DIY Arduino based Toroid coil winding Machine | Arduino project
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- เผยแพร่เมื่อ 28 พ.ค. 2020
- $2/5pcs 2Layer & $5/5pcs 4Layer PCBs: jlcpcb.com
Hello friends In this video I have made a toroid coil winding machine using arduino as controller,
This machine is automatically winding the turns and also rotate toroid core automatically.
For user input and interaction I have used a rotary encoder and 16x2 LCD display.
User can enter data like diameter of toroid core, number of turns and how much area of toroid core need to wind.
I have program it in a way so it can be used for variety tor ID/OD toroid cores just enter the core OD and do some mechanical adjustment.
Currently this machine giving just ok ok result but I want it to upgrade further so it can be practically useful, please give your suggestions and ideas in comment box because I am not familiar with toroid coil winding machine, I have never seen in it live in my whole life. I made this project by just watching video on net. so I might be not completely aware about its working process.
All details like code, circuit, item list, construction details etc are available on my website.
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I'm genuinely impressed that you actually made a perfectly working toroidal core winder!
The inaccuracies you are getting result from the wood construction and a less effective wire guiding system, but the concept is there and is perfect! Well done!
You can use printer pickup rollers for driving and guiding the toroid (with plastic washers to form flanges). In fact, you can disassemble an old inkjet printer (you probably can get it for free) and salvage most of the parts required (depending on the printer model: belts, rollers, optical sensors, stepper and drive motors, plus assorted hardware that may become handy in construction), to get yourself a winding machine that will cost you mainly the hours spent building it.
Finally, I must congratulate you for making all the information freely available - it's relatively easy to find used toroidal transformers in scrapyards, that can be rewound to meet to personal needs - normally the primary can be used as it is (assuming primary is OK) and the secondary (outer windings) can be taken out and rewound with your machine.
I suggest winding experimental 10 turns secondary and measure the voltage obtained, to get the volts per turn ratio (voltage measured divided by ten, normally much less than 1). If you need more accuracy, wind 100 turns, measure and divide by 100 and then multiply by the desired voltage to get the corresponding number of turns, not forgetting the wire gauge must be enough to handle the current (that depends also on the power the core can provide).
I believe there are a lot of capable young people that would benefit from this - Transformers are expensive (shipping is expensive too, due to weight). Even a burnt transformer can be salvaged, because the core is normally OK, but then you need to wind both primary and secondary(ies).
To calculate primary and secondary turns from scratch, I suggest a very good tutorial from Ampletos (th-cam.com/video/Q6GkSNfAEx4/w-d-xo.html). It's in Spanish, but if you turn CC on, you can have subtitles in your language - technical information is normally understandable, even if YT translation gets a bit awkward.
Long post, in the hope that this may help any enthusiasts out there :-)
Thanks man for guidance 👍 really helpful
@@MrInnovative I'm glad you liked it! Your project deserves attention from young enthusiasts and the reuse of old printers and transformer cores is the way to go - recycling is the last resort!
Ampletos's video is by far the most clear I've seen.
I built an entire CNC-like woodburning machine entirely out of parts found in a photocopier. Steppers, rollers, gears - that thing had entire assembly. I have a video somewhere on my channel. Best part, there is a ton of office equipment that gets discarded as trash. They are a great source of parts for makeshift automation.
Where would you find a toroidal transformer at scrapyards? I need some but nobody sells the cores and the wound ones are really expensive
I don't care that people are saying that it could be better, that's true of anything. The fact that you made a working toroid coil winder is impressive in and of itself.
This is a lot of work. This man had to do a lot of hands-on basic experimentation work, a lot of design work, a lot of re-design and refinement work, then a lot of work to make it instructional to others, and a lot of work of filming and post-production to make it easy to follow. I do not see a lot of women doing this kind of stuff. Hats off to his intellect and perseverance.
