Automatic Coil Winding Machine

Update 2/24/2022: I've uploaded the STL files for the machine. Note that not all of these parts are used in the final iteration and I didn't sort them yet
www.thingiverse.com/thing:526...
Update 1/17/2022: Schematics and code are linked below. Currently I only have the values for 26 AWG in the code so you'll have to extrapolate for other wire gauges
drive.google.com/file/d/16xQJ...
drive.google.com/file/d/1ZFmo...
In this video I'll show how i made a machine to automate the process of coil winding. It can be used for electromagnets, tesla coils, loopstick antennas, transformers, generator coils or indcutive chokes - all things I use a lot of.
Code, Schematics, STLs:
I'm still making a few tweaks. Check back in a few days and I'll update this field with links to all of these.
Hardware:
-3A / 12V Wall wart with 5.5mm barrel jack
-A4988 Stepper Motor Drivers
-NEMA17 Stepper Motors
-3d printer leadscrew (8mm pitch?)
-20mm V-slotted rail
-M5 screws + T-nuts for railing
-M3 screws for motor mounts / set screws
-16x2 LCD with I2C bus driver
-LM7805 For logic supply
-ATMega328P-PU as the brain
Music:
Kevin MacLeod - George Street Shuffle
Serge Pavkin - Tech Research
Serge Pavkin - Futuristic Documentary

[@HyperspacePirate]

I've added links to code & schematics in the description

[@_Aryan98]

But code is not upload in arduino uno at mega 328 p

[@HyperspacePirate]

​@@_Aryan98 If you're using the Atmega 328p chip without the arduino you need to burn the bootloader first and use Tools -> Board -> breadboard avr -> ATMega328 on a breadboard (8 MHz internal clock). Also check that you're giving the chip 5V and make sure its ground pin is tied to the ground of the arduino you're using to upload code

[@shawncalderon4950]

You are brilliant!

[@boulos007]

The issue you tried to solve with limit switches is what we call in yarn winding "lip breaking". the reason is simple : as you lay one layer over the other, the motor basically stops to reverse, which automatically means that it lays x2 on the particular point. Also the speed of the winding affects it because the motor basically never stops on the spot (even with high end servos). The solution is to break the speed a couple of mm before the ends and to implement the lip breaking : you lay a couple of layers at full length and then others at length - x . The number of winds on full and those on full-x need to be programmable

[@kekunfica]

I made a similar winder but for textile threads, I solved this issue by speeding up the follower/guide when it comes within few mm of the edge to almost the double speed. Also one other factor that probably helped is that I made guide part as light as possible and left the motor at full step mode so it can change direction faster without losing steps. It needs a bit of tweaking with the speed but its easy to calibrate.

[@artbyrobot1]

I am blown away by your channel. You are doing such a great job on these videos. I appreciate what you are doing here and am learning alot!

[@Mikhael1313]

Very insightful and creative as usual, and I like how you come up with creative solutions to achieve desired outcome. One thing I might suggest is that the wire that is being fed to the winder needs more tension points (ex. wires go around pully gears with spring tension), and the Feedpoint should have a tension of sorts which presses the wire down or up depending on the vertical height difference between the Spool and Feedpoint.

[@alocin110]

I have been watching your videos for few weeks. I accidently hit your channel but I am glad I did. Your videos are very inspiring, real world design, and well explained. You are a true engineer who knows how to implement ideas into workable results. Thank you very much for the details, schematic, and explanations on solving the issues. Great teaching skills you have. I watched it with great interest. Thank you for sharing. I liked your channel and also subscribed to it.

[@ChiefBridgeFuser]

I find myself needing a solenoid winder, sort of like you've done here. Thanks for the ideas!

[@Meccanokinematics]

Great vid. If you want to avoid any electrical noise by your stepper motors don't use A4988 or DRV8825 drivers, but TMC drivers, like TMC 2226. These are socalled silent steppers. After substituting my DRV drivers by silentsteppers I was absolutely astonished! Steppermotors were silent. No vibrations either whatsoever. Philips has written a very interesting paper about orthocyclic coil winding in the early 60's. They were able to make perfect orthocyclic coils after more than 2 years of research. If you want I can mail the paper to you.

[@LilBigDude28]

Definitely needed one of these. Thanks for the files.

