MXPA06004210A - Magnetic core winding method, apparatus, and product produced therefrom - Google Patents

Abstract

The invention relates to winding wire around a magnetic core. The invention includes forming corners on the wire that align with inside corners of the magnetic core such that the wire is more tightly wound around the magnetic core. The invention also includes pinching a portion of wire that is positioned on the internal diameter of a magnetic core when the wire is wound around the core to provide more turns of the wire around the magnetic core. A magnetic inductor made in accordance with the present invention can have increased inductance, lower temperature rise, smaller size, and exhibit less EMI noise than the prior art.

Description

METHOD OF WRAPPING MAGNETIC NUCLEUS, APPARATUS AND PRODUCT PRODUCED FROM THE SAME FIELD OF THE INVENTION The present invention concerns the winding of wire on a magnetic core and with apparatus used to wind the wire around the magnetic core and is concerned with transformers and inductors produced from it. I BACKGROUND OF THE INVENTION U.S. Patents of the prior art of magnetic coil windings, which include but are not limited to toroidal coilers, include U.S. Patent Nos. 5,331,729; 4,379,527; 4,872,618; 6,557,793; 4,288,041 and 5,875,988. In general, the prior art as shown in Fig. 1 to 3, illustrate the principle of winding magnet wire on a magnetic core (hereinafter the present "core") to create an inductor. The prior art utilizes a supply ring 10 and winding ring 20 with pull ring or open / close holes 12 and 22 to allow a core 30 to be arranged with rings 10 and 20 passing through the center hole of the ring. core 30. In the prior art, the openings 12 and 22 are manually opened and the core 30 is passed through the holes in such a manner that each ring passes through the central hole of the core, with the central axis 34 of the core magnetic 30 at right angles to the central core 25 of the rings. The supply ring 10 has a U-shaped groove around its circumference. In order to allow the wire 40 to be wound to the slit 14, the end of the wire 40 is attached annually to the supply ring 10. The winding ring 20 has substantially .the same diameter as the supply ring 10, with which it is concentrically aligned. The winding ring 20 has a wire guide 24 via which the wire 40 is withdrawn from the supply ring 10 and a guide roller 26 for guiding the wire 40. In a real winding operation, the core 30 is first inserted manually on the rings 10 and 20 via the holes 12 and 22 and positioned as shown in Figure 2. Then the end of the wire 40 is attached to the supply ring 10 and the supply ring 10 is rotated about its central axis to wind the required amount of wire 40 to the slit 14. After cutting the end of the rear wire 40 the cut end is passed through the wire guide 24 and around the guide roll 26 and is pulled radially outwardly. -from between the rings and fixed to retaining means or the like (not shown) provided on the periphery of the group 30. As shown with Figure 3, when the core 30 is wound, an actuator (not shown) is used for rotating the supply ring 10 and the winding ring 20 in the opposite direction from that used to load the wire 40 on the supply ring 10 and the wire 40 is attracted from the supply ring 10 through the wire guide 24 and guide roller 26 on the winding ring 20 and attached to the core 30. In this state, the wire wound around the supply ring 10 is wound spirally a required number of turns around the core 30 and wire left on the ring Supply 10 is manually separated. Finally the core wound on the wire, that is, the inductor is separated. The ideal single-layer inductor would have a low temperature rise, high inductance and small size. In addition, it has been found that by increasing wire size, total number of turns and decreasing core size, these more desirable properties can be obtained.

Also, since the rectangular wire has a smaller width than the round wire (for a given gauge) efl - Rectangular wire can be used to increase the number of turns on a core and thus increase the inductance. As such, US patents directed to the manufacture or formation of rectangular wire from round wire are found in the art for example US Pat. No. 6,553,650. However, the rectangular wire winding on the edge is extremely difficult. Referring now to Figure 4, when the wire 40 is formed around the corners 34 of the core 30, the wire has a tendency to twist and fall diagonally. If the wire 40 is guided strongly on either side of the corner, twisting can be prevented, but in the winding of the core there is insufficient space to guide the wire as it wraps around the inner wall 36 of the core. . In some instances, the rectangular wire is formed and the core has a cut piece thereof that allows the wire to be slid over the core. However, when a part is removed, the magnetic properties may decrease and the inductance of the core may be reduced. It is thus an object of the present invention to overcome the problems associated with the prior art while maintaining an inductor with low temperature rise, low inductance and small size.

