation of the pin jig and
reciprocation of the reciprocating mechanism;
whereby the insulated wire is drawn from the reciprocating stylus
by the pins on the pin jig as the pin jig rotates to arrange the
insulated wire on the pin jig in the form of a wire-wound disc
armature.
3. An apparatus as in claim 1 wherein the means for synchronizing
the rotation of the pin jig and the reciprocation of the wire
dispensing mechanism is a mechanical power transmission assembly
driven by the means to drive the reciprocating rod and arranged to
rotate the pin jig.
4. An apparatus as in claim 3 wherein the means to drive the
reciprocating rod is comprised of a power source; a rotating
scotch-yoke support shaft driven by the power source; a gear formed
on the rotating support shaft; a scotch-yoke mounted on the
rotating scotch-yoke support shaft; and mounting means to mount the
reciprocating rod on the scotch-yoke for reciprocation and wherein
the mechanical power transmission assembly driven by the means to
drive the reciprocating rod and arranged to rotate the pin jig is
comprised of a power transmission shaft; a driven gear fixedly
mounted on the power transmission shaft adapted to engage the gear
formed on the rotating support shaft mounting the scotch-yoke; a
drive gear mounted on the power transmission shaft; a rotatably
mounted cylindrical pin jig driven shaft arranged axially with the
rotatable pin jig support shaft; a driven gear formed on the
rotatably mounted cylindrical pin jig drive shaft adapted to engage
the drive gear mounted on the power transmission shaft; and means
to couple the pin jig drive shaft to the pin jig support shaft.
5. An apparatus as in claim 3 wherein the means to drive the
reciprocating rod is comprised of a power source, a rotating
scotch-yoke support shaft driven by the power source and a
scotch-yoke fixedly mounted on the scotch-yoke rotating support
shaft and coupled to the reciprocating rod to convert the
rotational movement of the rotating shaft to reciprocating movement
of the reciprocating rod; and
wherein the mechanical power transmission assembly arranged to
rotate the pin jig is comprised of:
a gear formed on the rotating scotch-yoke support shaft;
a first power transmission shaft;
a gear arranged on the first power transmission shaft to mate with
the gear on the rotating scotch-yoke support shaft;
a first change gear assembly having a drive gear fixedly mounted on
the first power transmission shaft, a driven gear and an idler gear
adapted to engage both the drive gear and the driven gear;
a second power transmission shaft having the driven gear of the
first change gear assembly fixedly mounted thereon;
a drive gear fixedly mounted on the second power transmission
shaft;
a third power transmission shaft;
a worm gear arranged on the third power transmission shaft;
a driven gear fixedly mounted on the third power transmission shaft
adapted to engage the drive gear on the second power transmission
shaft;
a pin jig drive shaft;
a worm gear fixedly mounted on the pin jig drive shaft and arranged
to engage the worm gear on the third power transmission shaft;
and
means to couple the pin jig drive shaft to the pin jig support
shaft.
6. An apparatus as in claim 5 wherein the third power transmission
shaft is comprised of:
a first shaft section;
a differential gear assembly comprised of first, second, third and
fourth bevel gears arranged in a box, the first bevel gear being
axially aligned with the third power transmission shaft and
connected to the first shaft section, the second bevel gear being
in axial alignment with the first bevel gear;
a second shaft section axially aligned with the first shaft section
and rigidly attached to the second bevel gear on the differential
gear assembly;
a worm gear fixedly mounted on the second shaft section;
a third shaft section fixed to the rotating differential gears and
arranged coaxially within the second shaft section and the second
bevel gear and which mounts the worm gear adapted to engage the
worm gear on the pin jig drive shaft; and
means to rotate the worm gear mounted on the second shaft
section.
7. An apparatus as in claim 6 further comprising means to lock the
worm gear mounted on the second shaft section from rotation.
8. An apparatus as in claim 4 wherein the means to couple the pin
jig drive shaft to the pin jig support shaft is an arm extending
transversely from the pin jig drive shaft, which arm has a hole
therein and a spider, which post fits slidably in the hole in the
arm extending transversely from the pin jig drive shaft.
9. An apparatus for making wire-wound disc-type armatures
comprising:
a rotating turret assembly;
a pin jig arranged on the rotating turret assembly for rotation
therewith having a plurality of strategically located pins
projecting therefrom;
a reciprocating rod;
a stylus mounted on the reciprocating rod through with conductor
wire can pass to wind on the pin jig to form an armature;
means to rotate the turret assembly;
means to drive the reciprocating rod for radial movement with
respect to the rotating pin jig;
means for locking the reciprocating rod from movement; and
means for rotating the turret assembly independently of the
reciprocating rod when the reciprocating rod is locked.
10. An apparatus as in claim 9 wherein the means for rotating the
turret assembly when the reciprocating rod is locked from movement
is a mechanical power transmission assembly comprised of:
an index motor;
a first turret index power transmission shaft driven by the turret
index motor;
a second turret index power transmission shaft driven by the first
turret index power shaft;
means for coupling the first turret index power transmission shaft
and the second turret index power transmission shaft; and
means for coupling the second power transmission shaft to the means
for driving the rotating turret assembly.
11. An apparatus as in claim 9 wherein the means to rotate the
turret assembly is a power transmission assembly driven by the
means to drive the reciprocating rod and the means for rotating the
turret assembly when the reciprocating rod is locked from movement
is a mechanical power transmission assembly comprised of:
an index motor;
a first turret index power transmission shaft driven by the turret
index motor;
a second turret index power transmission shaft driven by the first
turret index power shaft;
means for coupling the first turret index power transmission shaft
and the second turret index power transmission shaft; and
means for coupling the second power transmission shaft to the power
transmission assembly which drives the rotating turret
assembly.
12. An apparatus as in claim 11 wherein the power transmission
assembly which drives the rotating turret assembly is comprised
of:
a power source;
a rotation support shaft driven by the power source;
a scotch-yoke mounted on the rotating support shaft adapted to
mount the reciprocating rod for reciprocation;
a gear on the rotating support shaft;
a first power transmission shaft;
a gear fixedly mounted on the first power transmission shaft
arranged to mate with the gear on the rotating support shaft;
a second power transmission shaft;
means to couple the first and second power transmission shafts;
a third power transmission shaft comprised of a first shaft
section; a differential gear assembly comprised of first, second,
third and fourth bevel gears in a box, the first bevel gear being
axially aligned with and connected to the first shaft section, the
second bevel gear being in axial alignment with the first bevel
gear, a second shaft section aligned axially with the first shaft
section and rigidly connected to the second bevel gear, a third
shaft section fixed to the rotating third and fourth bevel gears
and arranged concentrically within the second shaft section; a worm
gear mounted on the third shaft section;
a rotatably mounted support shaft for the pin jig and a worm gear
mounted on the rotatably mounted support shaft for a pin jig.
13. An apparatus as in claim 10 wherein the means for coupling the
first turret index power transmission drive shaft and second turret
index power transmission drive shaft is a change gear assembly
comprised of:
a drive gear mounted on the first turret index power transmission
shaft;
a driven gear arranged on the second turret index transmission
shaft; and
and idler gear arranged to engage both the driven and drive
gears.
14. An apparatus as in claim 12 wherein the means to couple the
first turret index power transmission drive shaft and a second
turret index power transmission drive shaft is a change gear
comprised of:
a drive gear mounted on the first turret index power transmission
shaft;
a driven gear arranged on the second turret index transmission
shaft; and
an idler gear arranged to engage both the driven and drive
gears.
15. An apparatus for making wire-wound disc armatures
comprising:
a rotating turret assembly;
a pin jig having a plurality of strategically located pins
projected therefrom on which conductor wire is wound to form an
armature and which pin jig is arranged to be mounted for rotation
on the rotating turret assembly;
a reciprocating rod;
a stylus mounted on the end of the reciprocating rod through which
conductor wire can pass to wind on the pin jig;
means to rotate the rotating turret;
means to drive the reciprocating rod for radial movement with
respect to the rotating pin jig; and
means to vary the length of the reciprocating stroke.
