Automatic winder for an inside brushless stator

Abstract

An apparatus for manufacturing an internal wound stator includes a winding arbor configured to receive a conductive wire. The apparatus also has a stator loader with a stator having a generally cylindrical shape with an interior opening and having a plurality of axial slots formed therein. The interior dimension of the stator is larger than the exterior dimension of the winding arbor such that the winding arbor and stator may traverse with respect to one another. The apparatus also has a first movable member configured for moving at least one of the winding arbor and the stator. The apparatus also has a second rotating member configured to rotate at least one of the stator and the winding arbor. The conductive wire is introduced through an interior of the winding arbor. The first movable member is configured to move at least one of the winding arbor and the stator relative to one another to wind the conductive wire in a first longitudinal manner and into a first of the plurality of axial slots. The second rotating member is configured to rotate at least one of the first winding arbor or the stator relative to one another to align the wire relative to a second axial slot of the plurality of axial slots. The first movable member is configured to move at least one of the winding arbor and the stator relative to one another to wind the conductive wire in a second opposite longitudinal manner and into the second axial slot.

1 . An apparatus for manufacturing an internal wound stator, the stator having a generally cylindrical shape with an interior opening and having a plurality of axial slots formed therein, the apparatus comprising:
 a winding arbor configured to receive a conductive wire;   a stator loader for supporting a stator, the stator having an interior dimension larger than an exterior dimension of the winding arbor such that the winding arbor and stator may traverse with respect to one another;   a first movable member moving at least one of the winding arbor and the stator;   a second rotating member configured to rotate at least one of the stator and the winding arbor;   the conductive wire being introduced through an interior of the winding arbor;   the first movable member configured to move at least one of the winding arbor and the stator relative to one another to wind the conductive wire in a first longitudinal manner and into a first of the plurality of axial slots;   the second rotating member configured to rotate at least one of the first winding arbor or the stator relative to one another to align the conductive wire relative to a second axial slot of the plurality of axial slots; and   the first movable member configured to move at least one of the winding arbor and the stator relative to one another to wind the conductive wire in a second opposite longitudinal manner and into the second axial slot.   
   
   
       2 . The apparatus of  claim 1 , further comprising a first spool providing at least a first conductive wire through a collector; and
 a second spool providing at least a second conductive wire through the collector and to form a composite conductive wire bundle made from the first conductive wire and the second conductive wire.   
   
   
       3 . The apparatus of  claim 1 , wherein the second rotating member is configured to rotate at least one of the first winding arbor or the stator relative to one another to align the conductive wire relative to another axial slot of the plurality of axial slots. 
   
   
       4 . The apparatus of  claim 1 , wherein the stator loader comprises a cylindrical bushing member having an aperture surrounded by an orientation collet configured to align the stator therein. 
   
   
       5 . The apparatus of  claim 4 , further comprising a locking ring having a locking ring aperture, the locking ring being placed over the stator loader with the stator in the collet and aligned with the locking ring aperture for holding the stator in the stator holder. 
   
   
       6 . The apparatus of  claim 1 , further comprising a controller configured to control the movement of the first movable member and the second rotating member. 
   
   
       7 . The apparatus of  claim 1 , wherein the winding arbor is stationary and the stator moves. 
   
   
       8 . The apparatus of  claim 1 , wherein the stator is stationary and the winding arbor moves. 
   
   
       9 . The apparatus of  claim 2 , further comprising three or more spools configured to introduce at least three conductive strands to form a conductive wire bundle. 
   
   
       10 . The apparatus of  claim 9 , wherein the three conductive strands are configured to enter a respective first through third openings in the collector. 
   
   
       11 . The apparatus of  claim 1 , wherein the second rotating member further comprises a pulley device connected to a contact surface surrounding the stator loader, the pulley device being operatively connected to a controller to rotate a predetermined radial amount, the predetermined radial amount moving the conductive wire bundle into another axial slot. 
   