BRIEF DESCRIPTION OF THE INVENTION In view of the foregoing deficiencies of the prior art, an object of the present invention is to provide an inductor with a data at a lower temperature rise, higher inductance, smaller size or less included EMI when compared to an inductor manufactured according to the prior art. To obtain the above object, the present invention provides a core to be wound with a wire. A portion of the wire is first wrapped around an outer edge of a forming tool placed in front of the core. The outer edge of the forming tool is formed similarly to the inner diameter of the core. Once the portion of the wire is formed around the forming tool, the portion of the wire will be deformed with a shape that matches the internal shape of the group. Thus, an airtight fit around such inner diameter of the core is provided. The forming tool can be retracted in such a way that the wire can be pulled through the core where the preformed portion of the wire is aligned with the inner shape of the core. This process can be repeated until the core is wound up to form an inductor. This process is also preferred when the wire is rectangular. In a mode where the wire is round, the wire once formed around the forming tool is flattened or pressed. The pressed portion of the wire once wound around the core will allow a more efficient winding around the core and thereby provides an inductor with a lower temperature ratio, higher inductance or smaller size. The process can be obtained either with an automatic winder or by using a hook winding method manually. After a first layer of wire is wound around the magnetic core, multiple layers can be rolled using the same process to test formers. When changing to a second layer, the information tool must be replaced by a second information tool that has an external shape that matches the internal shape of the first layer of wire, such that the second layer of wire is wound closely around the first layer. The process of providing an inductor with a preformed wire as described above can be manufactured as the rectangular wire or the round wire and by a weekly data winding process or in an automatic winder.

BRIEF DESCRIPTION OF THE FIGURES A full understanding of the foregoing can be had by reference to the attached figures, wherein: Figure 1 is a disassembled perspective view of a shuttle of the prior art; Figure 2 is a perspective view of a shuttle of the prior art; Figure 3 shows the direction of rotation of the shuttle and the hip of the winding wire using a reel of the prior art; Figure 4 illustrates the supply of the wire figure during each rotation of the shuttle of a prior art winder; Figure 5 shows the main parts of an automatic core winding apparatus according to the present invention; Figure 6 is the automatic winding apparatus of the core of Figure 5 rotated 180 °; Figure 7 shows the automatic winding apparatus of the core of Figure 5 with the flattening tool that crimps the wire; Figure 8 is the automatic winding apparatus of the core of Figure 6 with the retracted forming tool; Figure 9a is a cross-sectional view in core and deformation illustrating the wire wrapped around the forming tool; Figure 9b is a cross-sectional view of the core of Figure 9a with the forming tool retracted; Figure 10 is a cross-sectional view of the core with the pressed wire and with the forming tool retracted; Figure 1 a is a side view of an inductor; Fig. 11b is a cross-sectional view of the inductor of Fig. 1a; Figure 11c is a view of a transformer including two wires of different laying each rolled, about half a magnetic core; Figure 12 shows the main parts of a hook winding apparatus according to an embodiment of the present invention; Figure 13 is a perspective view of the hook winding apparatus of Figure 12 illustrating the working tool that makes the wire; Fig. 14 is a perspective view of the hook apparatus of Fig. 12 illustrating the flattening tool and the forming tool that is retracted; Figure 15 is a perspective view of the hook winding apparatus of Figure 12 illustrating the wire being pulled tightly around the core; Figure 16a is a perspective view of hook winder uri-apparatus with a guiding tool positioned around the forming tool to prevent a rectangular wire from buckling while the wire is wound spirally around the core and Figure 16b is a perspective view of the hook winder apparatus with the guide tool partially spaced from the forming tool table, made for purposes of illustration only.