Superlative work :) Being a long time coiler i can appreciate the thought, effort and time that went into designing and testing this lovely device. Liked and subbed.
CR
Thank you for showing us this! I watched a video about winding toroids but apparently only half-understood it. Thanks for making this great project!
It's super impressive work! Something I wonder might help: Currently the wire comes from anywhere on the spool (depending on position of the unravel) to the toroid and this might be causing an innaccuracy in position. I'm thinking if you added a little guide ring in front of the spool (between the spool and the toroid) and thread the wire through it before attaching to the toroid, the wire will always be coming from the same spot. The distance between the spot the toroid will always be the same. I'm not basing this idea on anything more scientific than a vague recollection of a sewing machine feeding mechanism though. :D
really thanks for your guide....
Yeah, that's probably what caused most of the variability in the turns spacing
I was just thinking of a sewing machine when reading the first half of your comment, it is very very common to use a guide when dealing with anything on spools, even like fishing rods that take the line coming in and run it through a reciprocating guide to make sure it winds up neatly and evenly and without tangles.
Back in in the early 1980’s one of my jobs had me operating a toroid winding machine. This is a good example of one. All our transformers had to subsequently pass an insulation test where the transformer was connected to a “HiPot” tester and the coil was immersed in a weak saline solution with the other lead from the HiPot hooked to a metal tab also in the solution. Any electrical leakage was a fail.
I'm really impressed by your work!!! For a device that has lots of manually created elements (by manually I also mean elements that you made with a lathe but not an automatic lathe) it works really smothly. Of course there are some things to fix to make it more reliable and consistent (irregular gaps between windings etc.) But still, amazing! Just subsribed your channel!
I'm not sure how you would improve the machine but what you have created is VERY impressive, great job Sir!
Even after seeing the video we struggle to imagine the concept. God gift. Thanks
Magnificent!!! Innovative and nicely done. You asked if there were any suggestions for improvements and the only thing I could see was the need for a feed spool tensioner. But with this comment being a year after posting, Your keen insight has probably already addressed this. 👍
That was surprisingly satisfying to watch. Great job :)
Thanks for sharing this build ! Well made !
Muy bueno!!
Todo de madera y con rodamientos, como me gusta a mí. Un espectáculo.
Thanks for sharing your knowledge wiith us!!!!!
That is a *VERY* useful build. For more placement accuracy, I suggest using a swinging arm that is anchored by the spool, with the wire going through an eyelet at the end, positioned as close to the toroid as possible without running into it.
Damn. Such clean work. I learned a few things. :)
Great engineering work! Thanks for sharing this with us! Will start to buil it soon! Thanks again
Hi, great work! I was do similar machine for standard transformers many years ago (over 30). Speed of my machine was lower to more control of the layering.
SENSACIONAL MEU AMIGO! PARABENS!
Wonderful projects, building quality is superb, congratulations sir
You should replace the DC motor with another stepper, the winding would be much more precise.
Anyway this is a smart idea.
Why do you need another stepper motor when you have the revolution counter? The problem seemed to be the jerky feeding of the toroid.
@@nixxonnor because you have 24 steps per revolution.
this construction/design is commonly found in Chinese made coil winder.
@@nixxonnor at 1:06 - 1:07 it appears to have skipped a tick.
@@recer_ but the winding count increases even though the led isn't on at that time. I think this is because the camera shutter isn't synchronized with the rotation.
VERY impressive ! This project must have required Much time and effort. Congratulations.
Отличное видео и идея, отличный токарный станок для реализации небольших задач! Спасибо
nice lathe. I've got one too. It's the first time I've seen the wood working attachment actually used on this lathe.
this is one of my favorite channels on youtube
This is very cool. Quite amazing! I'm sure with this prototype running you can see where and how to refine it.
Nice work Mr Innovative, keep on going!
