Method of making a stator connection assembly

Claim 1

A method of fabricating a dynamoelectric machine stator assembly including a magnetic core having axially extending slots, at least one winding formed from multiple turns of a conductor and having end turn portions thereof disposed about at least one face of the magnetic core, and at least two lead wires electrically interconnected with tap wires of the at least one winding, said method comprising: extending tap wires of the at least one winding to a common connecting region; deforming the end turn portions into a predetermined configuration including a deformed section on the outer periphery of the end turn portions for receiving a connection insulator; connecting a first lead wire to at least one tap wire and thereby establishing a connection point; connecting a second lead wire to at least one other tap wire and thereby establishing another connection point; relatively moving a connection insulator having a plurality of holsters and the connection points so that each connection point and wires extending therefrom are relatively moved through an aperture at one end of the respective holster and so that each connection point is disposed within a respective holster for supporting and electrically isolating each connection point; positioning and retaining said connection insulator against the outer periphery of said deformed end turn portions of the at least one winding so that wires interconnected by the connection points extend through respective apertures at one end of the connection insulator; and securing the connection insulator to said deformed section of the end turn portions at the outer periphery thereof.

Claim 2

A method of fabricating a dynamoelectric machine stator assembly including a magnetic core having axially extending slots, at least one winding formed from multiple turns of a conductor and having end turn portions thereof disposed about at least one face of the magnetic core, and at least two lead wires electrically interconnected with tap wires of the at least one winding, said method comprising: extending tap wires of the at least one winding to a common connecting region; deforming the end turn portions into a predetermined configuration including a deformed section on the outer periphery of the end turn portions for receiving a connection insulator; connecting a first lead wire to at least one tap wire and thereby establishing a connection point; connecting a second lead wire to at least one other tap wire and thereby establishing another connection point; relatively moving a connection insulator having a plurality of holsters and the connection points so that each connection point and wires extending therefrom are relatively moved through an aperture at one end of the respective holster and so that each connection point is disposed within a respective holster for supporting and electrically isolating each connection point; positioning and retaining said connection insulator against the outer periphery of said deformed end turn portions of the at least one winding so that wires interconnected by the connection points extend through respective apertures at one end of the connection insulator; and securing the connection insulator to said deformed section of the end turn portions at the outer periphery thereof.

Claim 6

A method of fabricating a dynamoelectric machine stator assembly including a magnetic core having axially extending slots, at least one winding formed from multiple turns of a conductor and having end turn portions thereof disposed about at least one face of the magnetic core, and at least two lead wires electrically interconnected with tap wires of the at least one winding, said method comprising: extending tap wires of the at least one winding to a common connecting region; connecting a first lead wire to at least one tap wire and thereby establishing a connection point; connecting a second lead wire to at least one other tap wire and thereby establishing another connection point; placing a connection insulator having a plurality of holsters over the connection points with each connection point being received within a respective holster for supporting and electrically isolating each connection point; positioning and retaining said connection insulator against the outer periphery of end turn portions of the at least one winding; securing the connection insulator to the end turn portions at the outer periphery thereof by disposing lacing material about the end turn portions and the connection insulator; wherein the method further includes pressing the winding end turn portions for varying the relative distance between the end turn portions and at least one face of the core after the tap wires have been extended to the common connecting region and wherein the pressing of the winding end turn portions includes deforming a section of said end turn portions for subsequently mounting the connection insulator thereto.

Claim 7

A method of fabricating a dynamoelectric machine stator assembly including a magnetic core having axially extending slots, at least one winding formed from multiple turns of a conductor and having end turn portions thereof disposed about at least one face of the magnetic core, and at least two lead wires electrically interconnected with tap wires of the at least one winding, said method comprising: extending tap wires of the at least one winding to a common connecting region; connecting a first lead wire to at least one tap wire and thereby establishing a connection point; connecting a second lead wire to at least one other tap wire and thereby establishing another connection point; placing a connection insulator having a plurality of holsters over the connection points with each connection point being received within a respective holster for supporting and electrically isolating each connection point; positioning and retaining said connection insulator against the outer periphery of end turn portions of the at least one winding; securing the connection insulator to the end turn portions at the outer periphery thereof by disposing lacing material about the end turn portions and the connection insulator; wherein the method further includes pressing the winding end turn portions for varying the relative distance between the end turn portions and at least one face of the core after the tap wires have been extended to the common connecting region and wherein the pressing of the winding end turn portions includes deforming a section of said end turn portions for subsequently mounting the connection insulator thereto.

