Author Topic: Miniature coil winder  (Read 3447 times)

Offline Doc

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Miniature coil winder
« on: October 05, 2018, 02:34:46 AM »
Ok going to build (or attempt) to build miniature coils first need to build the winder. I'll post here if there is any interest in it if not no big deal we will see.
Anyway the first thing will be the gear package for it. It will be a version of the Side Winder miniature coil winder from Bob Shores book.  The book is a very good book if you want info on coils and windings  I recommend it.


Offline Ye-Ole Steam Dude

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Re: Miniature coil winder
« Reply #1 on: October 05, 2018, 09:27:57 AM »
Hello Doc,

I'm on board and a nice video.

Have a great day,
Thomas

Offline Chester

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Re: Miniature coil winder
« Reply #2 on: October 05, 2018, 10:56:03 AM »
Iím with you Doc, this sounds very useful

Offline Doc

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Re: Miniature coil winder
« Reply #3 on: October 05, 2018, 09:01:21 PM »
Ok setting up machine to cut gears for the winder.

There are several gears needed all are 48dp  need one 16t three 32t one 72t and one 81t. Going to start with the 16t then the 32t after that probably the 72t as my indexer will index even degrees. For the 81t I may set up the machine to make my index strip for me first. Sure wish I would have gotten the A  axis when I got my machine. That would have mad things so simple oh well I always said I like a challenge. Haha


Anyway here is a video of setting up machine.


Offline Doc

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Re: Miniature coil winder
« Reply #4 on: October 06, 2018, 02:49:31 PM »
Ok cutting the first gear a 16t x 48dp  After this I will cut the 32t then the 72t and last will be the 81t. But before I cut the 81t I will set up the machine to create my index strip.

Here is #3


Offline Don1966

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Re: Miniature coil winder
« Reply #5 on: October 06, 2018, 04:02:28 PM »
  Cool Doc I had started to build it years back just to do it but will watch your progress. Bobs book is a great book to read.  :ThumbsUp:

 :cheers:
Don

Offline Doc

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Re: Miniature coil winder
« Reply #6 on: October 06, 2018, 07:24:26 PM »
 Thanks Don wasn't real sure if anyone had any interest in this. I am more or less just building it to satisfy my wanting to see if I can do it or not. I have always been fascinated by electronics and electrical things (I know just enough about electronics to get into trouble). I sometimes think about taking some class's in it but never do.

Offline Steamer5

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Re: Miniature coil winder
« Reply #7 on: October 06, 2018, 11:38:05 PM »
Hi Doc,
 Following along, unlikely to make the winder, but interested in gear cutting & that sure went easy!

Cheers Kerrin
Get excited and make something!

Offline Doc

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Re: Miniature coil winder
« Reply #8 on: October 07, 2018, 12:20:16 AM »
Still not done with the gears have the larger ones to do yet. I think I'm going to make a spring loaded pen for my machine and let it create the index strip for me, The lager gear is 81 tooth. So I'll take my paper strip length is (5.04 the indexer dia x 3.1414 = circ) and let the machine put the pen marks on it for me. I took an old pen and put it into a tube that fits the 7/16 machine collet and JB weld. Then take the ink cartridge of the pen and make it spring loaded. It should work we shall see. The JB weld should be set up in the morning so I can move forward with the plan.

Offline Doc

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Re: Miniature coil winder
« Reply #9 on: October 08, 2018, 02:08:51 AM »
Preparing to cut final gear for build. Set up and let machine create the indexing strip.



Offline Doc

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Re: Miniature coil winder
« Reply #10 on: October 09, 2018, 12:30:33 AM »
Ok I setup machine and machined the last gear so the gears are completed. Next I'll start on the side plates and spacer block. The gears went pretty good. I'll have to remember to do my index strips like I did this one sure beats laying them out by hand. If I was still working I could have plotted them out on the plotter but the machine came through for me and did it correctly. Any way here is some clips of the last gear getting machined.


Offline Don1966

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Re: Miniature coil winder
« Reply #11 on: October 09, 2018, 12:56:04 AM »
Cool Doc still following your progress. I will attach the Gear Hob Calculacation sheet if anyone hasn't download it from plans and drawings yet see below.


 :cheers:
don

Offline Doc

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Re: Miniature coil winder
« Reply #12 on: October 09, 2018, 01:27:01 AM »
Thanks Don that spread sheet is nice does all the math for you and makes it easy!

Offline Doc

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Re: Miniature coil winder
« Reply #13 on: October 15, 2018, 11:50:27 PM »
Tested the transmission gear train with a small 12v dc motor. And here are the results.


Offline Don1966

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Re: Miniature coil winder
« Reply #14 on: October 16, 2018, 12:17:57 AM »
Cool Doc you made a lot of head way on it. Are those motors from a swivel sweeper because I have a few of those?  :ThumbsUp:

 :cheers:
Don

Offline Doc

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Re: Miniature coil winder
« Reply #15 on: October 26, 2018, 01:30:51 AM »
Don not sure where I salvaged these motors. Things like that I tend to hang onto.


Thanks Tom
Well getting down to the finish but I did have a error some where. The wire guide I made from a hypodermic needle and some spring steel but ended up to long and would be to close to the spool. So I need to shorten it and I also missed the feed hole in the one side plate.
Once I get those errors fixed I'll get the counter mounted and the motor and I'll be ready for a trial run. 

Offline Don1966

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Re: Miniature coil winder
« Reply #16 on: October 26, 2018, 04:04:17 AM »
Looking good Doc now need to see it in action!


 :cheers:
Don

Offline Doc

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Re: Miniature coil winder
« Reply #17 on: October 31, 2018, 02:01:50 PM »
Thanks Don!