16. An apparatus as in claim 15 wherein the means for varying the
length of the reciprocating stroke is a stop assembly comprised of
a first stop member fixedly mounted on the reciprocating rod; a
second stop member; and means to selectively locate the second stop
member in the path of the first stop member.
17. An apparatus as in claim 16 further comprising means for
mounting the reciprocating rod for slidable movement.
18. An apparatus as in claim 16 further comprising a rotating
support shaft;
a scotch-yoke mounted on the rotating support shaft;
a mounting block slidably mounted on the scotch-yoke having a
passage therein in which the reciprocating rod is slidably
mounted;
a first sleeve member fixedly mounted on the reciprocating rod
nearest the rotating turret assembly;
a second sleeve member fixedly mounted on the reciprocating rod on
the opposite side of the mounting block from the first sleeve
member; and
spring means arranged to bias the mounting plate against the second
sleeve member.
19. An apparatus as in claim 16 wherein the means to selectively
locate the second stop member in the path of the first stop member
is an actuator piston on which the second stop member is
mounted.
20. An apparatus as in claim 18 wherein the means to selectively
locate the second stop member in the path of the first stop member
is an actuator piston on which the second stop member is
mounted.
21. An apparatus for making wire-wound disc armatures from
conductor wire comprising:
a reciprocating rod having a stylus through which the conductor
wire can pass;
a rotating turret assembly;
a pin jig having a plurality of strategically located pins
extending therefrom, which pin jig is rigidly mounted on the
rotating turret for rotation;
means for driving the reciprocating rod such that the stylus passes
beyond strategically located pins on the pin jig;
means for rotating the turret such that the movement of the pins
draws the conductor wire through the stylus onto the pin jig;
and
means for holding the conductor wire on the pin jig.
22. An apparatus as in claim 21 wherein the pin jig is comprised of
a base plate;
an outer circular row of pins;
an intermediate circular row of pins arranged concentrically with
the outer circular row of pins; and
an inner circular row of pins arranged concentrically with the
outer circular row of pins.
23. An apparatus as in claim 22 wherein the means for holding the
conductor wire on the pin jig is an annular plate having an inside
diameter slightly larger than the diameter of the circle formed by
the intermediate row of pins and an outside diameter slightly
smaller than the circle formed by the outer row of pins; the
annular ring being arranged to fit on the pin jig to occupy the
area between the intermediate and the outer circular rows of pins;
and wherein the annular pressure and support ring is fixedly
mounted and has a slot formed therein in alignment with the path of
the stylus on the reciprocating rod to allow communication between
the stylus and the pins on the pin jig.
24. An apparatus as in claim 23 wherein the pressure and support
ring is further provided with a ramp which extends from the stylus
opening therein to the bottom of the pressure and support ring.
25. An apparatus for making wire-wound disc armatures
comprising:
a rotating turret assembly;
a pin jig mounted on the rotating turret for rotation
therewith;
a reciprocating rod;
a stylus mounted on the reciprocating rod through which conductor
wire can pass;
means to rotate the rotating turret such that the movement of the
pins draws the conductor wire through the stylus onto the pin jig
to form an armature;
means to drive the reciprocating rod such that the stylus moves
radially with respect to the pin jig; and
means to lower the pin jig as wire accumulates thereon.
26. An apparatus as in claim 25 wherein the means for lowering the
pin jig as wire accumulates thereon is a pin jig lowering power
transmission assembly driven by the means to drive the
reciprocating rod.
27. An apparatus as in claim 26 wherein the pin jig lowering power
transmission assembly is comprised of:
a worm gear formed on the means to drive the reciprocating rod;
a first pin jig lowering power transmission shaft;
a worm gear formed on the first pin jig lowering power transmission
shaft which engages the worm gear on the means to drive the
reciprocating rod;
a gear fixed on the first pin jig lowering power transmission
shaft;
a second pin jig lowering power transmission shaft;
a first gear mounted on the second pin jig lowering power
transmission shaft adapted to mate with the gear on the first pin
jig lowering power transmission shaft;
a vertically movable support shaft for the rotating turret; and
means to couple the rotating turret with the second pin jig
lowering power transmission shaft whereby reciprocation of the
reciprocating rod lowers the pin jig.
28. An apparatus as in claim 25 further comprising means to
manually move the pin jig vertically.
29. An apparatus as in claim 27 wherein the means to couple the
rotating turret with the second pin jig lowering power transmission
shaft is comprised of a second gear on the second pin jig lowering
power transmission shaft; and idler gear adapted to engage the
second gear on the second pin jig lowering power transmission
shaft; a third pin jig lowering power transmission shaft; a first
gear on the third pin jig lowering power transmission shaft, which
first gear mates with the idler gear; a second gear on the third
pin jig lowering power transmission shaft; a gear on the vertically
movable support shaft for the rotating turret, which gear is
adapted to mate with the second gear on the third pin jig lowering
power transmission shaft.
30. An apparatus as in claim 25 further comprising means to
manually move the pin jig vertically.
31. An apparatus as in claim 30 wherein the means for manually
moving the pin jig vertically is comprised of:
a slidably mounted shaft to mount the idler gear;
spring means arranged to bias the idler gear into engagement with
the first gear on the third pin jig lowering power transmission
shaft; and
means to overcome the spring force to disengage the idler gear from
the third pin jig lowering power transmission shaft.
Description
RELATED PATENTS AND APPLICATIONS
Copending applications and related patents assigned to the same
assignee as the instant application are: Ser. No. 860,389-- DISC
TYPE WIRE WOUND ELECTRICAL MACHINES, U.S. Letters Pat. No.
3,525,008-- ELECTRICAL WIRE WOUND MACHINES, U.S. Letters Pat. No.
3,431,638-- TOROIDALLY WOUND DISC ARMATURES, U.S. Letters Pat. No.
3,524,251-- DISC TYPE WIRE WOUND ELECTRICAL MACHINES, U.S. Letters
Pat. No. 3,524,250-- ELECTRICAL WIRE WOUND ELECTRICAL MACHINES,
U.S. Letters Pat. No. 3,534,469-- WIRE WOUND ARMATURE, METHOD AND
APPARATUS FOR MAKING SAME, U.S. Letters Pat. No. 3,550,645-- WIRE
WOUND ARMATURE, METHOD AND APPARATUS FOR MAKING SAME, and Ser. No.
871,586-- WIRE WOUND ARMATURE, METHOD AND APPARATUS FOR MAKING
SAME
FIELD OF THE INVENTION
The machine of the subject invention is designed generally for
laying wire on a jig in a pattern to effect an article formed of
wire. In particular, the machine has application in winding
insulated conductor wire to produce wire-wound disc armatures.
BACKGROUND OF THE INVENTION
In recent years, the demand for thin, low mass armatures for
electric machines has steadily increased. The electric motors in
which the thin low mass armatures are used are generally referred
to as printed circuit-type motors. Originally, printed circuit
motors were found to be particularly suitable for high performance
servo applications, however, more recently a variety of other uses
have been found for them.
Printed circuit motors are characterized by a disc shaped armature
in which radially extending arrays of conductors are usually bonded
to opposite sides of an insulating carrier. The design of an
armature formed of radially extending arrays of conductors affords
a low inertia armature which replaces the conventional iron core
armature with coil slots.
A variety of techniques have been employed to produce printed
circuit motor-type armatures. Chemical etching techniques, chemical
plating techniques and mechanical stamping techniques have been
used to make printed circuit motor armatures. The printed circuit
motors using armatures formed by the conventional techniques such
as chemical etching, chemical plating or metal stamping exhibit
high acceleration and smooth low torque characteristics.
Consequently, they have been found to be particularly suitable for
many special applications.
However, small printed circuit motors having armatures formed by
the above-described techniques are limited by the inability to
operate at high voltages. This restriction results from the
requirement that the armatures made by the above-described
techniques must be formed with a finite number of single turn coils
due to the physical space limitations.