Claim 8

A method of making an electrical connection in a dynamoelectric machine stator assembly including a core having axially extending slots, at least one winding formed from multiple turns of a conductor and having end turn portions thereof disposed adjacent at least one face of the core, and at least two lead wires electrically interconnected with tap wires of the at least one winding, said method comprising: interfitting a tap support and aligning means with a core having at least one winding disposed thereon and thereby defining a temporary common connecting region; locating end portions of the at least one winding within the tap support and aligning means at the temporary common connecting region; placing and aligning said core with the tap support and aligning means interfitted therewith at a connecting station; connecting at least two lead wires to respective end portions of the at least one winding and thereby establishing electrical connection points at the temporary common connecting region; placing a connection insulator including a plurality of holsters over the electrical connection points with each connection point being received within a respective holster for supporting and electrically isolating each connection point; removing the end portions from the tap support and aligning means; removing the core and the tap support and aligning means from the interfitting relationship; positioning and retaining said connection insulator against the outer periphery of end turn portions of the at least one winding at a final common connecting region; and securing the connection insulator to the outer periphery of the end turn portions.

Claim 9

A method of making an electrical connection in a dynamoelectric machine stator assembly including a core having axially extending slots, at least one winding formed from multiple turns of a conductor and having end turn portions thereof disposed adjacent at least one face of the core, and at least two lead wires electrically interconnected with tap wires of the at least one winding, said method comprising: interfitting a tap support and aligning means with a core having at least one winding disposed thereon and thereby defining a temporary common connecting region; locating end portions of the at least one winding within the tap support and aligning means at the temporary common connecting region; placing and aligning said core with the tap support and aligning means interfitted therewith at a connecting station; connecting at least two lead wires to respective end portions of the at least one winding and thereby establishing electrical connection points at the temporary common connecting region; placing a connection insulator including a plurality of holsters over the electrical connection points with each connection point being received within a respective holster for supporting and electrically isolating each connection point; removing the end portions from the tap support and aligning means; removing the core and the tap support and aligning means from the interfitting relationship; positioning and retaining said connection insulator against the outer periphery of end turn portions of the at least one winding at a final common connecting region; and securing the connection insulator to the outer periphery of the end turn portions.

Claim 14

A method of fabricating a dynamoelectric machine stator assembly including a magnetic core having axially extending slots, at least one winding formed from multiple turns of a conductor and having end turn portions thereof disposed about at least one face of the magnetic core, and at least two lead wires electrically interconnected with tap wires of the at least one winding, said method comprising: extending tap wires of the at least one winding to a common connecting region; deforming the end turn portions into a predetermined configuration including a deformed section on the outer periphery of the end turn portions for receiving a connection insulator; connecting a first lead wire to at least one tap wire and thereby establishing a connection point; connecting a second lead wire to at least one other tap wire and thereby establishing another connection point; relatively moving a connection insulator having a plurality of holsters and the connection points so that each connection point and wires extending therefrom are relatively moved through an aperture at one end of the respective holster and so that each connection point is disposed within a respective holster for supporting and electrically isolating each connection point; and positioning and retaining said connection insulator against the outer periphery of said deformed section of the end turns of the at least one winding so that wires interconnected by the connection points extend through respective apertures at one end of the connection insulator.

Claim 15

A method of fabricating a dynamoelectric machine stator assembly including a magnetic core having axially extending slots, at least one winding formed from multiple turns of a conductor and having end turn portions thereof disposed about at least one face of the magnetic core, and at least two lead wires electrically interconnected with tap wires of the at least one winding, said method comprising: extending tap wires of the at least one winding to a common connecting region; deforming the end turn portions into a predetermined configuration including a deformed section on the outer periphery of the end turn portions for receiving a connection insulator; connecting a first lead wire to at least one tap wire and thereby establishing a connection point; connecting a second lead wire to at least one other tap wire and thereby establishing another connection point; relatively moving a connection insulator having a plurality of holsters and the connection points so that each connection point and wires extending therefrom are relatively moved through an aperture at one end of the respective holster and so that each connection point is disposed within a respective holster for supporting and electrically isolating each connection point; and positioning and retaining said connection insulator against the outer periphery of said deformed section of the end turns of the at least one winding so that wires interconnected by the connection points extend through respective apertures at one end of the connection insulator.