DETAILED DESCRIPTION OF THE INVENTION While the invention is susceptible to embodiments in many different forms, preferred embodiments of the present invention will be shown in the drawings and will be described herein in detail. However, it should be understood that the present disclosure will be considered as exemplification of the principles of the invention and is not intended to limit the spirit or scope or scope of the invention and / or claims of the illustrated modes. Referring now to FIG. 5, an automatic core winding apparatus 100 of magnetic core 100 is illustrated. (winder) according to the present invention. In this embodiment, the winder 100 includes a supply ring and a winding ring, hereinafter referred to as a shuttle 102. A shuttle rotation mechanism (not shown) drives the shuttle 102, while a rotation mechanism of the shuttle 102 is provided. The core and support 106 rotate a magnetic core 200. The apparatus 100 further includes a control unit 105 for controlling the rotation mechanisms 112 and 106. The magnetic core 200 (hereinafter referred to as "core") is in general, but not limited to, electric oval shape or other non-circular core shapes and may be as shown toroidal. In addition, the magnetic core 200 may have a solid ring, such that the ring may include liquid / solid hybrid liquid or interior. The shuttle 102 includes a U-shaped winding groove (not shown) for retaining a wire 150 and a shuttle guide roller 108 which guides the wire 150 out of the shuttle. The rotation mechanism of the shuttle is used to independently rotate the shuttle, such that wire 150 can be pulled outwardly from shuttle 102. The shuttle rotation mechanism includes a drive roller 112 that engages and drives the shuttle. shuttle 102. In addition, a plurality of driving support rollers 114 may be included to assist in guiding or rotating the shuttle during winding of the core 200. The apparatus 100 may also include a brake mechanism 104, also controlled by the unit. of control 105, for placing tension on the wire 150. The brake mechanism 104 includes a first brake part 104a and one. second brake piece 104b secured around the shuttle 102. The second brake piece -104b is suspended from the first brake piece 104a by bolts 110. When the brake mechanism is activated by the control unit 105, tension is applied to the wire 150, such that the wire 150 is held in a taut position. The rotation mechanism of the core 106 includes two drive rollers 116 positioned at a specified point along the shuttle 102, with one drive roller above the shuttle 102 and the other below. The two driving rollers 116 engage with the core 200, such that when put into operation the core 200 can rotate about its axis. Referring also to Figures 6 to 8, the automatic winder 100 further includes a forming table 130 positioned and aligned with the core 200. The forming table 130 includes a forming tool 132 that is movable horizontally in relation to the table. formation 130. The forming tool 132 can thus be moved a specified distance D (Fig. 9a) 'from the outer wall of the core 200. The specified distance is defined as substantially equal to the length of the outer wall 206 of the core 200. Training tool 132 is also retractable less of training table 130, which as explained in greater detail below, is. It does when the wire 150 is wrapped around the core 200. Also referring to Figure 9a, the forming tool 132 includes an outer profile 135 which is substantially the same as an inner profile 205 defined by the core 200. As used throughout this invention, the outer profile 135 of the forming tool 132 can be defined as just the inner wall 136 or can be defined to include the side walls 138. In addition, the inner profile 205 defined by the core 200 can include only the inner wall 207 or can be included to define the side walls 209, such that the walls formed between the inner wall 213 and the side walls 209 are defined by the definition of the inner profile of the core 200. Thus, the inner profile of the core 200 can include corners straight, rounded or slightly arched. Regardless of the exact form, it is an important aspect of the invention that the forming tool has a matching profile, such that the wire 150 is tightly wound against the inner profile 205 of the core 200. Also, as used in this invention , the core may include an outer profile 206 which may include any portion not covered by the inner profile 205. If the wire 150 is rectangular, the wire 150 is wrapped around the forming tool 132 and then the forming tool 132 is retracted (shown in Figure 9b removed for clarity and as seen in Figure 8, the forming tool 132 is housed in the forming table 130). The wire 150 thus includes a preformed portion 154 (identified by numerals 152) which is substantially aligned with the inner profile 205 defined by the core 200. As such, the core 200 will be wrapped with a more tightly fitting wire that provides an ideal inductor . Referring still to figure 7, if the