Recently, a technique of winding disc-type armature coils from
insulated copper wire was developed. This technique provides a thin
low inertia armature which is referred to as a wire-wound disc
armature which is similar to the printed circuit armature but
considerably superior in certain respects.
In a copending application, Ser. No. 511,608, filed Dec. 6, 1965,
in the name of Robert Page Burr, having a common assignee with this
application, an insulated wire-wound-type disc armature is
illustrated as well as the methods for making it. This type of
armature can be constructed with considerably more single turn
coils since the insulation of the wire enables compacting a
multiplicity of turns in intimate contact. Consequently, the
wire-wound disc armature can operate over a greater spectrum of
voltages than printed circuit armatures.
In addition, the wire-wound disc armatures are considerably less
expensive since the exacting precision necessary to etch or stamp a
printed circuit armature is not necessary. Moreover, there is a
saving in copper since, unlike the etched and the stamped
armatures, copper need not be removed from a blank to form the
armature.
To produce wire-wound disc armatures in volume and at a rate which
will make the wire-wound disc armature commercially attractive, the
machine of the subject invention was developed. The method of
winding insulated conductor wire to form a wire-wound disc armature
is specifically described in copending application Ser. No.
620,306, filed Mar. 3, 1968, in the name of Raymond J. Keogh which
is assigned to the same assignee as this application.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a machine which
will wind wire into a predetermined pattern at a rapid rate.
It is a further object of the present invention to provide a
machine that will wind insulated conductor wire into thin, low mass
disc-type wire-wound armatures for use in electric machines.
To this end, the machine of the subject invention is comprised of a
spindle assembly which dispenses insulated conductor wire, a turret
assembly on which the insulated wire is wound to a predetermined
design and a power transmission system for synchronizing the
movement of the spindle assembly with the movement of the turret
assembly. More particularly, the spindle section is comprised
basically of a scotch-yoke drive means to power the scotch-yoke, a
reciprocating rod which mounts a stylus adapted to dispense copper
wire and means to control the length of reciprocating rod stroke.
The rod mounting the stylus reciprocates as a function of the
movement of the scotch-yoke while the stroke length of the rod is
controlled by a stop which can be selectively engaged. The turret
assembly mounts a pin jig on which pins are arranged in a
predetermined pattern to project upwardly. The pin jig provides the
form about which the stylus lays the wire and is basically
comprised of three concentrically arranged circular rows of pins.
Functionally, the pin jig rotates in synchronization with
reciprocation of the stylus to align various openings between pins
with the path of the reciprocating stylus. The drive assembly,
which operates to synchronize the rotation of the pin jig in
accordance with the reciprocation of the scotch-yoke and stylus, is
provided with an ancillary motor and power transmission system to
index the pin jig with respect to the spindle after a predetermined
number of turns to thereby advance the winding pattern to a set of
pins different from the previous set. In addition to the
synchronization of the turret assembly rotation with the spindle
assembly reciprocation, a power transmission assembly is also
provided to effect depression of the pin jig as the wire wound on
the pins begins to accumulate.
In operation, the machine is controlled by commands from a control
module which reads a closed loop of punched paper tape. Basically,
the sequence of commands begins by a signal to energize the motor
to drive the spindle. The spindle and turret begin operating
concomitantly by virtue of the power transmission assembly.
Initially, a command is also given to locate the rod stop in the
path of the spindle reciprocating rod to limit the travel of the
stylus to a point between the intermediate row of pins and the
innermost row of pins on the pin jig. After a predetermined number
of armature turns have been made, the stop is removed from the path
of the rod and the reciprocating rod is thereby allowed to travel a
full stroke. The full stroke of the reciprocating rod takes the
stylus beyond the innermost row of pins to make a commutator
pullout in the armature. Next, the machine is stopped and a turret
index motor and power transmission takes over to rotate the pin jig
while the spindle is locked in a fixed position. A different set of
pins is now arranged to provide the form on which the next set of
armature turns are to be wound. The machine is restarted and
follows a set of commands similar to those originally given to wind
another set of armature turns. The sequence is repeated until the
armature is completed.
DESCRIPTION OF THE DRAWINGS
An illustrative embodiment of the invention is set forth in the
drawings which form part of the specification and wherein:
FIG. 1 is a plan view of the machine of the subject invention
showing the spindle and turret sections generally;
FIG. 2 is a side elevational view of the machine taken through line
2-2 of FIG. 1;
FIG. 3 is a side elevational view of the machine of the subject
invention taken through line 3-3 of FIG. 1;
FIG. 4 is a front elevational view of the turret assembly;
FIG. 5 is a plan view of the turret assembly shown without the pin
jig or holddown ring;
FIG. 6 is a sectional plan view of the turret assembly taken
through line 6-6 of FIG. 4;
FIG. 7 is a sectional elevational view of the turret assembly taken
through line 7-7 of FIG. 4;
FIG. 8 is a plan view of the spindle assembly shown without the
reciprocating rod;
FIG. 9 is a sectional elevational view of the clutch assembly in
the spindle drive shaft taken through line 9-9 of FIG. 8;
FIG. 10 is a sectional elevational view of the cam and cam slot in
the scotch-yoke taken through line 10-10 of FIG. 8;
FIG. 11 is a front elevational view of the spindle assembly taken
through line 11-11 of FIG. 8;
FIG. 12 is a sectional elevational view of the spindle assembly
taken through line 12-12 of FIG. 8;
FIG. 13 is a rear elevational view of the spindle assembly taken
through line 13-13 of FIG. 8;
FIG. 14 is an exploded view of the pin jig assembly;
FIG. 15 is a detail view of the pin jig plate with the stripper
plate mounted thereon;
FIG. 16 is a schematic diagram of the power transmission assembly
and synchronization system of the machine;
FIGS. 17A--17D are a series of diagrams illustrating an armature
winding sequence.
FIG. 18 is a schematic of a punched paper tape controlled logic
unit adapted to control the functions of the machine.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention relates to a machine adapted to wind wire
around a form in a specified pattern to form a wire-wound armature
for use in low inertia electric machines. Basically, the wire-wound
armature formed by the machine of this invention is comprised of a
closed winding having a plurality of single turn armature coils
interconnected in a wave configuration. The armature coils are
divided into a plurality of similar groups which are indexed
relative to each other to provide a uniform distribution of
armature coils.
The complete machine 2 of the subject invention, except for the
associated electrical circuitry, is shown in FIGS. 1, 2 and 3. The
machine 2, as seen in FIGS. 1,2 and 3, is comprised of three major
subassemblies; the spindle assembly 4, the turret assembly 6 and a
drive and power transmission assembly adapted to synchronize the
movement of the spindle assembly 4 with the turret assembly 6.
The spindle section 4 is comprised of a scotch-yoke 8 and drive
means to provide reciprocation for the stylus carrying rod 10 which
mounts the stylus 12. The insulated conductor wire which ultimately
forms the wire-wound armature is threaded through the stylus 12
which is arranged to overlay the turret assembly 6 and reciprocate
with respect thereto. The stylus 12 is mounted on the stylus rod 10
which is, in turn, mounted on the scotch-yoke 8. The scotch-yoke 8
is powered by the main motor 14 which transmits power through a
double V-belt band 16 arranged around the motor pulley 18 and the
scotch-yoke drive shaft pulley 20. A secondary or auxiliary motor
22 is provided to facilitate braking of the main motor and aid in
driving the spindle shaft 26 which rotates the scotch-yoke by two
V-belts 24 which are arranged around a pulley on the shaft 28 of
the auxiliary motor 22 and the pulley 20 on the spindle drive shaft
26.
The stylus rod 10 mounting the wire-dispensing stylus 12 is
slidably mounted in the scotch-yoke 8 and has a stop member 30
(FIG. 3) fixedly attached thereto. Two sleeve members 32 and 34
fixedly attached to the rod 10 and a spring 36 are arranged to
slidably mount the stylus rod 10 on the scotch-yoke 8. A guide 38
extends upwardly from the stylus rod 10 and rides on a guide rod 40
to preclude rotational or skew movement of the stylus rod 10.