It's a very nice build. I like it. I don't really see anything particularly wrong with it at this stage, just needs refining of individual elements like others have said. Improve the tracking of the moving parts, add in some better wire guidance. Personally I would probably 3d print an outer gear ring to replace the belt drive and have it engage a stepper for precise control and no slipping, but that's just me.
I do like how on commercial models, the large drive ring is itself a giant spool that you prefill with enough wire to do the job.
YOu are hands down on clever person. Really enjoyed the show.
Great to see something new. Keep making such projects and all the best!
Este es un vídeo increíble y muy útil, gracias y saludos desde México
This is and amazing video, is also very practice, thank you very much and greetings from México
An excellent video. I watched every second with pleasure.
Thank you very much!
th-cam.com/video/y0IdJuD3ggk/w-d-xo.html
This really excellent work. If you were winding a toroidal transformer you would need to have automatic adjustment of the turning mechanism for the toroid as the thickness of the coil increases
Much better with the sound off. Fascinating project, looks great.
Amazing. Excellent job. Congrats.
You made a beautiful thing. Very nicely done!
Love you brother. Love your dedication
Regardless of the initial outcome, it's still a proof of concept that actually worked even though you used fairly primative parts and pieces scavenged from other unrelated devices. With some further investment of time and energy, this coil winder will be an intricate part of a much larger apparatus, that will contribute to the building of all kinds of much needed equipment. Well done ! You have an exceptional ability to visualize in 3 dimensions.
thank you...
This is very appreciable. Although there is always a scope of improvement as per available comments.The PCB shown is the only outsourced requirement, rest is self manageable.Also for thick wire size like swg12/13/14 we have to take the necessary measures of the parts. Again a very very useful successful attempt. All the very best.
Overall, this is a highly informative and enjoyable video for anyone interested in engineering. It showcases your talent and expertise while providing valuable insights and inspiration to fellow enthusiasts. Keep up the great work, and I look forward to watching more of your content in the future 👍👍👍
Excellent project! Congratulations
Приятно смотреть,смесь человеческого разума с механикой.
Truly amazing and nice project
🙏
Congratulation 100k Subscriber MR! ...
Great job ! Very ingenious.
Well done, impressive work making complex parts by hand! Imagine this guy let lose with a 3d printer
Très belle initiative je vous remercie c'est Vraiment merveilleux.
Very good project, friend!! 👏👏👏
Excellent! As for improvements maybe make the ring opening larger (to add and remove large toroid coils more easily) - I’d have 2 splits rather than the 1 you have. Also your code can adjust for toroid diameter but can the machine? Maybe need to add adjustment in the 3 supports in/out. Also is your code adjusting for diameter increase of multiple winding layers? Does it auto stop of out of wire? Can the wire diameter be changed?
that's incredible and finally useful device on Arduino)))) and it is not a toy. Great job and tech idea
For the toroidal core holder, I would have used a solution like the one you used for the main drive wheel, but with spring loaded gripping arms. I would use a spring on the drive wheel also, instead of a wing nut. As for the control system, I'd probably go with a raspberry pi instead of arduino, but that's purely personal preference. I love the simplicity of the interface. I'd probably try to add a linear coil winder also. Maybe using a linear screw to move the coil and wind smoothly.
An arduino is much much more suitable here than a raspberry pi. Why would you need a pi for this? What benefits would it bring? This is something that needs precise timing and not much processing, essentially the opposite of what you get with a pi, lots of processing power and not a real time system. So microcontrollers are much more suitable for this application.
What a thing of beauty.
This build is really innovative. I love it. Simple but yet effective.
We should collaborate on a build sometime my friend. Cheers!!
Between 1978 to 1990 I worked for a company that made Toroids. We made them G.R.O.S.S. and Mu-metal. We also manufactured C cores, E cores and distributor gap.
Ur the first person to make this machine I mean diy project
Somebody need to give this man a million dollar so the next project can become reality
This isn't just cool, this is leading towards JoeBob homie being able to invent their own electronic components at home instead of only in big fancy lab factories. This opens the door for more overlooked geniuses to be able to do their stuff.