wire 150 is round, the automatic winder 100 is also equipped with a leveling tool 160. The smoothing tool used can be pneumatic presses, hydraulic presses, tilting presses, flywheel presses or hammers. The flattening tool 160 includes a notched section 162 that accommodates the forming tool 132. When the flattening tool 160 is pressed onto the wire 150 (Figure 7) the preformed portion 154 of the wire 150 is pressed or substantially flattened. Once flattened, the flattening tool 160 is lifted from the forming table 130 and the forming tool 132 retracted (FIG. 8) to allow the preformed and flattened wire 150 to be pulled and wrapped around the core 200. In the figure 10 illustrates the preformed portion 154 of the wire 150 is flattened and as shown has a thickness greater than the flattened portion, generally illustrated as the wire, illustrated preformed 156. It will be appreciated by those skilled in the art that the portion of the flattened wire 150 may be smaller or more than those illustrated without deviating from the teachings herein. In addition, the substantial change in thickness of the wire 150 is made only to illustrate that a change in thickness has taken place. The change in thickness may be less dramatic such as that formed by a tapering region between the flattened and non-flattened portions of the wire 150. Then the core 200 is rotated and the process repeated until the desired turns are made spirally wrapped to forming an inductor 210, illustrated in Figures Ia and llb. By flattening or forcing the wire portion, the width is reduced, allowing more turns per wire layer around the core. This creates an inductor 210 that can have a lower temperature rise, higher inductance and be smaller in size compared to an inductor manufactured according to the prior art. As illustrated, the wire 150 is preferably pressed at an angle such that it is a taper region 158 of the unpressed wire to the crimped wire.

It is appreciated from the present invention that after the core is wound spirally, additional layers of wire can be added. The teachings of the invention stipulate that a forming tool has an outer profile that matches the inner profile of the wire layer that the additional layer is placed on it. In addition, wires of different caliber can be used in the same core, as illustrated in Figure 11c. A first gauge wire 150a is wound spirally around a first portion 220a of a core 200 and a second gauge wire 150b is wound spirally around a second portion 220b of the same core 200. The angle at which the wire is Pressing can be different to obtain several results. However, the angle that allows the greatest number of turns for a given wire will depend on the interior of the core when the outer turns touch each other. Mathematically, the angle is determined by the following (wire diameter Angle = sin-1 diameter _ of the wire + outer diameter _ of the _ core) When using the present invention the following characteristics are determined: (1) increased inductance - using the present invention more turns of the same wire size can be added to the same core, this will increase the inductance of the inductor when all other things remain the same. (2) lower temperature rise - the present invention allows a larger diameter wire to fit the inner diameter of the core without changing the size of the core, a larger diameter wire reduces copper losses and consequently will reduce the lift of temperature (3) decreased size - the present invention allows more turns of the same size of wire to be wrapped around a smaller core and consequently decreases in size and weight, as such a smaller design will be apt to have the same inductance and temperature rise and (4) decreased noise - the present invention also decreases the electromagnetic interference ("EMI") a noise normally produced by an inductor this is due to the space between the start and end of the rolled wire, since the larger space decreases the EMI. The core 200 may also be manually wound in a process known as "hook winding" the present invention includes the winding of a core during a process and hook winding apparatus with the general appearance of forming corners in the wire corresponding to the inner corners of core and / or flatten or press a portion of the wire that wraps around the side wall, inner corners and inner wall of the core. It will also be appreciated that the pressed portion may be larger or smaller than what is illustrated herein. Referring now to Figures 12 to 15, a hook winding apparatus 300 is illustrated and a method for winding a core using the apparatus will be disclosed. A wire 150 (commonly round for this example) is provided with a front portion 151 secured to a post 302. The post 302 can be provided on the rotation mechanism of the core and support 106. The wire 150 is wrapped around the tool 132 and placed on a hook 312 that is extended to an initial position from a hook support 310. The hook 312 is retracted to pull the wire around the forming tool 132 to form a preformed portion 154 (as shown in the figure). 