My Arduino driven Coil Winder


          I am 64 years old! In my lifetime I have bought and built many computers. Four years ago I took an old Timex computer and built a backup memory board so I could do all kinds of projects. After I had it all working I realized the BASIC in the Timex did not have a way to call up a DATA string without knowing machine code. I put the project aside after many hours of hard work. Enter Arduino! After doing some reading I ordered a Genuine Arduino! When I got it I did the BLINK LED program and then put it aside.


          In the picture you can see I started building a Coil Winder. Rather than run the stepper motors with a piece of tape on their shafts I bite the bullet. I built an X axis using the trim channel design borrowed from my Vamp CNC machine design. Blocks of Delrin with a "V" cut in them run on the lip of the Trim Channel. There is no play in the bed!

        The coil winder arm is on a shaft that has a bearing on each end. There is no side to side play out at the tip of the needle. The needle is a piece of Delrin plastic. The bottom of the needle is rounded so it can climb over previous windings. The hole in the needle was drilled in three stages. A tiny exit hole, a larger travel hole and a top funnel like entrance.

        The hole in the needle needs to be in the center of your coil form! The plastic pulley delivers the wire into the funnel hole of the needle. The top of the hole is funnel the exit hole is tiny! Get it?

        Here is a picture of 100 turns of sewing thread done WAVE style! The coil is not solenoid wound it is WAVE! No glue or WAX!

        I bought a Shield kit. I wired a start switch some resistors and Tip 120 transistors on it. After getting the winder to work with Step and Direction boards I went with old style Phase Drive.

        Felt drag strips added to keep the spool from free wheeling too fast!

        50 turns Litz wire without wax!

        Close up view....see the WAVE?

        So what did I learn? If you search the Internet about Wave and Progressive Universal wound coils you will find little information. I will give you the trick! Are you ready? As the machine moves back and forth driven by steppers your program will try to wind the wire in the same spot over and over if you are trying to wind a WAVE coil. Winding back and forth on a bobbin is a solenoid coil! A wave wound coil looks like it was woven or sinewave. Here is the Trick! Stepper are even number devices. You need to add extra steps for the spindle motor outside of the Loops in your program. In a mechanical winder they use a gear with an odd number of teeth. With every cycle of the machine the spindle jumps ahead. I did not use a stepper library. I used only Arduino code. It took one loop to go right and one to go left. Those were inside a third loop. In between the two loops I put some extra 17 steps for the spindle. Each loop has a spindle step in it! I was also able to drive the Tip120s as PHASE drive. Much more thinking will be required!!!! The back and forth motor or X axis uses a 1/4-20 rod so it needs 4000 steps per inch. The spindle motor needs only 200 steps to go around once! Have fun! It took my old brain many hours to get the thing working. It was a HOOOOT!

YouTube video of winder

Email: John a quick question

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