Absolutely stunning work. Thanks for sharing.. Kudos
such a neat design, love it!
Good job! Getting stability or robust is only a little step. Congratulations. You gave me a lot of ideas. Really you did.
Molto bravo! Bellissimo lavoro!!
Отлично! Спасибо за идеи! Хороший станочек! Прекрасная работа,золотые руки!
вирус не поймал по его первой ссылке?
Great engineering job. Not all can not do. Only high knowledge person can do. Thanks for edua
Congrats for your success (100k).
Congratulations. Very good design and work.
बहुत सुन्दर एक कम रूपयों में अच्छी मशीन और वर्किंग भी अच्छी पूरी मेहनत से बनी है काम भी अच्छा करेगी थैंक्यू
That is just brilliant!
My respect to you, Mr innovative. 👍😊
Thank you! Cheers!
Im impressed. It is quite amazing.. Good job
Only suggestion I would make is to put some sort of tensioner on the wire coming from the coil... This will improve the winding by double. As it looked like there may have been slack wire winding that allowed it to drift sideways. Othwise a nice looking and well working machine !!
I see several improvements I can make for example a guide arm for the wire(more even spacing and all that), definitely going to print one of these when I get a 3d printer
Awesome build. Appreciate your effort. Lot of effort must have be put to make this. 👍👍
If you were to rebuild what changes would you make ? As I would like to build one like this.
Nice work. Consider buying a 3d Printer as well.
Great project! any thoughts on a ring that holds the wire on the outside? Having that wire bobbin really creates problems in terms of ID of the toroid core. Thanks
Doug
I remember using a coil winding machine with #46 AWG magnet wire or something and 3000 turns on a 1 inch diameter toroid for a current sensor.
Great job ! Very talented .... you are.
This is a work of art! I admire the craftsmanship.
So amaizing. Big up brother.
Nice machine, I'd suggest the upright supports would be more stable if the shafts weren't so flexible, also replace the 12V motor with a second stepper
that is very good. well done mate.
To the owner of this channel thanks this is the type of machine i was invisioning in my dreams thanks for making this happen
One question why isn't this a product
Your art is wonderful
realy u are nice man because u give all details thank u very much
Ha, this used to be the industry I was in for 17 years, winding, assembling and eventually designing... Excellent work, a break to keep the windings tighter would be useful.
Before cutting the wheel, you should plane it so that it's absolutely flat. Could help reduce the wobble.
Amazing machine, you are a genious!, congratulations
Interesting! We posted this videos on our homemade tools forum yesterday :)
Very interesting, a clever design.
Add a DTMF keyboard to input the numbers. It will simplify operation. Keep the rotary switch to access various modes, speed, pause, etc.
thanks for share, beautiful project 👌
Very cool, thanks for sharing!
Wonderful !!! very very smart machine.....bravo !!!!
That's spot on lol
Need to make smaller one cud be bobbin type and moves coil out the way be harder to make tho ...that needs a number pad with +100 button lol
Had to turn off due to the music. However, I love the project. Truly impressive!
But.. please consider ditching the music. 👍🏼
Parabéns !!! ótimo vídeo .
I guess that adding a wire guide at the supply coil would give a neater result, although it would not much affect the functionality of the induction.
Mann,! You are a genius.
Impressive machine!
Ottima realizzazione, componenti👍👍👍
You can be proud of this achievement! Well done, except for the flashing LED which looks like a big fat electrical spark to me and had me backing away from my screen 😉
I have burned that sensor off camera so I changed the smd IC meanwhile unfortunately LED trace also get removed so I added external LED to it..
Part of the time the core rollers are on windings and part of the time not leading to uneven winding. Possibly more rollors would help or a way to accurately monitor the degrees of rotation. Right now it's open loop.