[@anthonybaransky137]

All I can say is WOW. I used to work in a cable manufacturing company and I ran a machine like you built but the machine that I ran could take up to an 84" spool. And the had rewinder machines that could run a 10' spool

[@nerddub]

Aweosme project! Looks like you could improve the compactness of the coils maybe by replacing / modifying the sliding mechanism with a linear rail or a carriage with v-slot wheels and maybe adding a wire tensioning system, the motion of the wire outlet moving down the track looks pretty wobbly, but for ease of use and ability to make many different kinds of coiis within your frame, this is great!

[@PrinceAlhorian]

A must have for building a DIY Gauss Cannon

[@nigelhungerford-symes5059]

Nice build and great explanatory video

[@gfr2023]

9:40 you have to look at textile machinery to find the simple solution for correct wire alignment. Yes the feed point must be near the bobbin you are winding but the spool from which the wire come from must be offset aside from the feed point. basically you want the wire touch always the same edge of the hole. If not the wire will go left and right random. Tensioning the wire is very simple and precise if you copy design from textile machinery, your method does not guarantee constant tension because the spool changes diameter as the wire is consumed.

[@vobinhthu5299]

This project is very good!

[@txkflier]

Excellent work. It could very easily be adapted to winding guitar pickups. However, uniform-wound pickups have more distributed capacitance due to the wraps of wire being mostly parallel to each other. To decrease the distributed capacitance, the wraps need to be laid down randomly. The stepper motor that moves the wire guide could be programmed to do that. Or, it could just be sped up so that each wrap is further away from the previous wrap.

[@wtechboy18]

I have a suggestion! Instead of using a fixed clamped feed point, what about using a free-swinging feed arm that has a tiny roller on the end, so that the feed point is always basically sitting directly on the surface of the existing coil and just "rolls" against the surface? You could have your feed distance be almost zero with that setup.

[@greatdane3343]

Cool build. Thanks for sharing.

[@colbyjohnson2344]

This would pair nicely with my litz wire machine. I would love to make something like this

[@whatelseison8970]

This is awesome! I've been wanting to build one of these for some time now. Lately I've come into quite a few nice little steppers from label printing machines I found so I've started gathering supplies and thinking of a design for a sort of general purpose desktop CNC rig for laser, router and hopefully 3D printing but I may just have to take the plunge and buy a commercial rig for the latter. Regarding this thing though, you might be able to get even better performance and open up the possibility of using less-than-pristine magnet wire if you use a wire guide based on a series of brass V pulleys arranged in 2 rows with the wire zig-zagging between them. With a 90 degree V in the pulleys the arrangement naturally straightens the wire in both transverse axes simultaneously and can even be driven to precisely regulate the wire speed regardless of the upstream tension. I've been messing around with using that method just to straighten salvaged wire (seriously, who _buys_ wire? lol 😜) with good results.

[@beautifulsmall]

Thats alot of 3D printing, looking to make something similar . Love the channel.

[@elyaabe.inventions]

Excellent invention👍👍👍👍👍👍👍👍💪💪💪💪✅✅✅✅✅✅✅✅✅✅❤❤❤❤❤❤❤❤❤❤

[@Edmorbus]

Thanks for sharing

[@amosdecarmo5970]

Sorry to bother you Hyperspace Pirate But ,I am Having a senior moment here. I have down loaded your code & schematic and at a quick look over the pinout on the code does not match the schematic.

[@estebanamaya4523]

Great video! I want to make one myself. How did you manage the different diameter each time the coiling started another layer??

[@simonlaker2139]

One other thing. The actual gauge of wire isn't the end size . The enamel can add a hole gauge.

[@typewriteraudio]

This is awesome

[@RicardoGarcia-fx6qp]

Nice job, You are doing such a great job on these videos, do you have the final code? is not working on the board

[@der_pickelhauber]

Hello sir, great engineering! I want to build your machine at home but a few .stl files from the final version are missing :( Are you going to upload them? Or did I just overseeing them ? Greetings from Germany 🇩🇪

[@darrenglynn597]

I am very impressed with your design. How much would it cost to make as i would like to make my own transformers and chokes and high frequency transformers for repairing switch mode voltage power packs.

[@jefferyswan4401]

@Hyperspace Pirate - Awesome project! I built one with a few modifications but would like to tweek on the 3D files some. Is there a chance you would be willing to send a set of STEP files?

[@CuriousChan]

How I wish I have a 3D printer😭 Just kidding, you have an awesome build there😄

[@yanculacount234]

Very nice. What are the dimensions for the threaded rod for follower?

[@yuribiktop6595]

Nice job mate! , Should we have the link where to purchase the exact hardware?

