Introduction: Automatic Coil Winder

Picture of Automatic Coil Winder

everyone that has made a faraday power generator, or a transformator, or had to wind X with copper wire has encountered this problem: anoyed fingers, anoying repetitive tasks, and taking FOREVER just to get 10 winds.
with this easy to build jig, its alot faster, ur fingers will hurt less, and becouse its fast, its less repetitive.
also, its completely made of scrap (with exception of the dremel :D) and olmost any part used can be replaced.
and, becouse of only using scrap its really cheap (+-$5 without dremel)

no, it doesnt look pretty, but yes it does what its supposed to do.

please, read the instructable first, then think of what you will use it for, and think of a picture in your head first/draw some scetches, every build will be different due different sizes, different items used, different things to wind, etc. etc.


there are 3 things you will need to remember;
1: im dutch, so my english is far from perfect (but understandable i hope) if u have any comments on that, please point out wich section i misspelled/used wrong grammar, and il fix it.

2: this thing doesnt look dangerous, but in any case, i am not responible for any kind of damage this thing will produce when you have build this.

3: it can  take longer or shorter to build this, since everyone will use different scrap, this also influences the price and how good it works.




Step 1: Tools and Scrap You Will Need

il add pictures if anyone needs them, but i dont think anyone does :D

well, the tools are pretty straightforward:

*dremel - some use in the build, but mostly for the final product
*diagonal cutters - cutting the wood and metal (can be done by metal saw)
*strong Xacto knife - for smoothing the wood
*soldering iron and tin- for melting together pieces of steel
*anything to lift the dremel, i used 3d hands

scraps, note, olmost anything can be replaced, use the stuff you have since olmost anything is usable:

*wood
*metal pipe
*broken dremel bit
*paper towel
*scrap pieces of metal sheet (coke can)
*some metal wire

Step 2: Building the Base

Picture of Building the Base

first off, if ur using anything else (wich you probably are) some steps will be different, just figure out ways to replace/leave out certain parts. use ur imagination!

i started with a length of wood that would be certainly long enough to hold everything and cut trenches in it about the same size as the item i was winding (picture 1)

then i took 2 smaller pieces of wood, drilled holes in them with my dremel (picture 2)

after that, i simply placed them, and hot glued them (with my soldering iron at a low setting, glue gun is broken >.<) (picture 3 and 4)

make sure the size is a bit wider than needed, i made a small mistake with those bumps in the midle of the wood, so i had to cut away some with my Xacto (pictures 5 and 6)

Step 3: Making Things Go Round and Round

Picture of Making Things Go Round and Round

i realised that with a connection that couldnt spin around for itself, it would lose alot of power there, so i added some metal wire to loosen things up (picture 1)

the pipe's endings where way to big to get the broken drill bit in directly (picture 2), so i took a 7up
can, and added some of that stronger metal off  the bottom and soldered it to the pipe. (picture 3)

make sure ur soldering iron is as hot as it can, and that you dont touch any metal part that connects to the metal pipe, EVERYTHING will get extremely hot.
soldering wont be easy, the pipe will take some time to heat up, and as long as its hot, the solder wont solidify completly and wont get hold of the pipe/7up metal, so hold the metal in place with your pliers for about 3-5 minutes.

then, pulling the wood backwards, see if everything fits, if not, you better try again with new materials, since its a pain to get that solder all off (picture 4)

Step 4: Fill It Up!

Picture of Fill It Up!

this step is probably different for most of u, since i was using a tube that was empty from the inside.

anyway, i added some paper towels and ductape so it would have room to slide the holder in, and still enough strength so it wouldnt just spin the insides instead of the outside (picture1)

add just enough so you have to push with force to stick it in (picture 2)

then, insert the whole thing inside the base, if everythings good, the tube just wont touch the wood.  (picture 3)

ul also need something that holds the wire, but thats on the last picture

Step 5: Last Thing to Do, and Some Tips How to Use.

Picture of Last Thing to Do, and Some Tips How to Use.

add a  dremel, MAKE SURE ITS ON THE LOWEST SETTING!!!

hold the wire with your hand, that way you can guide it to the right place, and by squeezing harder or softer, you can make it spin faster/slower.

when changing to a faster setting, more power will come on it, thus youl need to hold the wire harder for the same speed.
also, when going to fast, the wire could cut into your flesh, so hold it low or wear some kind of protection.
look at the video in the first step for how i do it.

as a last thing (wich comes with any instructable, like the "im not liable for anything" warning)
please rate, comment, and please, if you made one upload a picture or a video. il inlclude those in this last step.
those pictures and videos could help others when building, since everyone will probably build theyr  own version, add improvements, or other techniques.

thanks for reading, and good luck winding!

Comments

3leftturns (author)2010-01-09

I meant something more permanent than a stack of shop supplies. Maybe a wooden spool holder?

BTW, I love making stuff with what I have laying around. The hunt for supplies is just as much fun as the project.

Put heat the foam tube around the metal center, then heatshrink around the foam.

Cool project!

godofal (author)3leftturns2010-01-10

well, making stuff out of scrap is great :D
but then u would need like a 5inch heatshrinking tube?
i think that would cost alot more than ductape, and ppl have ductape lying around more often than 5inch heatshrink...

3leftturns (author)2010-01-08

Cool idea, some improvements could be a dremel holder and wire spool holder. Also some foam tube and heat shrink could replace the paper towel/duct tape for a cleaner look.

Thanks for sharing!

godofal (author)3leftturns2010-01-09

wire spool holder? i described that in the last step (picture), its nothing fancy, but thats nothing on the project :D
but i saw a nice one made out of knex last time, il ask if i can link to that...

and heat shrink around the copper wire u mean? i think when winding ALOT of wire, ul have like 3 extra inches around, but it would hold/look better indeed...

foam tube instead of paper towels might be a good idea to, but i just used what i had, so if u have foam instead of paper towels, it should work :)

and thnx for the tips for building, could help others.

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