CNC Coil Winding Machine

[Seadog]

Vector motor?

[Arash]

8 hours ago, ClaudeJ1 said:

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.

very good way to wind coils. he sure knows what he does. but you know what winding perfect coils is all about control. if you feed the wire by hands you can't keep the wire tension steady so there is always a lot of possibility that wire will slip so it will be place in elsewhere than it's right position in the bobbin. when you control everything the wire has no way other than being placed precisely among previous turns. will result in a gapless coil.

 

6 hours 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.

thanks bro for your promotion

 

6 hours ago, CECAA850 said:

The very first post is a video of it in action.

 

actually that's a Bachi Winder machine. Actually Bachi machine is the best thing we ever found on the planet. it's totally the best winding machine a coil and inductor manufacturer can thing about. but it costs about $38K and would end up something about $80K if we wanted to buy it from Iran.

 

4 hours ago, Marvel said:

I believe the video is the Bachi, that would have cost them $80k.

 

that's right. 

 

2 hours ago, JL Sargent said:

Arash is always creating something awesome. Good luck with this latest project!

 

 

Oh thanks dude! 

 

1 hour ago, oldred said:

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,

Thanks George,

Yes actually it's a lathe machine with a computer controlled wire feeding mechanism. for control system I'm gonna use a PLC. the PLC will have a HMI (Human Machine Interface) which is a 7" touchscreen display (you see it on the Bachi in the video at post #1). this is what a HMI looks like:

Yes there will be an encoder for counting spindle turns. About braking. the main motor which is a 3-phase three horse power motor has an electrical control brake. the PLC will take of brake automatically.

 

 

43 minutes ago, Seadog said:

Vector motor?

the motor itself is not variable (I think you mean a variable motor by "vector motor"?) I hope I'm not in a language barrier about vector motor. as I said the motor itself is not variable but we will have an inverter that controls motor speed. the PLC also takes care of inverter as well.

[Arash]

We did some other parts and put everything together to see how it works. the linear bearing works flawlessly:

 

 

 

and we added tailstock holder:

 

[Tarheel]

You have serious skills Arash.  Well done!

[Arash]

It was time to weld the feet. this CO2 welding machines are great:

 

 

We also bought some other parts. Pneumatic jack for the tailstock:

 

A new thicker ballscrew and it's nut:

 

and ballscrew nut and it's journal bearing:

 

 

 

 

[Arash]

and the feedscrew for tailstock position adjustment:

 

the a 2HP electromotor:

 

 

 

 

[Arash]

and we painted the structure:

 

and other parts:

 

wheels installed:

 

[CECAA850]

You own a welding mask?

[Arash]

9 minutes ago, CECAA850 said:

You own a welding mask?

yes sure! sometimes you need to hold the piece with one hand and the welding torch with another hand and close your eyes for a gentle connection to hold the piece in place. you don't have to look at the ark directly it's so harmful to the ye

[CECAA850]

Eye lids won't block uv.

[Arash]

one of the tapping screw treads broke in a hole of this part so we decided to throw it away and mill a new one. it was a symmetrical part and we could sweep it 180 degree and drill the holes on the other side but we just decides to build a new one and it's gonna be a one-time-built machine:

 

and the new one we milled this time no Iron but 7075 Aluminum:

 

and we just put togheter this jigsaw puzzle to see how it looks like after painting. we didn't paint machines surfaces so we will always remember how accurate it was built! a machined surface speaks very loud to a machinist:

 

 

 

this week the machine will be assembled. we are gonna work on the PLC and HMI and electric parts next week. this knitter lady should be working about ten days from now. I hope so...

[oldred]

Arash,

I am really enjoying seeing your progress.

As far as the broken tap....Here in the USA ...in the machine building trade.... our saying for broken taps ....is ....(Shit happens)......and it has happened to all of us.

I have been a machine builder ever since I finished my apprenticeship in 1980.....a long .........long time ago.

Keep the pics coming....I am really looking forward to a video of your test winding.

 

Once again....Great job,

 

George,

 

 

[oldred]

Arash,

   One other thing ....that device in the milling head in the pic of your replacement piece......Is that an edge finder....it looks different than the ones we use in the US.

Thanks again,

 

George,

[Arash]

8 hours ago, oldred said:

Arash,

I am really enjoying seeing your progress.

As far as the broken tap....Here in the USA ...in the machine building trade.... our saying for broken taps ....is ....(Shit happens)......and it has happened to all of us.

I have been a machine builder ever since I finished my apprenticeship in 1980.....a long .........long time ago.

Keep the pics coming....I am really looking forward to a video of your test winding.

 

Once again....Great job,

 

George,

 

 

 

George,

Thanks for your motivation. Yes sure sh!t happens!

Oh man you were a machine builder before I was even born!

Thanks again

 

Arash,

[Arash]

8 hours ago, oldred said:

Arash,

   One other thing ....that device in the milling head in the pic of your replacement piece......Is that an edge finder....it looks different than the ones we use in the US.

Thanks again,

 

George,

 

that's right. it's an edge finder. we also call it "wiggler".

[Arash]

the ball-screw was installed:

 

 

and it looks like this:

 

 

we are gonna build the feedscrew of tailstock bearings:

 

 

the ball-screw feeding mechanism turned out to be very accurate. it works flawlessly you can see in this short clip:

 

 

[CECAA850]

It's progressing nicely and quickly as well.

[Arash]

the electro motor was installed:

 

 

the tailstock was painted and installed:

 

 

we also built some of there rollers for wire tensioner:

 

 

the tailstock feeder screw parts are also installed and the pneumatic jack is in its place:

 

 

 

mechanical part of the project is almost completed. the wire tensioner is yet to be built. you can see how tailstock feeder works in action:

 

 

 

[Woofers and Tweeters]

I like that vise

 

[Woofers and Tweeters]

Nice job on the wire winder.

To share with you what I do, when I can, to make a motor mount. 

1) I try to not hang in, and if I have to, I hang the mounting plate low enough to still put the motor on top of the plate

2) I make a hinge mount so that I only have to worry about belt alignment one time, belt maintenance is simplified