[@miriamramstudio3982]

Looks like the follower is not going fast enough (timestamp 10:52+). The Angle theta is clearly increasing overtime in both direction (easier to see with video playing at x2). It could be an idea to check the calibration of the follower axis. Just my 2 cents. Great video. Thanks

[@matt759537]

hey great video and build! im looking to try building this myself and am wondering how long are the 2020 rails and what size the bearings are?:O

[@tomhague1162]

Glad I stumbled on your video. Am presently working on the exact same project. You have answered many of the problems I have been having. One question, You added limit switches but they are not in your schematic or code. Were they tied into the jog buttons or do they have their own inputs and code? Great Job.

[@theodoreroberts3407]

I'd like to see your plans. I have much bigger coils to make.

[@mehdighazavi2424]

Thanks

[@GaryMcKinnonUFO]

Additionally, the new loop wants to sit in between the 2 loops below it rather than being right on top of one of them.

[@splendensregan5270]

How about building a machine that cuts, strips and bends wires into various lengths for on-demand use on breadboards?

[@medaturbo9899]

Thank You

[@chinosts]

Ummm... Your channel is awesome.. Thats all I wanted to say :)

[@simonlaker2139]

Generally the winding machines I've worked on don't use the spool weight to get the tension. They stand upright and de-spool from the top through a cone /funnel. The wire then goes through two rollers. First the wire goes around 420 deg (over one turn and comes out at 90 deg from entry point) This is the tensioner roller that has a felt pad at the end that is tightened for appropriate tension. Wire leaves at 90 deg from entry. Then goes up to second roller, does a 90 deg turn, then goes through a v roller. This keeps it center of the moving carriage.

[@HyperspacePirate]

I'll probably end up with a setup similar to that whenever i upgrade this thing

[@szekerespista3758]

Good work! I am interested to buy a winding machine!

[@marlonglodo1930]

hello sir i love your design quite simple, but the stepper driver not include in the code

[@tsclly2377]

A tesla winding automated: Tesla coil winding machine - powered by Arduino Nano Kaj Luukko Now.. I's get a Mini Lathe and automate it.. and you have to calculate the wire stepping into the 'groove', perhaps at the end having 'soft(er)' foam rubber [paper] ends.. and slowing down the winding process (, also with an inspection camera set to spot the jump; 4 core Raspberry Pi) I think you have to much backlash on your screw - spring tension it. (An automatic lacquer brush.. LoL) Well, one step at a time according to need ... Good show.. I couldn't determine if your coil holder came apart....

[@ccicyou]

Any chance of releasing the SLT files?

[@Jkauppa]

try a belt wind making machine, yes the wind that is created between two friction surfaces, fins or just plain surface friction

[@francisaryeetey3896]

hello Sir, Please where do i get all these materials for a project work

[@primorec17]

hi, nice videos. well done, nice projects :D! WIll you ever do a video about bifilar coils how to make them ?? PLEASE

[@albertalbert4747]

Hi. Can I ask for a diagram with two stepper motors? The video shows the wrong year :)

[@aramisdamasceno8692]

montei o circuito do jeito que manda no projeto, ta tudo funcionando mais so tive um problema as teclas de mover a guia jog_left jog_right não estar funcionando, ta faltando comentar algo no codigo do arduino ?

[@wesleyfish6635]

Can this setup be used with a Arduino mega 2560, Ive been been trying to learn Arduino to build just such a coil winder for some other projects, learning curve is steep if your not a programmer..

[@HyperspacePirate]

Yes, but i think a few of the pinouts might be different

[@L3X369]

Why not put the foam pads in the wire follower? this way the wire is always a bit tensioned on the coil that is being winded.

[@alanlautenslager7141]

Found most of pins but it looks like pin 4 is used twice? Once for enter button and once for left limit switch. Also schematic for first version is shown for using Mosfets and one A4988 driver board? Thank you.

[@ranulfo102]

AMIGO, PRIMEIRO QUE TUDO, MEUS PARABÉNS PELO BELO TRABALHO, E EM SEGUNDO LUGAR, OBRIGADO POR DISPONIBILIZAR UM PROJETO TÃO FANTÁSTICO E FUNCIONAL. A MINHA PERGUNTA É, POSSO UTILIZAR UM ARDUINO UNO NESSE PROJETO ? TERIA QUE MODIFICAR MUITA COISA ? OBRIGADO MESMO. FRIEND, FIRST OF ALL, CONGRATULATIONS ON THE BEAUTIFUL JOB, AND SECONDLY, THANKS FOR MAKING SUCH A FANTASTIC AND FUNCTIONAL PROJECT AVAILABLE. MY QUESTION IS, CAN I USE AN ARDUINO UNO IN THIS PROJECT? WOULD YOU HAVE TO CHANGE A LOT OF THINGS? THANK YOU SO.

