Arash Posted May 31, 2017 Share Posted May 31, 2017 Hello everybody, it's been a long time I had no thread in the forum. As you probably know we have been designing and building speakers for almost a decade in Iran for various of applications. If you have ever built a crossover network you probably know that the inductors are really pain in the butt to build specially when you need high quantities so the winding will be a job of attrition. this is why I decide to design and build a high torque winding machine with a CNC rotary and wire feeder mechanism to wind perfect lays inductors and autotransformers. I wanted to submit a thread here to let you know what I am doing and have your possible tips and ideas. maybe someone here want to build something similar so this would be a good clue to start. Last year we contacted a US company named Bachi that manufactures some very nice and advanced winding machine. we checked the shipping cost and importing taxes of this machine from US to Iran and it turned out to be something about $80K! our pocket was not that deep. the plan B was to buy a machine from China but after all we decided that we have to build it ourselves as we have experience in designing and building other type of machines. Quote Link to comment Share on other sites More sharing options...
Arash Posted May 31, 2017 Author Share Posted May 31, 2017 Project budget was estimated between 5 to 6 thousand dollars. the machine has a 3HP motor and a heavy duty spindle with a 3-jaw turning chuck. we design everything more than adequate strong to make sure we can build coils down to AWG#8 thickness. using a turning chuck will make us able to use any mechanism needed to wind coreless inductor and inductors with bobbin and also transformers. air core inductors (without any bobbin) are tricky to wind as the coil won't slip right off the core very easily. We will design some kind of mechanism that lets the coil slip off after winding. this will be done after the main part of the machine is built. the machine will have a dedicated PLC and touchscreen HMI for functions. the motor has a electrical break so the PLC can freeze the spindle as fast as possible so the coil won't get loose. wire feeder arm will have a linear bearing and ballscrew with a 180-steps stepper motor. this will make the machine able so precise to wind wires are thin as AWG#38 (0.1 mm Ø). we may never wind a coil than thin but we have to keep the tolerance at bay. the machine should have a tolerance about 0.05mm. we will build a pneumatic air tailstock to support turning parts and keep them steady. we have yet to design a wire tensioner with shellac injection system and an optional hot air gun. after countless of hours 3D modeling in Solidworks this is the result: 1 Quote Link to comment Share on other sites More sharing options...
Arash Posted May 31, 2017 Author Share Posted May 31, 2017 after some cutting and welding of main chassis: we welded some 10mm strips on the chassis so it is ready for machining: Quote Link to comment Share on other sites More sharing options...
Arash Posted May 31, 2017 Author Share Posted May 31, 2017 we bought some parts. 3-jaw turning chuck: linear bearings: spindle ball-bearings: Quote Link to comment Share on other sites More sharing options...
Arash Posted May 31, 2017 Author Share Posted May 31, 2017 we built spindle bracket. it's a huge piece and far more tougher than adequate: and complete spindle: and after ball-bearings installation: Quote Link to comment Share on other sites More sharing options...
Arash Posted May 31, 2017 Author Share Posted May 31, 2017 we milled the feeder arm: machining this part was a really challenge. we have to position it like this: and it turned out perfect as we expected: Quote Link to comment Share on other sites More sharing options...
Arash Posted May 31, 2017 Author Share Posted May 31, 2017 the main post gate of the machine was milled with high accuracy: Quote Link to comment Share on other sites More sharing options...
CECAA850 Posted May 31, 2017 Share Posted May 31, 2017 That's a lot of work to wind coils. You must need a bunch of them. Thanks for the pictorial. VERY interesting. 1 Quote Link to comment Share on other sites More sharing options...
Arash Posted May 31, 2017 Author Share Posted May 31, 2017 14 minutes ago, CECAA850 said: That's a lot of work to wind coils. You must need a bunch of them. Thanks for the pictorial. VERY interesting. thanks bro yes actually we need a lot of coils. Iran is #12 biggest producer of copper in the world so why not. we have copper wire 99.999% purity so we can build inductors here and save a lot. to be honest designing and building this machine is a little bit a long time personal game and we can also save a lot of money so why not! 1 Quote Link to comment Share on other sites More sharing options...
CECAA850 Posted May 31, 2017 Share Posted May 31, 2017 11 minutes ago, Arash said: Iran is #12 biggest producer of copper in the world I had no idea. 1 Quote Link to comment Share on other sites More sharing options...
Arash Posted June 1, 2017 Author Share Posted June 1, 2017 ballscrew tail ball-brearing bracket which will be placed at the right end of the machine: Quote Link to comment Share on other sites More sharing options...
Arash Posted June 1, 2017 Author Share Posted June 1, 2017 proving parts of a machine is a very entertaining! it's like a jigsaw puzzle as you put it together you see the result of countless of hours working in the final image Quote Link to comment Share on other sites More sharing options...
JJkizak Posted June 1, 2017 Share Posted June 1, 2017 On 5/31/2017 at 2:45 PM, Arash said: we milled the feeder arm: machining this part was a really challenge. we have to position it like this: and it turned out perfect as we expected: Nice welds. Looks like Mig. JJK 1 Quote Link to comment Share on other sites More sharing options...
ClaudeJ1 Posted June 1, 2017 Share Posted June 1, 2017 My best friend build a coil winder out of a sewing machine and an old calculator with an equal key. He used plastic bobbins, but fed the copper wire by hand. An LED and Opto detector with a paddle interruptor counted the windings, by keying in "+1=" and wiring the output of the Opto transistor as a switch to the Equal Key. He was able to make coils within 1% by overwinding then trimming, using a bridge for measurement. 1 Quote Link to comment Share on other sites More sharing options...
MyOwn Posted June 1, 2017 Share Posted June 1, 2017 Arash Dude...It's wonderful what you can do with your mind and hands, I cannot wait till you show this up and running. 2 Quote Link to comment Share on other sites More sharing options...
CECAA850 Posted June 1, 2017 Share Posted June 1, 2017 29 minutes ago, Steve_S said: Arash Dude...It's wonderful what you can do with your mind and hands, I cannot wait till you show this up and running. The very first post is a video of it in action. 2 Quote Link to comment Share on other sites More sharing options...
Marvel Posted June 2, 2017 Share Posted June 2, 2017 I believe the video is the Bachi, that would have cost them $80k. 1 Quote Link to comment Share on other sites More sharing options...
CECAA850 Posted June 2, 2017 Share Posted June 2, 2017 53 minutes ago, Marvel said: I believe the video is the Bachi, that would have cost them $80k. I think you're right. 1 Quote Link to comment Share on other sites More sharing options...
JL Sargent Posted June 2, 2017 Share Posted June 2, 2017 Arash is always creating something awesome. Good luck with this latest project! 1 Quote Link to comment Share on other sites More sharing options...
oldred Posted June 2, 2017 Share Posted June 2, 2017 Arash, Great work. The design is what I call a simple elegance. What you have done is built a lathe head (love the 10 mm 3 jaw chuck). Then you use the ball screw for the winding progression. What do you have in mind for a control system. I see in your Solidworks assembly you have an encoder mounted to take of turn counts. How do you plan on braking the turn count motor. George, 2 Quote Link to comment Share on other sites More sharing options...
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