Basically, the scotch-yoke 8 is comprised of a rotating table 42
having a cam race or slot 44 formed therein, parallel guide members
46 and 48 and a reciprocating block member 50 arranged to slide in
the guide members 46 and 48 for reciprocation.
A pneumatically operated stop 52, or similar device, is mounted in
alignment with the stop 30 on rod 10 to afford selective shortening
of the stroke of the rod 10.
As generally indicated in FIGS. 1, 2 and 3, the turret assembly 6
of the machine 2 is comprised of a housing 54 which mounts the
turret spider 102 and a pin jig assembly generally indicated as 70.
Basically, the turret assembly 6 is the section of the machine 2
which mounts and rotates the pin jig 70 around which the conductor
wire is wound to form the wire-wound armatures. Although a variety
of mechanisms can be used to mount and rotate the pin jig 70, it
has been found that a centrally disposed turret support shaft 88
terminating in a turret spider 102 and an outer cylindrical turret
drive shaft 86 coaxially arranged with the turret support shaft 88
is particularly suitable (FIG. 2). In addition, since it has been
found desirable to lower the pin jig 70 as the wire accumulates
thereon, the turret support shaft 88 is arranged to travel
vertically with respect to the turret drive shaft 86. Therefore, in
practice it has been found convenient to arrange the turret support
shaft 88 for vertical movement with respect to the drive shaft 86.
The shafts 86 and 88 are connected by means of a drive arm 90 which
extends from the shaft 88 and a pin 94 depending from an arm of the
turret spider 102 into a hole 92 in the arm 90. Similar means for
insuring coincident rotational movement between shafts 86 and 88
while affording axial movement therebetween, such as splined
shafts, can also be used.
The turret spider 102 is provided primarily to mount the pin jig
assembly and for that purpose is provided with means, such as
holddown clamps 220 located near the end of each spider arm 130, to
positively attach the pin jig baseplate 188 thereto.
The housing 54 which mounts the turret spider 102 also accommodates
the power transmission mechanisms for rotating and indexing the
turret table and for depressing the turret spider 102 as the wire
accumulates on the pin jig.
Also, as seen in FIGS. 1, 2 and 3, the machine 2 is provided with
an ancillary support structure 72, which may be of any suitable
form. The support structure 72 serves to mount the guide rod 40 and
supports 74 for the stylus rod 10. In addition, the support
structure can be used to conveniently mount the wire spool 76 from
which conductor wire 78 is taken as the stylus 12 winds an armature
on the pin jig 70. For this purpose, a support arm 80 can be
extended over the turret assembly 6. The support arm 80 can also be
used to mount means for maintaining the wire on the pin jig.
The turret assembly 6 is best seen in FIGS. 4, 5, 6 and 7. The
drive for the turret (FIG. 6) is provided by a shaft 58 extending
from the spindle assembly 4. A gear 60, in which the shaft 58
terminates, engages a mating gear 62 on a worm gear drive shaft
assembly 64. The worm gear drive shaft assembly 64 is comprised of
shaft stub 64a, a differential gear mechanism 66 having four bevel
gears 68a, 68b, 68c and 68d in a boxlike arrangement,
concentrically arranged shafts 64b and 64c and shaft stub 64d. The
centrally disposed shaft 64b is attached at one end to the bevel
gears 68b and 68d for rotation therewith, while the other end of
the shaft 64b extends through gear 66c to rigidly attach to a worm
gear 76. The stub shaft 64a mounts the gear 62 and the cylindrical
shaft section 64c connects the bevel gear 64c with a worm gear 110
from the turret index assembly. Thrust bearings 82 and an
antibacklash nut 96 are also provided on the worm gear shaft
assembly 64 to enhance alignment and reliability.
A worm gear 84, rigidly affixed to the cylindrical turret drive
shaft 86, mates with the worm gear 76 to complete the turret power
transmission assembly. The cylindrical turret drive shaft 86 is
driven by the worm gear 76 and, in turn, drives the turret support
shaft 88 through the drive arm 90 and rod 94.
Structurally, the outer cylindrical shaft 86 is mounted for
rotation in a bearing assembly 98 in the housing 56 and prevented
from elevational movement by appropriate means, such as a flange
and shoulder assembly 100. The turret spider shaft 88 arranged
coaxially with the turret drive shaft 86 is mounted for both
rotation and axial movement by a sleeve bearing 132.
The housing 54 also accommodates the transmission assembly for
indexing the turret spider 102. An index motor is arranged to drive
the index shaft 104 through two V-belts attached to the pulley 106
on the end of the shaft 104. The shaft 104 terminates on its other
end in a change gear assembly 108 comprised of a drive gear 108a
which engages an idler gear 108b which, in turn, is arranged to
engage a driven gear 108c. The driven gear 108c is mounted on the
end of a shaft 114 which carries a worm gear 116 adapted to engage
the indexing gear 110 on the worm gear shaft assembly 64.
The means for elevating and depressing the spider 102 is provided
by the change gear assembly 118 consisting of the drive gear 118a,
idler gear 118b and driven gear 118c. The drive gear 118a is
mounted on a shaft 120 which extends from the spindle section 4
through the housing 54 to an appropriate bearing mount. The driven
gear 118c is arranged on a shaft 122 having an array of gear teeth
126 that engage directly with gear teeth 128 on the turret spider
support shaft 88. A manual control knob 124 is provided to
facilitate disengagement of the driven gear from the change gear
assembly 118 to allow for manual depression or elevation of the
turret spider support shaft 88.
The spindle assembly 4, as seen in FIGS. 8, 9, 10, 11, 12 and 13,
is provided to afford the means for feeding the insulated copper
wire to the pin jig 70 mounted on the turret assembly. Basically,
the spindle assembly is comprised of a scotch-yoke assembly 8, a
rod 10 terminating in a stylus 12 through which the insulated
copper wire is fed, and means to drive the scotch-yoke.
The scotch-yoke 8 best seen in FIG. 8, is comprised of a rotating
circular plate 42 having a cam slot 44 formed therein, a
reciprocating plate 144 arranged above the rotating circular plate
42 and guide rails 46--48 in which the rotating circular plate 42
slides. The flat plate 144 is provided with a cam follower 150,
best seen in FIG. 10, depending downwardly into a cam slot 44 in
the circular plate 42. The reciprocating flat plate 144 has the
stylus carrying rod 10 mounted thereon.
As seen in FIG. 8, the rotating shaft of main motor 14 terminates
in a pulley 18 and by means of a V-belt 16 is connected to the
spindle drive shaft pulley 20. Additional power for driving the
spindle drive shaft is afforded by the auxiliary spindle motor 22
which connects with the spindle drive shaft pulley 20 by means of
two V-belt pulleys 24.
The spindle drive shaft pulley 20 is fixedly mounted on the spindle
drive shaft 152, best seen in FIG. 12. The spindle drive shaft 152
has a worm gear 154 formed thereon which engages a worm 156
arranged on the spindle support shaft 158 on which the scotch-yoke
8 is mounted for actuation. Rotation of the spindle shaft 158 is
synchronized with the turret drive by a direct power transmission
connection through an assembly of change gears 160 comprised of a
drive gear 160a in which the spindle drive shaft 152 terminates, an
idler gear 160b and a driven gear 160c. The driven gear 160c is
arranged on the end of the power transmission shaft 58 which
extends from the spindle assembly to the turret assembly to drive
the turret drive shaft assembly.