[@dianac.1430]

ola amigo voce tem o codigo nao consigo baixar esse codigo ficarei grato se puder me passar

[@ranulfo102]

meu rei, mande seu e-mail ai te envio o código e o diagrama

[@marlonglodo1930]

and sir one more thing.. how to show in the screen the number of counts while in progress, thank you

[@primescienceprojects]

My setup is always skipping "position wire guide" and goes directly to starting winding. What is the problem? Please guide me

[@ewaldikemann4142]

Noice! But 5:56 : LCD Display?

[@gabrielwhite99]

How long are the extrusions and rods?

[@pranavramesh4888]

This would be REALLY useful for making Tesla coil, decreases the work by at least 10 times

[@HyperspacePirate]

Yeah, it could wind a Tesla coil in under 10 minutes

[@ccicyou]

How about the STLs?

[@alanlautenslager7141]

Hopefully you are monitoring this. I would like to build the Automatic Coil Winding machine. In looking at the Arduino code it seems to not match the pinout on the Arduino chip and also regarding the limit switches. What pins do they connect to on the Arduino chip. Thank you very much.

[@RUDY3098]

i made the coil wind that you described i uploaded it to the Arduino and cross reference the atmega to the nano. everything works as it should even the display the only trouble i am having is the jog buttons don't work and i can not enter the width of the coil it only displays mm ok then it ask me to center my wire feeder. Is there something turned off in the code. Thanks Rudy Subscribed in Florida.

[@HyperspacePirate]

If you can email me some pictures i might be able to figure it out

[@VAY01]

hello, did you fix the problem with buttons, i have same problem, only PIN D4 works for OK....

[@RUDY3098]

@@VAY01 He sent me a new code for something else but the jog buttons I still cannot get to work. So I use it as is .

[@_Aryan98]

Can pic16F882 be used to make automatic coil winding machine ?

[@HyperspacePirate]

I don't see why not. It's a microcontroller just like the Atmega328 in an arduino.

[@antoniostahl1995]

@HyperspacePirate hi you may have fix this in your newer videos but sometime you mic peek, at 5:26 the mic peek plz fix that in post, thx btw u make g8 videos keep it up!

[@caykendr]

Hello, my name is Cayke, your work is fantastic, and it caught my attention. I still don't understand much about programming, but from the analysis parameter I noticed that the source code of the Arduino circuit does not correspond to the download, the programming is different from the demonstration video... could you help me???

[@MrSailbadthesinner]

I just use a lathe, It will make the bobbins and wind them. The Victorians knew how to make coils!

[@nguyenvanlong7419]

Can you give me the code for your DC motor and stepper motor?

[@moazzemkhan245]

hello sir folower stepper not working please help me

[@rogerbrowne5514]

It must be nice to have that kind of money.

[@nguyenvanlong7419]

Hi. i am from vietnam, can you tell me the name of the dc motor you use in the terminal

[@HyperspacePirate]

www.amazon.com/Greartisan-Electric-Reduction-Eccentric-Diameter/dp/B0721T1PXQ/

[@nguyenvanlong7419]

@@HyperspacePirate i thank you...it helps me a lot

[@HyperspacePirate]

@@nguyenvanlong7419 www.amazon.com/Greartisan-Electric-Reduction-Centric-Diameter/dp/B072R57C56/ try this one if you need the concentric shaft one

[@_Aryan98]

Sir automatic change direction don't use jog button

[@tomhague1162]

Found the limit switches in code but now another problem. I could be totally wrong as my coding skills are limited but in the code is pin 4 shared by both the ent button and the left limit switch or am I missing something in translation?

[@manblack7131]

Hello, i downloaded the stl files but there doesn't seem to be one for the stepper motor mount you made to replace the DC motor. could you please add it to the files for this project. Thank You. John

[@diydancochran]

would you have a updated 2 stepper version ready to go code for arduino

[@diydancochran]

never mind, I see what went on, the pin chart posted in description threw me off with one stepper,, But I do see the code is setup for 2 :) ty.