Claim 17

A method of fabricating a dynamoelectric machine stator assembly including a magnetic core having a bore and axially extending slots therein, said method including: developing at least one winding by generating multiple turns of a conductor and accommodating the at least one winding on a magnetic core with side turn portions thereof being disposed in axially extending slots of the core and end turn portions thereof being disposed about at least one face of the core; disposing a piece of insulating material on at least one of a plurality of end portions of the at least one winding; routing the winding end portions to a common connecting region; pressing the end turn portions and thereby decreasing the spacing between the end turn portions and the at least one face of the core; interfitting a tap support and aligning means with the magnetic core; placing end portions of the at least one winding and at least two lead wires within the tap support and aligning means; placing and aligning the core with the tap support and aligning means interfitted therewith in a horizontal position at a connecting station; connecting the end portions to respective lead wires thereby establishing electrical connection points; placing a connection insulator having a plurality of holsters over the connection points with each connection point being received within a corresponding holster for supporting and electrically isolating each connection point; removing the end portions and the at least two lead wires from the tap support and aligning means; removing the core and the tap support and aligning means from the interfitting relationship; positioning and retaining the connection insulator against the outer periphery of end turn portions of the at least one winding; and securing the connection insulator to the end turn portions at the outer periphery thereof by disposing lacing material about the end turn portions and the connection insulator.

Claim 18

A method of fabricating a dynamoelectric machine stator assembly including a magnetic core having a bore and axially extending slots therein, said method including: developing at least one winding by generating multiple turns of a conductor and accommodating the at least one winding on a magnetic core with side turn portions thereof being disposed in axially extending slots of the core and end turn portions thereof being disposed about at least one face of the core; disposing a piece of insulating material on at least one of a plurality of end portions of the at least one winding; routing the winding end portions to a common connecting region; pressing the end turn portions and thereby decreasing the spacing between the end turn portions and the at least one face of the core; interfitting a tap support and aligning means with the magnetic core; placing end portions of the at least one winding and at least two lead wires within the tap support and aligning means; placing and aligning the core with the tap support and aligning means interfitted therewith in a horizontal position at a connecting station; connecting the end portions to respective lead wires thereby establishing electrical connection points; placing a connection insulator having a plurality of holsters over the connection points with each connection point being received within a corresponding holster for supporting and electrically isolating each connection point; removing the end portions and the at least two lead wires from the tap support and aligning means; removing the core and the tap support and aligning means from the interfitting relationship; positioning and retaining the connection insulator against the outer periphery of end turn portions of the at least one winding; and securing the connection insulator to the end turn portions at the outer periphery thereof by disposing lacing material about the end turn portions and the connection insulator.

Claim 23

A method of fabricating a dynamoelectric machine stator assembly including a magnetic core having axially extending slots, at least one winding formed from multiple turns of a conductor and having end turn portions thereof disposed about at least one face of the magnetic core, and at least two lead wires electrically interconnected with tap wires of the at least one winding, said method comprising: extending tap wires of the at least one winding to a common connecting region; pressing the end turn portions into a predetermined configuration including a deformed section on the outer periphery of the end turn portions for receiving a connection insulator; connecting a first lead wire to at least one tap wire and thereby establishing a connection point; connecting a second lead wire to at least one other tap wire and thereby establishing another connection point; relatively moving a connection insulator having a plurality of holsters and the connection points for moving each connection point and wires extending therefrom through an aperture at one end of the respective holster for disposing each connection point within a respective holster for supporting and electrically isolating each connection point; and positioning and retaining said connection insulator against said deformed outer periphery of end turn portions of the at least one winding so that wires interconnected by the connection points extend through respective apertures at one end of the connection insulator.

Claim 24

A method of fabricating a dynamoelectric machine stator assembly including a magnetic core having axially extending slots, at least one winding formed from multiple turns of a conductor and having end turn portions thereof disposed about at least one face of the magnetic core, and at least two lead wires electrically interconnected with tap wires of the at least one winding, said method comprising: extending tap wires of the at least one winding to a common connecting region; pressing the end turn portions into a predetermined configuration including a deformed section on the outer periphery of the end turn portions for receiving a connection insulator; connecting a first lead wire to at least one tap wire and thereby establishing a connection point; connecting a second lead wire to at least one other tap wire and thereby establishing another connection point; relatively moving a connection insulator having a plurality of holsters and the connection points for moving each connection point and wires extending therefrom through an aperture at one end of the respective holster for disposing each connection point within a respective holster for supporting and electrically isolating each connection point; and positioning and retaining said connection insulator against said deformed outer periphery of end turn portions of the at least one winding so that wires interconnected by the connection points extend through respective apertures at one end of the connection insulator.