Abstract: An improved method and apparatus for winding wire onto toroidal cores in which the wire is fed into a circular channel to form a coil that passes through the core repeatedly. The wire is fed to the apparatus by a cylindrical capstan for creating tension to straighten the wire. The wire is circulated in the channel by pairs of synchronously driven rollers, with one roller pair gripping the wire more loosely to permit slippage. The channel has a narrowed width adjacent to the rollers to control wire deflection. A movable feed track exit allows smooth feeding of wire into the channel, while permitting increased capacity by sliding the exit inward of the growing coil. A variable transmission adjusts the rate at which the wire is fed into the channel relative to the rate at which it circulates. A split block wire cutter is adjustable to compensate for cutter wear.

Abstract: A method for winding wire strands onto toroidal cores in which a length of wire is fed along a radially inwardly facing channel in an arcular guide to form a loop. As the leading end of the wire completes this loop it hugs the channel's radial boundary to form a second loop radially inside the first as the wire feeding continues. A gap is provided in the radial boundary of the channel for receiving the core with the core's central aperture in this gap so as each loop is formed the wire in that loop passes through the core. The upper and lower boundaries of the channel are spaced apart so as to maintain the loops in a single concentric layer around the guide and through the core. When enough wire has been fed the feeding is stopped, but the movement of the loops around the guide continues and winds (tightens) at least one new turn of wire onto the core for every complete circulation of the loops around the guide.