9b) in wire 150. Then the wire is pressed before winding around the core. A braking or pressing tool 160 is braked on the wire 150 (FIG. 13). As mentioned above, the wire can be pressed around the preformed portion 154 corresponding to the inner profile of the core 200. The wire can include a taper region between the portion and the non-pressed portion. The flattening tool 160 and the forming tool 132 is retracted (Figure 14). The wire 150 is pulled tightly around the core 200 (FIG. 15) in such a way that the pressed preformed portion is aligned with the inner profile of the core 200. The core 200 is rotated, the forming tool is extended and the hook 212 is extended or placed in the initial position. The process is repeated until the core is coiled spirally with the wire 150 with the corners formed. Referring now to Figure 16a and Figure 16b in another embodiment, a hook winder 400 is used with a rectangular wire 402 with a front portion 404 secured to a post 306. The post 306 may be provided on a core rotation mechanism. and support 408. The wire 42 is wrapped around a forming tool 410 with an outer profile as discussed previously. The wire 402 is also placed on a hook 412 that is extended in an initial position of a hook support 414. The hook 412 is retracted to pull the wire around the forming tool 410 to form a preformed portion 410 in the wire 402 A guide tool is used to guide the rectangular wire around the tool 410 without the wire twisting or wrapping when the preformed portion is formed. The forming tool 410 is retracted (not shown) and the wire 402 is pulled tightly around the core 425 such that the formed portion 426 is aligned with the inner profile of the core 425. The core 425 is rotated and the forming tool 410 is extended. The hook 412 is also extended or placed in the initial position. The process is required until the core is spirally wound with the wire 402. While FIG. 16b illustrates the guide tool 426 being moved or retracted it is only moved for purposes of illustrating other components of the apparatus 400. The guide tool 420 It can be fixed in the placement, such that the wire 402 slides between the guide tool 420 and the forming table 430. A comparison is shown between an inductor manufactured in accordance with the present invention that is transformed and pressed (hereinafter herein). "crimped wire") with a round wire inductor in the following tables: Table 1 depicts the "pressed wire" calculations for a core such as core number of parts 77803-A7 of Magnetics Inc. Using the present invention, calculates an inductance of 245 mH and a temperature rise of 38.5 ° C. All calculations in the table are based on a single-layer winding and a minimum start-to-end wire spacing of 0.319. This spacing and single-layer winding are necessary to maintain acceptable EMI levels.

Table 1 pressed wire Core size 1.95"OD x 1.57" OD x 0.57"height Bobbin size 0.77" ID x 1.75"OD x 0.75" finished height wire size 14 1/2 AWG (pressed dimension 0.038"X 0.090") Laps 55 Inductance 245 H Resistance CD 25 mO Elevation of 38.5 ° C temperature with 12 ACD Spacing between start and end 0.319" Table No. 2 shows the wire. round maximum that can be rolled on the same core (Magnetics Inc. p / n 77083-A7) in such a way that the same number of data are the same as that which was obtained in the previous pressed wire example. The calculations show that for an equivalent inductance, the wire size can be reduced to 17 1/2 AWG. The reduction in wire size produces a 104% increase in CD resistance and an 80% increase in temperature rise (such as temperature rise ° C = [total power dissipation W / available surface area cm2] 0.833 Table 2 maximum round wire using the same core Core size 0.95"OD x 1.57" OD x 0.57"height • Bobbin size 0.86" ID x 1.66"OD x 0.66" finished height Wire size 17 1/2 AWG Laps 55 Inductance 245 mH Resistance CD 51 mO Elevation of 69.4 ° C temperature with 12 ACD Spacing between 0.368"start and end Table No. 3 shows an increase in 11.4% in DO necessary, to maintain the same height, inductance and temperature rise as the technique of" crimped wire. "Smallest core / coil size for equivalent inductance, temperature rise and terminal spacing using round wire Core size 0.95" ID x 1.85"OD x 0.57" height Bobi size na 0.86"IDxl .95" OD x 0.68"finished Wire size 16 AWG Laps 46 Iductance 245 mH Resistance CD 36 m Temperature rise with 12 ACD 42.4 ° C Spacing between start and end 0.368" From the foregoing and as mentioned above, it will be noted that numerous variations and modifications can be made without deviating from the spirit and scope of the new concept of the invention it will be understood that no limitations with respect to the specific embodiments illustrated herein are intended. or it must be inferred. Of course, it is intended to cover all such modifications that fall within the scope of some claims by the appended claims.

