DIY Hand-Driller Coil Winding Machine with Digital Counter

Picture of DIY Hand-Driller Coil Winding Machine with Digital Counter
When I built prototypes of my invention (A No-Friction Bicycle Light Generator) before mass manufacturing, I need to test different kinds of coil to fit the product, so I made this coil maker (DIY winding machine). It is easy to be made, low cost and simple.

Link: A No-Friction Bicycle Light Generator
Link (webpage for this winding machine): DIY Hand-Driller Coil Winding Machine with Digital Counter

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Step 1: Step2

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Full view. You can get the pedometer on ebay for few dollars. There are many kinds of pedometer on market, in my mind, the cheaper one is better for building this winding machine. The magnet and reed switch can be bought as door alarm switch set in hardware shop. A old hand-driller.

Hand-driller's handle turning once, the coil will turning about 3.5 turns. So if the digital counter showed 100, the coil will be 350 turns. Each hand-driller may be in different rate, just test it before use it.

A no-friction bicycle lights dynamo

Step 2: 3

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Each time the magnet on handle passes (not touch) the reed switch, the padometer's figure go up 1. The handle turns 100 times, the padometer should show "100". Hold a button on pedometer to go back to zero.

Step 3: Step3

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other view

Step 4: Step4

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How the padometer works? Each time your body jumps, a metal hammer inside pedometer jumps once and touch a point (as a jump switch), send a electrical puls to counter, screen will show figure up "1". Take out the metal hammer, Lead 2 wires out from the jump switch to the reed switch.

Step 5: 5

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other view
uday.integral2 months ago

Nice Info

akhan1205 months ago
Very good your mind is good'''''
A very neat, novel and effective design. If a person didn't have a pedometer or an old el-cheapo electronic calculator to make a turns counter, a manual "people counter" (available at my local 'Dollar Store for $3.00) could be used.

The counter's push button could be pressed by a cam or lever once per revolution, and the "reset" knob turns it back to zero when you're done. Thanks for posting this nice and "outside the box" take on a coil winder.
flyingpuppy2 years ago
OMG that's good! A pedometer!
dawoj4 years ago
Good counter
edwianni14 years ago
Where can I find the site for your coil winder KIT? Thank You.
agis684 years ago
pretty smart....i have some step counters
WolfVecho6 years ago
very good Idea
paborralho6 years ago
Great! I think it can also be done with a bycicle speedometer, since it already as a magnet switch
The speedometer can be made into a tachometer. See my instructable where I did it.
I like the counter!
raelx7 years ago
Nice work, great use of the pedometer as a counter. Unfortunately your bike light is not resistance-less. It may be frictionless as there are no rubbing parts but every time that magnet swings by the generator it removes energy from the rear wheel. It's a great idea I just wouldn't advertise it as violating the first law of thermodynamics.
Derin raelx6 years ago
oh no,violating the law of thermodynamics!
later on,at the courtyard:
So,this person...son...son...son,has violated ...ted...ted...ted the law of thermodynamics...mics...mics...mics!So,he shall...all...all...all,be kickedked...ked...ked!
paborralho6 years ago
It´s simply wonderful! That must come from a briliant practical mind.
Ohm7 years ago
you could also use a cheapy little claculator as your counter, just wire the reed switch to the plus button and punch in a 1 to start it going.
rolan Ohm7 years ago
Great idea. You could also enter the number of windings then minus 1 to count down to zero! Soldering to those tiny zig zag button pads might be more difficult than to the large leads of the pedometer jump switch though.
abun19917 years ago
Brilliance Sheer Brialliance.
andy7 years ago
Oh excellent, this is exactly what I need, time saving and incredibly practical, and cheap too. Flexible as well, because it would work with non-round coils (i need a trapeze shaped coil) just attach bobbin of desired shape. No more hand winding for me (well... in a way, but not quite so time consuming and hard on the fingers) Like it. Andy
nah7 years ago
If you moved the magnet to the chuck and place the reed switch to match, then you wouldn't have to worry about what the ratio was between the crank and the bobbin. Other than that, it's a nice, simple rig.
royalestel7 years ago
This is great. I see you already have online DIY kit instructions. You should post them here as well to improve traffic (and sales). Nothing wrong with that.

Check out ladyada's stuff
dataphool7 years ago
Elegant. Deals with the problem in an efficient manner.
gmoon7 years ago
I like! I've thought about making a coil-winder for guitar pickups--what gauge wire you using? Pickups use 42AWG (.063mm), very easy to break...