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Re: [TCML] Need coil winding advice
----- Original Message -----
From: "Jim Harvey (UDN)" wrote:
I am designing my first TC and need to build a coil winder. My first
secondary coil will be:
Length: 18 inches
Wire: 26 AWG
Since the coil is not too long, I am thinking about a plywood frame
supporting a motor, turns counter, and arbor. A foot switch would be used
well as some type of speed control.
I used a section of threaded rod (3/8" IIRC) that passed through the
coilform (made plywood endcaps inside each end of the PVC pipe), and passed
it through ball-bearing units on each end (supported by 2x4s). This allowed
the coilform to freely rotate.
On one end, I attached a short section of automotive fuel line to the
threaded rod, the other end of the fuel line went to the shaft on my motor
(a modified kitchen blender). The fuel line was a good coupler in this
application, as it allowed for the motor to be slightly off-axis (not
intentional, just didn't want to fuss with perfect alignment), and also
functioned as a crude but effective clutch.
Below and in front of this was a horizontal ground rod that I used to hold
the spool for the wire.
As for speed control, since the blender motor was a universal motor (AC/DC),
I drove it with a variac for speed control. I used a footswitch (momentary)
to turn the motor on.
I also used a counter on mine, created by gluing a small magnet on one of
the plywood endcaps, with a stationary reed switch triggering an
electromechanical counting device.
The whole shebang was assembled using drywall screws and 2x4s and attached
to my workbench, which permitted me to dissasemble it and store it with a
very small footprint (ensuring future use).
Mind you, my first winder was a vertical winder, with the coil set on top of
a record player. Later incarnations of that design used a manually turned
bicycle wheel, but the horizontal motorized winder is a lot easier to use
(especially with longer coils).
Best of luck to 'ya,
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