Method and apparatus for winding toroidal coils

A method of winding a toroidal coil around a ring-shaped core having a central opening having a central axis and characterized by a peripheral surface and an annular surface on each side of said core, said method comprising the steps of:

• (a) inserting in said central opening a wire of predetermined length comprising a first end portion and a remaining portion, said first end portion being fed through said opening, contacting said remaining portion of said wire against an annular surface of said core such that said remaining portion radially extends at a predetermined length from said core, applying a tension to the wire, grasping said core by a core-turning means and turning said core in a first direction diametrically about an axis generally orthogonal to the central axis with said remaining portion of said wire,
• (b) inserting the first end portion of said wire into the opening of said core towards its other side, applying tension to said wire, rotating said core at a predetermined angle about the central axis by core rotating means independent of said core turning means in a first direction about said central axis,
• (c) grasping said core again with said core turning means to turn said core in said first direction about an axis generally orthogonal to the central axis;
• inserting the first end portion of said wire into said central opening of said core towards one side thereof, extending the first end portion of said wire under tension applied to said wire, rotating said core using said core rotating means to rotate said core back at said predetermined angle in a direction opposite to said first direction and form a layer of wound wire around said core,
• (d) repeating steps (a) through (c) to apply another layer of said winding to said core,
• (e) grasping again said core with said core turning means and turning said core in said first direction about an axis generally orthogonal to the central axis, inserting an end portion of said wire into the central opening of said ring-shaped core towards its other side, extending said first end end portion under tension applied to said wire, rotating the core at said predetermined angle by using said core rotating means in said opposite direction;
• (f) grasping said core again with said core turning means to turn the core in said first direction about an axis generally orthogonal to the central axis;
• inserting said end portion of said wire into the central opening of said core towards one side thereof, extending the said first end portion of the wire applied under tension, rotating the core using said core rotating means to rotate the core at said predetermined angle in said first direction;
• and
• (g) repeating steps (e) and (f) to form a toroidal layer of said winding.

A method for controlling tension applied to a wire wound on a coil-winding machine of an upright type comprising the steps of:

• (a) passing an end of said wire of predetermined length having a first end portion and a remaining portion through a central opening of a ring-shaped toroidal core having a center axis by means of a wire chuck holder;
• said core having a peripheral surface around which the wire is wound and an annular surface on each side of said core,
• (b) pulling the first end portion of said wire through the central opening of said toroidal core in an axial direction of said center axis;
• (c) applying a predetermined tension to the wire so as to lay the wire on the peripheral surface of said toroidal core
• (d) turning the toroidal core about an axis generally orthogonal to said central axis;
• (e) rotating the toroidal core about said central axis;
• (f) passing the first end portion through the central opening;
• and
• (g) repeating steps (b) through (f) to complete the winding of said wire around the peripheral surface of said toroidal core, wherein the tension applied to the wire is constantly controlled, the wire being wound on the core in a two-stage operation of a high-speed course positioning, including means for position detection, the high speed course position being achieved by using a servo-motor in accordance with said predetermined length of wire to be wound on the core, said position detection being achieved by employing a combination of an extension spring associated with said wire chuck holder that advances in response to pulses produced by said wire chuck holder grasping an end of said wire;
• the method also including the use of shutter members integrally associated with grasping means mounted on said chuck holder, said tension on said wire being monitored by tension detectors associated with said wire chuck holder in a direction opposite to said shutter members.

A winding machine for winding a wire of predetermined length having a first end portion and a remaining portion onto a toroidal core having a central opening and a center axis therethrough comprising,

• a turning clamp for holding said core together with an end of said wire, said clamp being adapted for turning the core about an axis generally orthogonal to the central axis upside-down;
• a feed clamp for holding said core, said feed clamp being adapted to travel along a circular guide rail relative to the central axis of said core and for rotating the core circumferentially;
• and
• a wire chuck assembly for inserting the first end portion of said wire into the central opening of said core and for applying a predetermined tension to said wire to wind the wire onto the core;
• means for turning the turning clamp about an axis generally orthogonal to the central axis;
• and
• means for rotating the feed clamp and the core about the central axis, whereby turning of the core is independent of the rotation of the core.

An apparatus for controlling tension during the winding of a wire around a toroidal core in a toroidal coil winding machine of an upright type, said core having a central opening and a central axis therein which comprises:

• an upwardly extending longitudinal guide rail having a top and a bottom,
• a servo motor mounted at the top of said guide rail,
• a belt cooperatively associated with said servo motor and adapted to be driven by said motor,
• a core clamp assembly positioned intermediate the top and bottom of said guide rail by means of which the core is grasped and horizontally supported and
• means for turning the core about an axis generally orthogonal to the central axis,
• means for rotating said toroidal core about the central axis,
• means for inserting one end of a wire into the central opening of said core from above or below said core, including means for pulling said wire alternatively in an upward and downward direction,
• said apparatus further comprising,
• a wire chuck holder having a slidable pull chuck for high speed positioning with respect to the servo motor along said guide rail in an up-and-down direction;
• an insertion chuck, said chuck being capable of being turned and reciprocated for alternatively pulling one end of said wire in an upwardly or downwardly direction;
• an extension spring disposed to cooperatively connect said pull chuck to said wire chuck holder,
• two shutter members projecting from said insertion chuck at an opposite end of said extension spring and said pull chuck, the shutter members differing in length from each other, and
• two tension detectors connected to the shutter members disposed on said chuck holder.