The spindle is provided with a second gear mechanism comprised of a
worm gear 162 located on the lower end of the spindle support shaft
158 which worm gear 162 engages a mating worm gear 164 arranged on
a stub shaft 166. This gear mechanism operates a power transmission
assembly which ultimately controls the vertical fall of the turret
spider and pin jig as a function of the rotation of the
scotch-yoke. A change gear assembly 168 is employed to transmit
power from the spindle assembly to the turret assembly at a
controlled rate. The change gear assembly 168 is comprised of a
drive gear 168a mounted on the end of the stub shaft 166, an idler
gear 168b and a driven gear 168c. The driven gear 168c is fixedly
mounted on the end of the power transmission shaft 120 which
provides the power to lower the turret spider as the wire forming
the armature accumulates on the pin jig.
In operation, the worm gear 162 on the spindle shaft 158 drives the
worm gear 164 on the stub shaft 166 which, in turn, drives the
driven gear 168c through the change gear assembly 168. The power
transmission shaft 120 on which the driven gear 168c is mounted
extends from the spindle assembly to the turret assembly to rotate
the drive gear 118a of the turret lowering change gear assembly
118, seen in FIGS. 6 and 7. The driven gear 118c of the turret
lowering change gear assembly 118 drives the shaft 122 in which
gear teeth 126 are formed. Consequently, the rotation of gear teeth
126 imposes a force on the turret support shaft 88 through gear
teeth 128 to lower the entire turret spider assembly as a function
of the speed of the spindle assembly. Essentially, the speed of the
spindle assembly is directly proportional to the amount of wire
laid down on the turret pin jig. Therefore, as the wire begins to
accumulate to the turret head, the turret will be depressed to
afford an adequate clearance area for passage of the stylus 12 as
it dispenses subsequent layers of wire.
In addition, the spindle assembly includes means to selectively
shorten the stroke of the stylus rod 10, such as a pneumatically
actuated stop assembly 52 which is arranged in alignment with the
stop 30 depending from the stylus rod 10. The stop assembly 52,
best seen in FIG. 12, is comprised of a housing 170, a stop member
172 slidably mounted in the housing 170, an actuator piston 174 and
the piston rod 176 which mounts the stop member 172. Chambers 178
and 180 are located on either side of the piston 174 and
communicate with a pressure source by means of lines 182 and 184
respectively. A pressure source, such as an air cylinder (not
shown) is arranged with a suitable two-way valve 186 to selectively
pressurize either chamber 178 or 180. The valve 186 can be
controlled by any suitable electromechanical transducer capable of
responding to signals from a control module.
The stop 172 acts to prevent the stylus rod 10 from making the
maximum stroke during the winding of the armature. Consequently,
when a commutator pullout must be made in the armature, it is
necessary for the stop to be depressed to allow maximum stroke
travel of the rod 10. Accordingly, the stylus rod 10 must be
stopped during the majority of the strokes since a commutator
pullout is made only on the order of once for every four loops. In
operation, pressure from the air cylinder is selectively directed
through valve 186, to either line 180 or 184 to enter chambers 178
or 180 respectively, and act on piston 174 to either elevate or
depress the stop 172. It should be noted that any means can be used
to raise and lower the stop; however, in practice, it has been
found that the positive actuation of a pneumatic actuator is
particularly suitable to perform the desired elevation and
depression of the stop 172.
Since the spindle drive must be stopped each time a turret index
step is required, it has been found convenient to provide both a
main UNIVERSAL motor 14 and an auxiliary spindle AC motor 22 to
drive the spindle shaft 152. The heavy duty main UNIVERSAL motor 14
is arranged with a V-belt 16 around a pulley 20 connected to the
spindle drive shaft 152. The auxiliary AC motor 22 is also
connected by a belt drive to the pulley 20. However, the pulley 20,
as best seen in FIG. 9, is provided with a clutch mechanism 222
which operates to insure concomitant rotation of the pulley
sections 224 and 226 when the main motor 14 is energized, but
independent rotation of the pulley sections 224 and 226 when the
main motor 14 has been deenergized and the entire rotation of the
spindle shaft 152 is being provided by the auxiliary motor 22.
In practice, it has been found that an "overrunning" clutch 222 is
suitable for use as the means to couple the output from the main
spindle motor 14 and the auxiliary spindle motor 22. The
"overrunning" clutch body 226 is fixedly mounted on the spindle
shaft 152 while the cooperating outer race 228 of the clutch is
fixedly attached to the pulley section 224. Spring loaded balls 230
are arranged in the clutch body 222 to bear against the clutch
outer race 228 in such manner that rotation of the pulley 20 in one
direction (clockwise) will provide a firm coupling between the
pulley sections 224 and the clutch body 222 through the balls 230.
Rotation of the pulley section 224 in the other direction
(counterclockwise) or decreased rotational speed of the pulley
section 224 relative to the shaft 152 will disengage the
coupling.
In operation, the main motor 14 and auxiliary AC motor 22 are
energized simultaneously to start the rotation of the spindle drive
shaft 152. However, to effect braking of the spindle drive shaft
152, the heavy duty UNIVERSAL motor 14 is deenergized on the stroke
prior to the actual braking operation. During the interval between
deenergization of the main motor 14 and the braking of the spindle
drive shaft 152, the auxiliary AC motor 22 drives the shaft 152.
Braking is finally accomplished by deenergizing the auxiliary AC
motor 22. It should be noted that any means which can insure
positive braking of the spindle shaft drive upon a command signal
can be used.
The machine can also be provided with means to automatically
control the operation of the machine functions. In practice it has
been found desirable to feed signals back to the control circuit
which indicate the completion of each rotation of the shaft 152,
the extended position of the stylus rod 10 and the retracted
position of the stylus rod. As seen in FIG. 11, a cam shaft 322 is
provided with cams 328, 330 and 332 which close contactor switches
276, 288 and 300 as the respective machine functions occur. A
timing gear 324 fixedly mounted on shaft 152 and a timing gear 326
fixedly mounted on the cam shaft 322 are connected by a timing belt
320 to insure coincident rotation of the cam shaft 322 and the
shaft 152.
The pin jig assembly adapted to be mounted on the turret spider 102
to afford the means around which to wind the wire into an armature
is shown in FIGS. 14 and 15. Basically, the pin jig is comprised of
a pin jig base 188, a stripper plate 190 and a pressure and support
ring 192. The pin jig base 188 has three circular rows of pins 194,
196 and 198 projecting upwardly.
An infinite variety of pin jig assemblies can be used to serve as
the form on which the armature is wound. However, for the purpose
of illustration, a 27 pin jig plate having 27 pins in the outer row
194 and the intermediate row 196 and 9 pins in the inner row 198 is
depicted. The pins in all three rows 194, 196 and 198 are
preferably formed of steel hardened rods. The nine inner pins are
referred to as commutator pullout pins since their function is to
provide the means around which to pass the insulated copper wire
when a commutator pullout must be made in the armature. The
stripper plate 190 is provided with three annular arrays of holes
200, 202 and 204, which are in alignment with the three annular
rows of pins 194, 196 and 198 on the pin jig base 188. In the
assembled state, the plate 190 fits over baseplate 188 with each of
the baseplate pins transpiercing the respective stripper plate
holes.
The stripper plate 190 is also provided with three cutout sections
206 which are arranged to afford the spider holddown clamps 130
with access to the pin jig base 188. It is the function of the
turret spider 102 to rigidly retain the pin jig baseplate 188 and
the stripper plate 190 on the turret assembly for rotation
therewith. Functionally, the stripper plate 190 is used to
facilitate removal of the completed armature from the pin jig
188.
The pressure and support ring 192 is annular in shape with the
width of the annulus being substantially equivalent to the distance
between the baseplate outer row of pins 194 and the baseplate
intermedially disposed row of pins 196. A stylus clearance slot 208
is provided in the support ring for the purpose of affording the
stylus with access to the pin jig interior and a means by which to
return outwardly therefrom on each stroke. A ramp or slope 210 is
also provided on the pressure and support ring 204 to facilitate
the passage of the insulated copper wire into and out of the pin
jig center. Means to mount the pressure and support ring in a fixed
location are also necessary and, in practice it has been found that
two holes 212 and 214 located in alignment with two posts 138 and
146 depending downwardly from the support frame arm 80 will serve
to fixedly mount the pressure and support ring 192 properly. Of
course, any means for maintaining the pressure and support ring in
a fixed orientation which will not impede the rotation of the
turret and pin jig baseplate 188 can be used.
