# US 2023/0066596 A1 · Device and Method for Winding Toroidal Cores Without Using a Magazine > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2023/0066596 A1 - Document ID: US20230066596A1 - Status: Published application - Kind: A1 - Application number: 17/794,593 - Filed: 2021-01-20 - Published: 2023-03-02 - Earliest claimed: 2020-01-21 - Assignees: Ruff GmbH - Applicants: Ruff GmbH - Inventors: Alois Hofer - Web page: https://patentgrep.com/patent/US20230066596A1 ## CPC - H01F 41/08: Winding conductors onto closed formers or cores, e.g. threading conductors through toroidal cores - H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES ## Abstract The invention relates to a device and a method for winding toroidal cores, which can be guided in a toroidal core retaining element, with a wire comprising multiple wire sections without using a magazine. The device additionally comprises: a substantially circular needle roller which is arranged on a winding plane substantially parallel to the wire, is rotatably mounted, and can be positioned relative to the toroidal core retaining element such that the needle roller winds a wire section located on the winding plane through and about a toroidal core which is guided in the toroidal core retaining element during operation. The needle roller additionally comprises a deflecting roller, which is rotatably mounted on the needle roller in a first recess on the winding plane and which is designed to wind the wire section located on the winding plane through and about the toroidal core during operation, and a baffle plate, which is arranged on the needle roller in a second recess on the winding plane adjacently to the first recess and which is designed to guide the wire to be wound between the winding plane and a storing plane arranged substantially parallel to the winding plane via a guide groove during operation. The device additionally comprises multiple storing elements which are arranged on the storing plane, which are mounted in a stationary and rotatable manner, and which are designed to store wire sections located on the storing plane. ## Claims ### Claim 1 A device with a toroidal core retaining element for winding toroidal cores, which can be guided in the toroidal core retaining device, with a wire comprising a multiplicity of wire sections, and further comprising: a substantially circular needle roller, arranged substantially parallel to the wire and mounted such as to be rotatably movable and which can be positioned relative to the toroidal core retaining element in such a way that the needle roller winds a wire section located in the winding plane through and about a toroidal core guided in the toroidal core retaining element when in operation, wherein the needle roller further comprises: a deflecting roller, which is rotationally mounted in a first recess in the winding plane at the needle roller, and is designed such as to wind the wire section located in the winding plane through and about the toroidal core when in operation; and a baffle plate, which is arranged in a second recess in the winding plane, adjacent to the first recess at the needle roller, and which is designed to guide the wire which is to be wound, during operation, via a guide groove between the winding plane and a storing plane arranged substantially parallel to the winding plane, and the device further comprises: a multiplicity of storing elements arranged in the storing plane, which are mounted in a stationary and rotatable manner, and are designed to store the wire sections located in the storing plane. ### Claim 2 (depends on 1) The device for winding toroidal cores according to claim 1, wherein an interruption interrupts the substantially circular form of the needle roller in one region, such that the needle roller can be positioned in a position provided for the winding of the toroidal core, and wherein the needle roller is arranged in such a way that it can be rotated through the toroidal core. ### Claim 3 (depends on 1) The device for winding toroidal cores according to claim 1, wherein the needle roller comprises a toothed rim, which is arranged in a drive plane arranged substantially parallel to the winding plane, and is designed to drive the needle roller rotationally. ### Claim 4 (depends on 1) DeviceThe device for winding toroidal cores according to claim 1, wherein the needle roller is designed such as to wind the wire section located in the winding plane, when in operation, simultaneously through and about the toroidal core which is being guided in the toroidal core retaining element and to store the wire section located in the storing plane onto the multiplicity of storing elements. ### Claim 5 (depends on 1) DeviceThe device for winding toroidal cores according to claim 1, wherein the deflecting roller is designed such as to wind the wire section located in the winding plane centrally through and about the toroidal core. ### Claim 6 (depends on 1) The device for winding toroidal cores according to claim 1, further comprising at least one wire brake, wherein the at least one wire brake is designed such as to brake the wire section located in the storing plane by pressing at intervals on at least one of the multiplicity of storing elements, and to keep the wire taut when in operation. ### Claim 7 (depends on 6) The device for winding toroidal cores according to claim 6, wherein the multiplicity of storing elements are rollers, which are driven in rotation at intervals in reciprocal effect with the at least one wire brake. ### Claim 8 A method for winding a toroidal core, which can be guided in a toroidal core retaining element, with a wire comprising a multiplicity of wire section, wherein the method comprises the rotation of a needle roller, comprising a baffle plate and a deflecting roller, through the toroidal core, and comprises the following steps: a. Guiding a wire section, located in a storing plane, of a wire stored on a multiplicity of storing elements from storing elements arranged in the storing plane, via a guide groove of the baffle plate, and onto the deflecting roller, which is arranged in a winding plane arranged substantially parallel to the storing plane, b. Guiding the wire section located in the winding plane about the deflecting roller as far as the toroidal core; c. Winding the toroidal core with the wire section located in the winding plane; and d. Guiding back a wire section located in the winding plane which has not been wound, via the deflecting roller, through the guide groove, and onto the multiplicity of storage elements in the storing plane. ### Claim 9 (depends on 8) The method for winding toroidal cores according to claim 8, wherein the toroidal core guided in the toroidal core retaining element rotates when in operation perpendicular to the rotation of the needle roller. ### Claim 10 (depends on 8) The method for winding toroidal cores according to claim 8, wherein the wire on the storing elements is tautened at intervals by at least one wire brake. ### Claim 11 (depends on 1, 8) The method for winding toroidal cores according to claim 8, wherein the method is carried out by making use of the device for winding of toroidal cores according to claim 1. ### Claim 12 (depends on 8) The method for winding toroidal cores according to claim 8, wherein, at the beginning of the method, the wire section located in the winding plane is wound simultaneously through and about the toroidal core, and the quantity of wire required is stored on the multiplicity of storing elements in the storing plane. ### Claim 13 (depends on 8) The method for winding toroidal cores according to claim 8, wherein the steps a to d are run through repeatedly, in order to wind the desired number of windings of the wire onto the toroidal core.