Claims (32)

1. CLAIMS 1. A method for winding a magnetic core, characterized in that it comprises: providing a shuttle loaded with a wire; 5 Fix a magnetic core on the shuttle, the shuttle goes through a central hole in the magnetic core; the magnetic core has an inner profile; providing a forming tool having an outer profile substantially corresponding to the inner profile defined by the magnetic core and unloading the shuttle wire to spirally wind the magnetic core in which the wire is wrapped around the outer profile defined by the forming tool before winding around the magnetic core to form a portion defined on the wire that substantially corresponds to the inner profile defined by the magnetic core.
2. 2. The method of compliance with the claim 1, characterized in that it further comprises automatically rotating the shuttle to automatically charge the wire during the winding of the magnetic core.
3. 3. The method according to claim ' 2, characterized in that it further comprises rotating the magnetic core around its central axis, in such a way that the magnetic core is wound spirally with the wire during the winding. of the same.
4. The method according to claim 1, characterized in that it comprises retracting the forming tool subsequent to the preformed formation on the wire.
5. 5. The method according to claim 1, characterized in that it further comprises pressing a portion of the wrapped wire around the forming tool.
6. The method according to claim 5, characterized in that it further comprises wrapping the wire around the magnetic core in such a way that the pressed portion of the wire is wrapped around the inner profile defined by the magnetic core.
7. 7. A method for winding a magnetic core characterized in that it comprises: providing a shuttle loaded with a wire; arranging a magnetic core in such a way that the shuttle passes through a central hole in the magnetic core, the magnetic core has an inner profile; secure a wire conductor of the magnetic core; providing a forming tool having an outer profile corresponding to the inner profile defined with the magnetic core and rotating the shuttle and unloading the wire to wrap the wire around the forming tool, such that the wire has a portion deformed corresponding to the inner profile defined by the magnetic core; temporarily suspend the rotation of the shuttle and retract the forming tool and resume rotation of the shuttle to pull the wire around the magnetic core, whereby the preformed portion of the wire is aligned with the inner profile defined by the magnetic core.
8. The core according to claim 7, characterized in that it further comprises rotating the magnetic core around its central axis, in such a way that the magnetic core is wound spirally with the wire.
9. The method according to claim 7, characterized in that it further comprises flattening a portion of the wrapped wire around the forming tool before retracting the forming tool to create a pressed portion of wire.
10. 10. The method according to claim 7, characterized in that it further comprises flattening the wrapped wire around the forming tool before retracting the forming tool to create a pressed portion of wire corresponding to the inner profile defined by the magnetic core.
11. The method according to claim 10, characterized in that the step of flattening the wire further includes flattening the wire at an angle to define a pressed region that is used from a non-pressed portion of the wire to a pressed portion of the wire.
12. 12. A winding magnetic core characterized in that it comprises: a magnetic core having an inner profile and an outer profile and a wire spirally wound around a portion of the magnetic core, the wire has a pressed portion and an unpressed portion, the pressed portion is spliced with the inner profile of the magnetic core and the unpressed portion is spliced with the outer profile.
13. 13. The magnetic core according to claim 12, characterized in that the wire has one. preformed shape that aligns with the inner profile of the magnetic core.
