CNC Coil Winding Machine

[CalG]

Glyptal might have a product for between layer insulation

It works for lower voltages,

http://www.glyptal.com/Glyptal_Product_Data_Sheets.htm

Inquire of their engineers.

Now if I could just get this old tractor magneto coil rewound.......

CalG

[BOOJAN]

does someone have some schematic for the controller...or how to control the stepper motors????

[amplexus]

Check out the cpld tutorial thread whem Mariss gets the rest of it up it will be the best open source controller at any price and it shoukd be cheap.

Amplexus Ender

[RomanLini]

Hey Synthesis, you put your ad in this thread, and when I went to your website to look at your coil winding machines it says I have to enter my email and phone number and stuff just to look at the "machine details"? That seems a bit rude!

[neilw20]

Over 30 years ago I was involved with winding EHT transformers for valve televisions. 20KV or so.

We would wind 10 or 12 side by side on the same cardboard tube, primary with taps, extra windings, etc, then the secondary.
As each winding layer was changing directions, without stopping the machine the operator would feed in a strip of very thin paper, just wide enough to wrap a bit more than 1 turn.

The tensioners were like fine fishing rods operating drag brakes, and fed through ceramic beads on the end of the 'fishing rod'.

Breakages were rare.

Once wound, they were cut into 10 or 12 pieces in a sort of lathe with a narrow slitting blade.

Then the start, and taps were fished out from the sides between the layers!!

Many layers. The whole lot was then vacuum impregnated with paraffin/beeswax. in electric frying pan with a 1" glass lid sat on it with a rubber gasket. We kept the fumes in!! It attracts swarms of bees!!!

There were also versions that used some sort of varnish, in a vacuum, then baked overnight.

[headsmess]

this has me thinking of an old project of mine i gave up on...winding guitar pickups.

(electric sitar pickups actually...)

the problem with the bobbins is that theyre long and narrow. i could never think of a way to feed 0.05mm wire without it snapping, other than the slow way.... hand and that still caused much anguish around turn 4538 when you snapped it accidently


the ideas resurfacing after having ripened i guess

ive had that bee problem before! never thought of sealing the pot though!

[neilw20]

Now with CNC it is fairly easy easy to make the tensioner/bobbin assembly track in and out on a guitar style oblong bobbin at reasonable speed, and even even servo control the tension better than a human can.

[RomanLini]

Agreed, humans are poor at tensioning very fine wires.

A CNC coil winder has been on my list of things to do for ages, although I really don't have any coils that need winding I just want the cool machine.

Thanks too NeilW for your experiences winding the old HT transformer coils. Some of those wax sealed cardboard tube coils were a real work of art (I worked in TV repair for many years in the old days).

[Smertrios]

I dont know about picking wire to use *but* here is a place selling enameled essex brand wire in 11 pound spools for a lot less per pound.

www.magnet4less.com

Maybe I underestimate just how much wire is in a pound =>

[bluejets]

I plan on using a PIC 16F870, with a 16 key keypad and LCD display. The display will prompt for wire size, length of the coil to be wound, and total number of turns. The two steppers will work in tandem, to provide linear movement / bobbin revolutions to space the wire properly. Winding speed will be controlled with a pot to feed an one of the ADC inputs on the PIC. The process will be to wind one layer, pause so insulating tape can be applied, then a key stroke will restart, moving the feed in the opposite direction, repeat, etc .


Ken

Just a thought for anyone wanting to go a slightly different route. This is a PLC program that runs on an old PC. I used it to build a crankshaft grinder for miniature engines and used optical switches, the kind from old printers etc. as limit switches. They are accurate to within 1 thou repeatedly. It operates in much the same manner only with an extra axis drive.
http://users.skynet.be/DCI_Site/dciplc.html