   
       12 . The apparatus of  claim 1 , wherein the first movable member comprises a support that rides on a track, the support being operatively coupled to a controller, the controller controlling the support to move relative to the track in a first axial direction and a second axial direction to wind the conductive wire in the first axial slot, and traverse in a second axial direction to wind the conductive wire in the second axial slot 
   
   
       13 . The apparatus of  claim 1 , wherein the stator is rotated about three hundred sixty degrees, and then removed. 
   
   
       14 . An apparatus for manufacturing an internal wound stator, the stator having a generally cylindrical shape with an interior opening and having a plurality of axial slots formed therein, the apparatus comprising:
 a winding arbor configured to receive the conductive wire, the winding arbor mounted on a support structure;   a stator loader being configured to support the stator, the stator having an interior dimension larger than an exterior dimension of the winding arbor such that the winding arbor and stator may traverse with respect to one another;   a first movable member configured to move the stator relative to the arbor, the first movable member being disposed on a second support structure that rides along a track;   a second rotating member disposed on the second support structure and configured to rotate at least one of the stator and the arbor relative to the other;   the conductive wire introduced through an interior of the winding arbor;   the first movable member configured to move the stator relative to the arbor to wind the conductive wire in a first longitudinal manner and into a first of the plurality of axial slots;   the second rotating member configured to rotate the stator relative to the arbor to align the conductive wire relative to a second axial slot of the plurality of axial slots;   the first movable member configured to move the stator in an opposite direction relative to the arbor to wind the conductive wire in the second axial slot;   the first movable member and the second rotation member alternating translation and rotation until substantially a remainder of the plurality of axial slots are wound with the conductive wire; and   the first movable member separating the stator from the arbor while holding the conductive wire in each of the axial slots.   
   
   
       15 . The apparatus of  claim 14 , further comprising a first spool providing at least a first conductive wire through a collector; and
 a second spool providing at least a second conductive wire through the collector and to form a composite conductive wire bundle made from the first conductive wire and the second conductive wire.   
   
   
       16 . The apparatus of  claim 15 , further comprising a cylindrical bushing member having an aperture surrounded by an orientation collet configured to align the stator in the first movable member. 
   
   
       17 . The apparatus of  claim 16 , further comprising a locking ring having a locking ring aperture, the locking ring being placed over the stator loader with the stator in the collet and aligned with the locking ring aperture, the locking ring configured to hold the stator in the stator holder. 
   
   
       18 . The apparatus of  claim 14 , further comprising a controller coupled to a memory and configured to control the movement of the first movable member and the second rotating member. 
   
   
       19 . The apparatus of  claim 14 , wherein the second rotating member comprises a wheel and a pulley configured to rotate the stator holder. 
   
   
       20 . A method of manufacturing an internal wound stator, the method comprising:
 detachably supporting a stator having a number of internal axial slots relative to an arbor;   passing a conductive wire through a first end of the arbor;   gripping the conductive wire through a second end of the arbor;   passing the arbor relative to the stator in a first direction to wind the conductive wire in a first axial slot;   rotating at least one of the arbor and the stator to introduce the conductive wire into a second axial slot;   passing the arbor relative to the stator in a second opposite direction to wind the conductive wire in the second axial slot;   repeating passing and rotating until a remainder of the axial-slots are wound;   supporting the conductive wire in the axial slots; and   removing the internally wound stator.   
   
   
       21 . The apparatus of  claim 1 , wherein the winding arbor is configured to receive a conductive wire bundle. 
   
   
       22 . The apparatus of  claim 1 , wherein the winding arbor further comprises a feed port, and wherein the conductive wire is introduced to the interior of the arbor to the feed port with the feed port configured to introduce the conductive wire into the plurality of axial slots. 
   
   
       23 . The apparatus of  claim 14 , wherein the winding arbor is configured to receive a conductive wire bundle. 
   
   
       24 . The apparatus of  claim 14 , wherein the winding arbor further comprises a feed port, and wherein the conductive wire is introduced to the interior of the arbor to the feed port with the feed port configured to introduce the conductive wire into the plurality of axial slots.