Getting close to the first coil wind and we will see if I end up with a usable coil or not. Always wanted to try this so it will be new to me. I'll need to build a vacuum chamber for it next.

 


Offline Doc

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Re: Miniature coil winder
« Reply #18 on: November 01, 2018, 09:22:57 PM »
Pretty much done withe the side winder did fix the control to be standard.
 
Made a broach rod for broaching the square hole in the spools. Now on to the vacuum impregnation chamber then I will give it a try.




Offline Don1966

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Re: Miniature coil winder
« Reply #19 on: November 06, 2018, 09:44:26 PM »
Looks good Doc just waiting to see you wound a coil with it. I have one of those speed control I think I paid $14 for it. On the speed pot just reverse the two outer wires to get it the right direction.



 :cheers:
Don

Offline Doc

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Re: Miniature coil winder
« Reply #20 on: December 22, 2018, 04:25:05 AM »
If I get my ignition system finished for my hoglet I'm building I may try and wind up a coil. I have gotten a plan together for the vacuum chamber to impregnate the coil with wax. But first I want to get to the last thing to do on the hoglet which will be the carb.

Offline Doc

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Re: Miniature coil winder
« Reply #21 on: January 27, 2019, 03:30:59 AM »
Well started winding my first coils I wound the primary which went pretty good and started on secondary (12,500 wraps).
I've got a plan for the vacuum  chamber in mind and going to start as soo as I get the first one wound up.

Offline Don1966

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Re: Miniature coil winder
« Reply #22 on: January 27, 2019, 04:24:22 AM »
Cool Doc waiting to see the results!


Don

Offline Chester

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Re: Miniature coil winder
« Reply #23 on: January 27, 2019, 03:48:14 PM »
Doc, I've been silently following along in the background. I find this very interesting. I just wanted to chime in to let you know that there is more following along

Offline Doc

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Re: Miniature coil winder
« Reply #24 on: January 27, 2019, 04:00:59 PM »
I have been making videos for those that wish to see the progress. If you go to my youtube channel they are there. I just stopped posting them on message boards so you can decide if you want to see them or not. I will post some final pictures when I get one done. I'm in the process of designing and building a vacuum impregnation chamber for them. S far has been working out ok. I did find an error in the book data. The data shown for the resistance for the secondary winding is incorrect it should have been over 8k listed was I think about 2.5k. Anyway still moving forward.

Offline Doc

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Re: Miniature coil winder
« Reply #25 on: January 31, 2019, 12:34:04 PM »
Well did get my first coil done AND IT WORKS. I tested it on 6v and no problems.  I now need to incase it I'm planning on a box a smaller version of a model T  coil. Here is a pic I took from the video.

Offline Admiral_dk

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Re: Miniature coil winder
« Reply #26 on: January 31, 2019, 04:37:42 PM »
Coil looks nice + great that it works as you expect  :ThumbsUp:

Offline Don1966

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Re: Miniature coil winder
« Reply #27 on: January 31, 2019, 06:42:55 PM »
Cool Doc I did watch the videos! Did you get the vacuum chamber done as well?


Don

Offline Doc

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Re: Miniature coil winder
« Reply #28 on: January 31, 2019, 07:37:56 PM »
  Yes I did it work fairly well. I need to get a new vacuum gauge but all in all it seemed to work pretty well. After I get this one in a case going to put it in a box to try and make it look similar to a model T coil so it will look more in the true hit miss engine style I'm going to try and make a 3 to 4 volt coil and see if it will work.  If I succeed at that I plan on putting it into a case to try and make it look like a miniature automotive coil. I happy that this one worked. I've always wanted to try and do this so it's one more thing I can cross off my list of things I want to try and do.

Offline Don1966

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Re: Miniature coil winder
« Reply #29 on: January 31, 2019, 10:00:50 PM »
Doc what did you impegnate the coil with wax?


Don

Offline Doc

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Re: Miniature coil winder
« Reply #30 on: February 01, 2019, 01:56:50 AM »
I used wax same stuff as in the canning dept. When I get the box made for it, it will have more wax to fill the box and totally encase it.
    I ordered more 44 gauge wire for the next one I'm going to try.  I did have to make a vacuum pump. I used an old bicycle pump it pulled the vacuum down to 25 on the gauge but not sure the gauge was working correctly.

Offline Don1966

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Re: Miniature coil winder
« Reply #31 on: February 01, 2019, 03:26:04 AM »
Doc I donít think thatís a good idea to fill the box with wax. The coil has to cool and wax will be coming out of it as it heats up. The wax is only to insulate the windings to keep them from jumping across each other and ruining the coil.



Don

Offline Doc

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Re: Miniature coil winder
« Reply #32 on: February 01, 2019, 03:58:19 AM »
The coil will not get hot enough to melt the wax and if it does it will not be any good anyway. Bob Shores describes doing this to his coils and didn't have any problems with it so thats why I'm going to give it a try. I know that model T coils are built very similar I have one laying on the shelf here that I plan on rebuilding (or attempt to LOL) at some point. Thats one of the reasons that I got started wanting to build a coil.

Offline Doc

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Re: Miniature coil winder
« Reply #33 on: February 15, 2019, 01:09:13 AM »
Here are some pics of the finished coil. It puts out a nice spark at 6V. The primary resistance is 3.0 ohm and the secondary is at 5600 ohms. I'm happy with the way it turned out one more thing I can cross off my would like to build if I could.

Offline Ye-Ole Steam Dude

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Re: Miniature coil winder
« Reply #34 on: February 15, 2019, 11:47:47 AM »
Hello Doc,

Really cool.

Have a great day,
Thomas

Offline Don1966

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Re: Miniature coil winder
« Reply #35 on: February 15, 2019, 03:38:54 PM »
Awesome Doc looks great! :ThumbsUp:


 :cheers:
Don