[@nabshear]

Anyone know how I get ahold of this guy? I would like the plans to this machine so I can build my transformer coils

[@_Aryan98]

Coil winder code not uploaded

[@abdulrahmanahmed4870]

What weight is this project?

[@y.rsuwandi4674]

Can you teach me how to make ignition coil for motor bike

[@adityaputranto8981]

HELLO I WOULD LIKE TO ASK THE VALUE OF THE BYTE OF WIRE_step_divisor[] .. THANKS MR

[@lukmandychannel6417]

Program sudah saya gunakan code arduino sudah saya kerjakan sesuai video dan sketch nya,kenapa waktu dinyalakan motor running sebelum disetting?

[@ashleyehle3382]

How TF does this man not have 1k subs yet smh

[@HyperspacePirate]

2 short, lol

[@pendulummotion112]

I want this project, can you help me

[@moazzemkhan245]

folower stepper not working

[@jasonellard3432]

Would you build one for sale?

[@bengagliano7415]

can the atmega328p be replaced by an arduino uno r3?

[@AnalogDude_]

Yep, changing / adapting the pin config or use the 32bit Microchip Fubarino witch is compatible with Arduino IDE.

[@channeltech1857]

Can you Please add the code and schematic

[@HyperspacePirate]

updated the description with links to both

[@adamw2785]

How hard would it be to modify so that it could wind and cut a shape of copper wire called "spiral prismatic packing"? It's like a coil, but instead of a circle it's triangular, and that triangle slowly rotates as you move down the coil, but I think this rotation happens naturally when the cut pieces are removed from the die, due to the springiness of the wire. Probably not explaining it right, google images should help explain it better. A tool like that would be super helpful in the hobby distilling world, where copper SPP (used for fractionating column packing) is expensive and overpriced.

[@bhallfdx12345]

code is no longer available for download

[@_Aryan98]

sir i want to make automatic coil winding machine from arduino uno + cnc shield how to make and where to get the code can you give

[@_Aryan98]

Please upload video please

[@HyperspacePirate]

@@_Aryan98 The code and schematics are in the video description

[@RasTona_]

Have u tried slowing down the RPM when u reach the ends and start a new layer? If the there’s a double wined the rest will start building on one imperfection. Think of a 3d printer if one layer is messed up…..

[@SquishyThing]

When I was younger I pretty much gave up at electronics because of fake chips. At the time I didn't even know I'd received fakes but none of the circuits I tried to make worked, ever. The 1st one I made worked okay and I blew up a MOSFET. Then after that the rest were fakes and wouldn't even work. Even though nothing else had changed in the circuit. Eventually just gave up and my passion for electronics slowly faded

[@HyperspacePirate]

That's why i get any kind of semiconductor product from a legitimate vendor like DigiKey/Mouser etc. Amazon/eBay chips/transistors/diodes are almost guaranteed to be fakes.

[@GuildOfCalamity]

...rail gun in the future?

[@chrisfuller1268]

Cool, I've wound coils by hand, but hate cross-threading. How about an automated toroidal winder!? I think they wind like a sewing machine? Rectangular toroids are the worst!

[@curiousviewer5991]

Hm. A magnet put into a copper pipe will slowly fall due to induction. If you make the pipe an electromagnet and turn it on while the magnet is falling I'm guessing the magnet will either shoot out faster at the bottom or be repelled out the top depending on the direction of the magnetic field? I don't recall anyone doing a video on that.

[@danielb.2873]

That's essentially the working principle of a Gauss cannon.

[@danielb.2873]

en.wikipedia.org/wiki/Coilgun

[@curiousviewer5991]

@@danielb.2873 I was thinking more in terms of controlling the speed up/down like an elevator not super acceleration horizontally.

[@szekerespista3758]

Hello

[@aramisdamasceno8692]

estrela

[@glasslinger]

Have you ever tried simply feeding that size wire by hand? It will be as easy, and give exactly the same coil result as you are now getting without all the complication. The first thing to do is DISMANTLE SOME OLD TRANSFORMERS! This will give you an idea on what is REQUIRED to get an even wind. (separator paper layers are MANDATORY for multi-layer coils with even lay. Use fine wire (#30 or smaller) in your tests. This is MUCH more difficult to wind than the huge wire you are now using. Also look at the design of professional coil winders. (US patent office) The way you are currently trying will end in frustration and piles of junked parts! (been there done that!)

[@stg9210]

Das Ergebnis ist bescheiden. Ohne mechanische Drahtbehandlung (richten, spannen) wird das auch nicht besser.