coil winding

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badger

Active member
Joined
Jun 5, 2004
Messages
32
Location
London
One for the transformer guys,I've built a small coil winding machine with a view to making small mic transformers. I'm interested to know the importance of wire tension and even layering .the machine has a  variable traverse and tensioning devise .the smallest wire diameter is .062.
Any info would be great.
 
.062?  or .0062? 
metric or English?  what gauge?

even layering is not as important with small wire as it is with trying to pull some #14AWG over #36, you want a smooth surface under heavy wire so you do not smash turns into a short,

even layering will get you more wire on a bobbin than random winding, but random winding will get you lower capacitance as the is more space between wire,

if you are trying to copy an xfmr with a full bobbin that is layer wound, you will need to also layer wind or else a random wound coil will run out of room,

tension is important but winding speed is important also, if you wind too fast you will end up with a round sponge,

you can buy fancy tension devices but you can DIY a tension setup for small wire buy simply putting different size weights on top of a piece of foam and also using a small compression spring to run the wire thru, this spring will help compensate for winding on a square bobbin where there are rapid accelerations of the wire, this is not important on the coil end, but for the spool end of the wire, if you de-reel the wire with the bobbin spinning, you want the spool to spin at the same speed so you do not stress out or break the wire, a full spool can weigh enough to fight the wire accelerations, which is bad,

you can run your traverse at a set speed and then adjust wind speed to get an even layer,

if you are de-reeling with the spool sitting on it's edge, then you do not need the spring,

so run the wire thru a spring with a teflon guide and then put a piece of cloth or foam over the wire with a weight on top and wind slow.

here is a pic showing a setup for both edge spooling and rotational spooling, spring circled in red, plastic ruler and whisker disk help smooth out edge spool wire, over hanging green guide is an old #44 winding spool, DIY tape dispenser also, 3M tape dispenser is about $200 ea, wood block on cloth is enough tension for #48,>

DIY Whisker Disc Tensioner>
http://groupdiy.com/index.php?topic=56712.msg723215#msg723215
 

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