14. 14. A winding apparatus for winding a magnetic core having an inner profile and an outer profile, characterized in that it comprises: a shuttle loaded with a wire; a support of the magnetic core supporting a magnetic core in such a way that the shuttle passes through a central hole of the magnetic core; a training tool having an outer profile corresponding to the inner profile defined with the magnetic core and shuttle rotation means for unloading and "wrapping the wire around the outer profile of the forming tool, such that the wire has a preformed portion corresponding to the inner profile defined by the magnetic core
15. 15. The apparatus according to claim 14, characterized in that further comprises means for retractable the forming tool
16. 16. The apparatus according to claim 15, characterized in that it further comprises a pressing tool positioned above the forming tool that when lowered towards the forming tool presses a portion of the wire wrapped around the outer profile defined by the forming tool.
17. 17. The apparatus according to claim 16, characterized in that it comprises the support of the magnetic core includes rotation means that rotate a pair of magnetic core rollers, the magnetic core is retained by a prescribed force between the magnetic core rollers, in the which its state the magnetic core is rotated by the rollers of the magnetic core around. of its central axis.
18. 18. The apparatus according to claim 15, characterized in that the press tool comprises the wire portion of an angle to create a taper region between the pressed portion of wire and an unpressed portion of wire.
19. 19. A method for winding a magnetic core, characterized in that it comprises: providing a wire; arranging a magnetic core on a support, in such a way that the wire passes through a central hole of the magnetic core, the magnetic core has an inner profile; providing a portion tool having an outer profile corresponding to the inner profile defined by the magnetic core; wrapping the wire around the outer profile defined by the forming tool to create a preformed portion corresponding to the inner profile defined by the magnetic core and winding the wire around the magnetic core, wherein the preformed portion is aligned with the inner profile defined by the magnetic core.
20. The core according to claim 19, characterized in that it further comprises: fastening the wire with a hook after wrapping the wire around the forming tool and retracting the hook to form the preformed portion on the wire.
21. The core according to claim 19, characterized in that subsequent to the step of retracting the hook and preforming the corners and the portion between them on the wire, the method includes the step of pressing a portion of the wire corresponding to the inner profile defined by the magnetic core.
22. The method according to claim 21, characterized in that the step of pressing a portion of the wire includes pressing the portion of the wire at an angle to form a tapered portion between the pressed portion and i the unpressed portion of the wire.
23. The method according to claim 19, characterized in that the step of providing a wire includes loading the wire onto a shuttle and passing the shuttle through the central hole of the magnetic core and includes mechanically rotating the shuttle in such a manner that the wire is unloaded from the shuttle automatically.
24. 24. The method according to claim 19, characterized in that it further comprises a guide tool positioned above the forming tool to guide the wire around the direction without having the wire wrapped.
25. 25. a magnetically wound core characterized in that it comprises: a magnetic core having an inner profile and a wire wound spirally around the magnetic core, the wire has a pressed portion and an unpressed portion, the pressed portion is spliced with at least one inner profile and wherein the wire has a preformed portion that is aligned with the inner profile of the magnetic core.
26. 26. The magnetic core wound with claim 25, characterized in that the pressed portion is also spliced with the inner profile of the magnetic core.
27. 27. The wound magnetic core according to claim 26, characterized in that the unpressed portion is spliced with at least one outer profile defined by the magnetic core.
28. 28. An inductor characterized in that it comprises: a magnetic core having an inner profile and an outer profile and a wire wound spirally around the magnetic core, the core having preformed portions that align with the inner profile of the magnetic core.
29. The inductor according to claim 28, characterized in that the wire is rectangular.
30. 30. The inductor according to claim 28, characterized in that the wire is round.
31. The inductor according to claim 28, characterized in that the wire includes pressed and unpressed alternating portions, wherein the pressed portions are butted with the inner profile of the magnetic core and the unpressed portions are butted with the outer profile of the core magnetic.
32. 32. The inductor according to claim 31, characterized in that the magnetic core * "is a toroid.