Coils are used for an abundance of projects, but are not very easy to make. Often, coils require 100's and sometimes 1000's of turns. Doing this by hand is extremely difficult, so I made my own coil winding jig that uses a pedometer to automatically count how many turns the coil is. (NOTE: I used MY Solidoodle 3D printer to manufacture many of the parts used to build this jig. A 3D printer is not necessary but will make the project easier to build. I will also include the 3D files.)
What did I make?
I made a manually operated coil winder that takes advantage of a cheap pedometer and a micro switch to automatically count how many turns are in the coil.
How Did I make?
This project came about when I was creating my science fair project ( a windbelt) and realized that I needed some custom coils. For me, the best way to solve this problem was to create a jig that would make winding coils easier and would automatically count how many turns are in the coil. A plus was that I did not have to buy any parts. Everything in this project can either be found at home, or bought really cheaply.
Where did I make it?
I made the coil winder at my house. Since I needed more space for this project I had to use my basement as a workshop and my ping pong table as a work table. Some members of the household dislike my use of the ping pong table, but I told them that science takes precedence over ping pong :)
What Did I Learn?
Well, there are many things to learn in this project. 3D printing precision parts is challenging with a $500 3D printer, but my Solidoodle held up great! I learned very quickly that it is important that you put glue on the coil as you're making it, or else it may fall apart in the end. I also learned that you do not have to sacrifice functionality for style, to the average person it may look like a machine, but to me it's a piece of art :)
Step 1: Materials
1 – 3/8in hex bolt
1 – 3/8 hex nut
1 – 3.5in x 3/4in x 13in wood plank
8 – 1/8in wood screws
2 – 1/16in eyebolts
2 – rubber bands
5 – 1/8in x 3/4in screws
1 – low cost pedometer (very important, must be a cheap pedometer)
As needed – electrical wires
3 – 1/16in bolts
3 – 1/16in nuts
1 – micro switch (other switches/ buttons may also work)
1 – 1/4in x 6in bolt
5 – 1/4in nuts
1 – 1/2in wde x 1/2in tall metal spacer (size depends on how tall you want the coil)
2 – 1.5in OD 1/4in ID washers (size depends on how wide you want the coil)
1 – 1/2in washers
1 - 1/2in ID washer
Copper enamel wire
Assorted printed parts
(http://www.thingiverse.com/thing:56493 All the printed parts can be found here!)