With this arrangement of parts, the pressure and support ring 192
serves to keep the insulated copper wire compacted as it is being
woven around the pins. In addition, the pressure and support ring
provides support for both the outer row of pins 194 and
intermediate row of pins 196 while reacting the pressure imposed on
the pins generated as the stylus draws the insulated copper wire
around the pins.
The synchronization of the machine is provided by a transmission
assembly shown in FIG. 16. The power to drive the transmission
assembly is provided by the main motor which drives the spindle
drive shaft 152 through a V-belt. The spindle drive shaft 152 has a
worm 154 fixed thereon which rotates the spindle shaft 158. In
addition, the spindle drive shaft 152 terminates in a drive gear
160a which engages an idler gear 160b that is, in turn, arranged to
engage a driven gear 160c. The driven gear 160c is rigidly attached
to the first turret drive power transmission shaft 58 which extends
to the turret assembly and drives the second turret drive power
transmission shaft assembly 64 through gears 60 and 62. The second
turret drive power transmission shaft 64 has a worm gear 76
arranged thereon which mates with the worm gear 84 on the turret
drive shaft 88.
Also included in the power transmission system is a turret indexing
mechanism. The turret index mechanism operates to index the turret
spider 102 relative to the spindle assembly. Thus, the turret
indexing mechanism is engaged to index the turret spider 102 and
pin jig baseplate when the spindle assembly is locked in a fixed
position. The turret indexing mechanism is driven by a turret index
motor through V-belts 136 which are arranged around a pulley 106.
The pulley 106 is fixed to the end of a first index power
transmission shaft 104 which terminates on the other end in a
change gear assembly 108. The driven gear 108c of the change gear
assembly 108 is fixed to a second index power transmission shaft
114 on which a worm gear 116 is formed. The worm gear 116 engages a
mating worm gear or index gear 110 which is connected directly to
gear 68c of the differential gear mechanism 66. Consequently,
during the period in which the main drive motor and the auxiliary
spindle motor are inoperative and the power transmission shaft 58
and the gears 60 and 62 are locked to prevent any rotation thereof,
the turret index mechanism can rotate the turret support shaft 88
through the worm gear assembly 76--84 and the turret drive shaft
86.
Means for lowering the turret spider 102 and pin jig assembly
synchronously with the rotation of the spindle assembly is also
shown in FIG. 16. A worm gear 162 formed on the spindle shaft 158
transmits power through a gear 164 on a first turret lowering power
transmission shaft 166 to a change gear assembly 168. The driven
gear 168c of the change gear assembly 168 is fixedly mounted on a
second turret lowering power transmission shaft 120 that terminates
in a change gear assembly 118. The driven gear 118c of the change
gear assembly 118 is fixed to a third turret lowering power
transmission shaft 122 on which a gear 126 is formed. The gear 126
is arranged in engagement with a gear 128 on the turret spider
support shaft 88. Consequently, as the spindle shaft 158 rotates,
the turret spider support shaft 88 is concomitantly lowered.
Control of the machine 2 is realized by a preprogramed control
system such as a punched control tape module. If punched control
tape is used, the program used varies for each armature design.
Functionally, the initial control message to the machine is a
command to close the power circuit to the main motor 14 and the
spindle auxiliary motor 22. Next, the machine is commanded to
continue operating until a specified number of armature loops have
been wound on the pin jig. After the specified number of armature
loops have been made, a command is sent to open the power circuit
to the main motor 14, thereby deenergizing the motor 14. However,
at this point in the operating cycle, the auxiliary motor 22
continues to drive the stylus shaft 158. As the final stroke of the
specific cycle is made, a command is sent to the mechanism that
determines the control of the air cylinder which operates the
pneumatic stop assembly 52. The signal adjusts the valve to a
position wherein communication between the air source and the upper
piston chamber 178 is provided. The air entering the upper piston
chamber 178 forces the piston 174 and the stop 172 downwardly and
out of the path of the stylus rod stop 30.
Consequently, with the machine running at the same controlled
speed, the stylus rod travels beyond one of the pins in the inner
row of pins 198 on one side thereof and returns on the other side
thereby making a commutator pullout.
After the commutator pullout stroke has been completed, a command
signal is sent to the auxiliary motor power circuit to open the
circuit thereby stopping the auxiliary motor 22. Concomitantly, a
command signal is sent to the turret index motor power circuit to
close the circuit, thereby energizing the turret index motor 134.
The turret index motor rotates the turret shaft 86 through the
mechanical paths comprised of shaft 104, change gear assembly 108,
shaft 114, gears 116--110, differential gear mechanism 66 and worm
gear 76. During this operation the mechanical power transmission
path from the spindle assembly is locked in place, hence the turret
and pin jig baseplate have been moved relative to the spindle.
Hence, a set of pins different from the set around which the
previous armature loops were wound will be used to wind the
subsequent cycle.
After the indexing of the turret has been completed, a cam switch
on the turret index motor will open the turret index motor power
circuit to deenergize the turret index motor.
Concomitant with the deenergization of the turret drive motor, the
main motor 14 and spindle auxiliary motor 22 are engaged to begin
another winding cycle.
In practice, it has been found desirable to control the armature
winding machine by a punched paper tape-controlled relay logic unit
designed to insure positive operation of each of the motor
operation. A variety of armature patterns can be wound on the
machine since the tape need only be punched in a pattern to signal
various operating parts of the machine.
Basically, as seen in FIG. 18, the punched paper tape-controlled
relay logic unit is comprised of the paper tape reading circuitry
and the logic circuitry. The paper tape reading circuitry is
adapted to read commands for seven machine functions. Channels
232--244 read the respective commands for the functions as follows:
deenergize the spindle drive motor 14, deenergize the auxiliary
spindle motor or spindle position motor 22, depress the stop member
52, signal the fully extended stylus rod 10, signal the fully
retracted stylus rod 10, read the signal to start the machine and
read the signal to terminate the winding cycle.
The logic circuit is comprised of six flip-flop circuits 246--256
with associated AND and OR gates. The flip-flop circuits 246--256
are shown with an s and c to indicate the set and clear states
respectively.
Flip-flop circuit 246 and its associated AND gate 258 are used to
detect the beginning and end command blocks in the tape. If channel
242 is punched and simultaneously the stylus rod 10 is in the fully
extended position, AND gate 258 will set flip-flop circuit 246. The
output of the flip-flop circuit 246 is coupled to one leg of AND
gate 260 and one leg of AND gate 262 associated with flip-flop
circuits 248 and 250 respectively. The flip-flop circuits 248 and
250 control, respectively, the spindle drive motor 14 and the
spindle position motor 22. Absence of a punch in channel 242 in the
first tape line will prevent operation of either of the motors. In
a similar manner the detection of a channel 244 punch in the tape
resets flip-flop circuit 246, thereby disabling the spindle drive
motor 14 and spindle position motor 22 at the end of the winding
sequence.
Flip-flop circuit 248 is connected to relay driver 264 which drives
relay 266 and hence controls power to the spindle drive motor 14.
If flip-flop circuit 248 is in the clear state, relay 266 is
deenergized. In this condition, no power is applied to the spindle
drive motor 14 but the capacitor 268 is shunted across its
terminals. In the set state flip-flop circuit 248 energizes relay
266, which closes the switch 274 thereby connecting the terminals
of motor 14 to an AC source and simultaneously charging capacitor
268 through the series combination of resistor 270 and diode 272.
The spindle drive motor 14 is a series wound motor which is driven
in one direction by the AC source when relay 266 is energized and
is braked by the energy stored in capacitor 268 when the relay 266
is deenergized.
