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Old 01-02-2004, 12:50 PM
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CNC Coil Winding Machine

Thought you IC types might get a kick out of this... it is one of the smaller CNC machines you'll ever see. It is a CNC ignition coil winding machine, powered by 2 stepper motors salvaged from 5.25" floppy drives. The mission was to wind 30,000+ turns of an incredibly fine-guaged copper wire in multiple layers on a Delrin spool. This wire was abysmally fragile, and the slightest drag caused breakage. The wire had to be laid down via 2 shafts in a CNC gear arrangement, with the pitch of the laydown feeder being the diameter of the fine wire - in other words, as the bobbin rotated once, the tiny tygon tube which fed the wire, traversed in X a distance equal to the wire diameter. Thus the coil was laid down in an appearance similar to a spring with no gaps.

Each layer of winds was insulated from the next with a section of kapton tape, very tedious. This was needed because the outer turns of wire ehibit a huge potential (>10,000V) relative to the first turns, and the spark would arc internally without the insulating layers.

The stepper drivers are 1A Ramsey stepper motor kit boards. The software I wrote using VB, directly "printing" to the parallel port.
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