A contactor switch 276 which can be arranged on a camshaft 322,
seen in FIG. 11, is closed each time the spindle drive motor 14
makes one full turn. The flip-flop circuit 248 is reset or cleared
through OR gate 278 which deenergizes relay 266, removing power
from the spindle drive motor 14 and simultaneously shunting
capacitor 268 across the motor terminals. The charge on the
capacitor 268 has the effect of quickly braking the spindle drive
motor 14 to a stop. The feedback from contact switch 276 also is
applied as a signal to the tape reader input causing it to advance
to the next punched line which continues the signal to AND gate
262. In operation, the reset or clearing of flip-flop circuit 248
and the subsequent setting thereof occurs instantaneously so as to
be unnoticeable in the operation of the machine.
The flip-flop circuit 250 controls power to the spindle position
motor 22 in a manner identical to that described for the control of
the spindle drive motor 14 by the flip-flop circuit circuit 248.
The circuitry from the flip-flop circuit 250 to the spindle
auxiliary motor 22 includes a relay driver 290, a relay 292, a
capacitor 294, a resistor 296, a diode 298 and a switch 299. The
circuit is connected in an identical manner to the circuit
connecting the flip-flop circuit 248 and the spindle drive motor
14. Similarly, the operation of the circuit is the same. There are,
however, additional inputs which control the set and clear
functions of the flip-flop circuit 250. These are performed by AND
gate 262 and OR gates 280 and 282 and will be described later.
The flip-flop circuit 252 is set by a command punched in tape
channel 238, and is a command to fully extend the stylus rod 10. In
this case, contactor switch 288 serves as a feedback element to
detect completion of this operation and transmits a signal to reset
the flip-flop circuit 252.
The flip-flop circuit 254 is set by a command punched in tape
channel 240 which is a command to fully retract the stylus rod 10.
Flip-flop circuit 254 is reset by the action of contactor switch
300 which senses the fully retracted position of the stylus rod
10.
The flip-flop circuit 256 controls the action of the index motor
134, in response to commands from AND gate 284 and OR gate 286. A
separate contactor switch 316, best seen in FIG. 6, is driven by
the turret index motor 134 and detects one revolution of the motor
which is geared in such a manner that one revolution corresponds to
one pin pitch of the pin jig assembly 70. The closing of contactor
switch 316 resets the flip-flop circuit 256 and simultaneously
commands the tape reader to advance to the next punched line.
The circuitry connecting the flip-flop circuit 256 with the turret
index motor 134 is virtually identical to the circuitry connecting
the flip-flop circuits 248 and 250 with the main drive motor 14 and
the auxiliary spindle motor 22. Again, the circuit includes a relay
driver 304, a relay 306, a capacitor 308, a resistor 310, a diode
312 and a switch 314.
Tape channel 236 controls the air cylinder switch which raises and
lowers the stop 52. The absence of a punch in the tape passing over
channel 236 signals the air cylinder to raise the stop 52 thus
shortening the stroke of the stylus rod 10. A punch in channel 236
causes the air cylinder to withdraw the stop 52 allowing a full
stroke of the stylus rod 10 for the purposes of making the armature
pullout at the appropriate times in the winding cycle.
The contactor switches 276, 288 and 300 are preferably arranged
with a camshaft 322 that is coupled to the spindle drive shaft 152
by a timing belt 320 which extends around a timing gear 324 on the
shaft 152 and a timing gear 326 on the camshaft 322 as seen in FIG.
11.
In operation, the machine is started by inserting a punched paper
tape in the tape reading circuitry. A start button (not shown) then
is depressed to provide power to the module and thereby cause the
tape reader to read the first command on the tape. With all the
gates in the closed position, the first signal will be a punch read
by channel 242. Channel 242 sends a signal through AND gate 258 to
set the flip-flop circuits 246. A signal from flip-flop circuit 246
is transmitted to AND gate 260 and AND gate 262 which, in turn, set
flip-flop circuits 248 and 250. The absence of a punch in channels
232 and 234 insures that the signal from the NO lines of channels
232 and 234 pass through AND gates 260 and 262 with the signal from
flip-flop circuit 246. Flip-flop circuits 248 and 250 set the
relays 266 and 292 to close the circuits to the spindle drive motor
14 and the spindle position motor or spindle auxiliary motor 22
respectively. At the end of each turn; i.e., a full stroke of the
stylus, contactor switch 288 is opened and a signal is returned to
the tape readout and flip-flop circuit 248 to insure continuous
reading of the tape. As the tape continues to read with none of the
channels punched, the signals from flip-flop 246 and channels 232
and 234 continue to set flip-flops 248 and 250 intermittently to
energize the spindle drive motor 14 and spindle position motor
22.
Succeeding tape lines have only the sprocket hole punched; hence,
the stop 62 is in the up or interrupt position and the winding
operation continues until a tape signal is received.
As the cycle approaches the point at which a commutator pullout
must be made, a punch in the tape in channel 232 opens the NO
circuit and shuts off the signal which sets flip-flop 248.
Coincident therewith, the signal from the contactor switch 276
passes through the OR gate 278 to clear flip-flop circuit 248. The
spindle drive motor 14 is stopped by the energy stored in capacitor
268. The overrunning clutch 222, best seen in FIG. 9, enables the
spindle assembly 4 to continue rotating by virtue of the spindle
position motor 22. As the tape continues to be read, the spindle
position motor 22 is deenergized by a signal resulting from a punch
in the tape at channel 234 whereby the NO circuit is opened. The
signal from channel 234 to AND gate 262 is thereby interrupted
while the signal from the contact switch 288 passes through OR gate
282 to close the flip-flop circuit 250.
Indexing of the pin jig 70 is the next machine function. The tape
command to index will have channels 232, 234, 236 and 240 punched.
The spindle drive motor 14 will remain disabled and the signal from
channel 240 will set flip-flop 254, the output of which will apply
a set signal to flip-flop 250 through OR gate 280 and AND gate 262
causing the spindle position motor 22 to rotate until a feedback
signal from contactor switch 300 indicates that the stylus rod 10
is in the fully retracted position. This signal will reset
flip-flop 250 through OR gate 282 and will also clear flip-flop
254. The simultaneous application of the ram-retracted signal plus
the hole-punch signals from channels 232, 234 and 236 to AND gate
284 will set flip-flop 256 through OR gate 286, thus energizing
relay 306 through relay driver 304 thereby applying power to the
index motor 134. The index motor 134 will make one revolution at
which point flip-flop 256 will be reset, the index motor 134 will
be braked to a stop by energy in capacitor 308 and a signal will be
delivered to OR gate 318 causing the tape reader to advance to the
next punched character.
The next command will be a command to make the commutator pullout.
This is accomplished by punching channel 236 which retracts the air
cylinder and stop 52, allowing a full stroke of the stylus rod 10
so that the armature wire passes around one of the commutator
pullout pins 198. Succeeding tape commands will have only the
sprocket holes punched and hence the stop 52 will return to the UP
or interrupting position and the spindle drive motor 14 will
continue to operate, laying down pairs of armature wires as
before.
The entire sequence will continue until all the pullout pins have
been traversed by the stylus 12 and until the winding form has
rotated to the initial starting position of the winding. At this
point, one final stroke with the stop 52 in the DOWN position will
be made, allowing the stylus to return to the initial starting
position. This final command character will also have channel 244
punched. Channel 244 will clear flip-flop 246 and subsequently
flip-flops 248 and 250 through OR gates 278 and 282, respectively,
thereby disabling the spindle drive motor 14 and ending the
operation. Upon removal of the winding and replacement of the
winding tool, it is only necessary to advance the tape to the
initial starting position to begin a new winding.
To begin operation of the machine, the stripper plate 190 is
mounted on the pin jig base 188 such that the three rows of pins
194, 196, and 198 project through the rows 200, 202 and 204
respectively, as shown in FIGS. 14 and 15. Next, the composite
assembly of the pin jig base 188 and stripper plate 190 are placed
on the turret spider 102 (FIG. 1). Holddown clamps 220 which are
located on each of the arms of the turret spider 102 are then
clamped over the pin jig baseplate 188 to secure the pin jig
baseplate 188 and stripper plate 190 to the turret spider 102. The
pressure and support ring 192 is then placed over the stripper
plate 190 to reset between the outer and intermediate rows of pins.
The holes 212 and 214 in the pressure and support ring 192 are
aligned with the retaining posts 138 and 140 which depend from the
support arm 80 of the support structure 72. Thus arranged, the
stripper plate 190 and pin jig base 188 must rotate with the turret
assembly while the pressure and support ring 192 remains
stationary.
Next, the stylus 12 is threaded manually with insulated copper wire
from the wire dispensing spool 76 and the end of the copper wire is
secured to the center of the stripper plate 190.
Alignment of the holes 212 and 214 with the retaining posts 138 and
140 necessarily locks the stylus clearance slot 208 in alignment
with the stylus 12, to thereby insure the passage of the wire
dispensing stylus 12 as it reciprocates.
The main motor 14 is then signaled to begin rotation of the
scotch-yoke 8 and, as a concomitant thereof, the turret spider 102
begins rotating by means of the synchronized power transmission
assembly, best seen in FIG. 16. As the baseplate or rotating table
42 of the scotch-yoke rotates (FIG. 12), the cam follower 150
attached to the reciprocating plate 50 follows the cam slot 44 and
provides reciprocating harmonic motion to the stylus rod 10. In
addition, the stop 30 on the stylus rod 10 engages the
pneumatically operated stop 172, thereby limiting the length of
travel of the stylus 12 to a point between the rows of pins 194 and
196 on the pin jig assembly as the rotation of the scotch-yoke 8
drives the reciprocating block 50 forward to overcome the energy in
the spring 36. Each stroke of the stylus rod 10 is accompanied by a
slight rotation of the turret assembly as a result of the
synchronized power transmission system. Consequently, as the stylus
12 passes beyond the stylus clearance slot 208 in the pressure and
support ring 192 to the right of one of the pins in the
intermediate row, pin 196a, for instance, the turret assembly
rotation will cause the pin 196a to move into engagement with the
insulated copper wire, as seen in FIG. 17 A--D, while the stylus 12
is held between the intermediate row of pins 196 and the inner row
198. On the return stroke, the stylus 12 will pass on the right of
the pin 196b, the pin adjacent to pin 196a thereby weaving the
conductor wire around the inside of two of the intermediate
pins.
At the same time, the spindle shaft 158 is transmitting power
through the change gear assembly 168 to the transmission shaft 120
which causes the turret assembly to continually depress (FIG.
16).
The pattern of winding the conductor wire on the pins continues
until a specific predetermined number of armature loops have been
made. When the cycle is complete, a signal is given to depress the
stop 172 to allow the stylus rod 10 a stroke of full unimpeded
travel. During this stroke, the stylus 12 and conductor wire pass
to the right of one of the inside pins, such as 198a, and on the
return stroke pass on the other (left) side of the pin 198a since
the rotation of the turret assembly has caused the pin 198a to move
through the path of the stylus stroke.
Indexing of the turret to provide a starting point for laying down
the conductor wire adjacent to the starting point of the first
pattern is then necessary. To effect this, the machine must be
stopped. Accordingly, a signal is given to the main motor 14 to
brake the motor at some point prior to the end of the cycle. At
this time, the small stylus drive motor 22 continues to drive the
stylus. When an absolute cessation of the stylus stroke is
necessary, the small stylus motor 22 is also stopped. At that
point, the turret index motor 134 is signaled to become engaged.
(FIG. 18) The turret index motor then rotates the turret shaft 86
through the path provided by the change gear assembly 108 and worm
gear assembly 116--110. After rotation of the turret through an
angle corresponding to one pin pitch of the pin jig plate, the
turret index motor 134 is deenergized and thereby locks the worm
gear 110 in place. The turret drive shaft 86 having been rotated a
few degrees while the transmission shaft 58 is fixed, will now
provide a new set of pins on which the conductor wire can by
systematically wound. With the worm gear 94 now locked in place,
any subsequent motion of the turret assembly must come from the
power transmission shaft 58 which is driven by the main motor 14
through a transmission system that includes the spindle shaft 158.
(FIG. 16)
The operation is repeated for the desired number of armature turns
including a commutator pullout, and upon completion of that step,
the main motor is again stopped and the turret assembly indexed to
start a subsequent winding of the coil. It should be noted that
indexing of the turret can be made after any desired number of
armature turns. Similarly, the commutator pullout can be made at
any time in the operation and need not occur immediately before the
indexing step.
The machine 2 is inherently versatile and capable of adaptation for
the use of copper wire of a wide variety of gauges and an infinite
variety of wire-wound armature patterns.
As best seen in FIG. 16, each of the change gear assemblies provide
the machine with versatility to afford an infinite variety of
winding patterns for the wire-wound armature.
Change gear assembly 160 fixes the rotation of the turret spider
and pin jig base relative to the rotation of the spindle.
Consequently, by replacing idler gear 160b with a smaller or larger
gear, the speed of driven gear 160c can be varied.
Similarly, change gear assembly 168 fixes the rate of depression of
the turret spider and pin jig base relative to the speed of the
spindle. Hence, by varying the size of the idler gear 168b, the
speed of the driven gear 168c can be varied.
The change gear assembly 108 determines the rate of turret index
during the time the index motor is energized. Therefore, a change
in the size of the idler gear 108b will vary the rate at which the
driven gear 108c is rotated.
FIGS. 17A--17D illustrate the step formation of an armature winding
for an eight pole machine including 117 armature coils and nine
commutator segments. The winding is formed about the pin jig. The
intermediate row of pins is designated 196a--196aa, and the outer
row of pins is likewise designated 194a--194aa, there being 27 pins
in both rows 194 and 196. The tabs for connection to the commutator
segments are designated 198A--198I in the order of connection,
there being nine pins in row 198.
Since the armature is for an eight pole machine, each armature loop
includes four armature coils. Since there are 27 positioning pins
each armature coil spans approximately eight positioning pins.
Since there are 117 coils and nine commutator segments, every 13th
coil is connected to the commutator.
The armature winding commences by attaching the insulated wire to
one of the commutator connection pins designated as pin 198a. Pin
198a is in radial alignment with the first set of positioning pins
196a and 194a. The winding then passes outside positioning pins
196b, 194c, 194d and 194e in succession. The first armature coil is
then completed by passing the wire inside pin 196g.
Next, the second armature coil is formed by passing the wire inside
pin 196h, outside pins 194j--194l, and inside pin 196n.
The winding continues by then forming the third and fourth armature
coils by passing inside pin 196o, outside pins 1941--194s, inside
pins 196u--196v, outside pins 194x--194z and inside pin 196a. At
this point the first armature loop spanning 360.degree. is
completed as is illustrated in FIG. 17A.
The second armature loop is in registry with the first armature
loop and is formed following the same sequence around the
positioning pins as shown in FIG. 17B. The third armature loop is
also in registry as well as the first coil of the fourth armature
loop. The winding as it appears after formation of three and
one-quarter armature loops (13 coils) is shown in FIG. 17C. Each of
the 13 coils in the first group are in registry with one another
and follow the same pattern about the positioning pins.
A commutator pullout is formed following the first group of 13
coils by passing the winding around tab 198b. At this point the
winding is also indexed so that the second group of 13 coils will
lie in positions adjacent the first group.
The winding progresses by passing outside pin 196h, outside pins
194i--194k, inside pins 196m and 196n, outside pins 194p--194r,
inside pins 196t and 196u, outside pins 194w--194y and inside pin
196aa. The winding as it then appears after completion of four
armature loops (16 coils), including three coils of the second
group, is shown in FIG. 17D.
The preferred embodiment invention has been described, however, any
minor variations which come within the spirit of the invention are,
or course, comprehended thereby.
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