Coil Winding Machine

thingiverse

Here are the parts for my coil winding machine. I haven't developed it further for many months now, but I hope somebody might get some inspiration from the design. The main winding motor is an L293D-driven servo motor with electronics removed. A linear guide has a NEMA 11 stepper that drives the wire, powered by a standard pololu stepper driver. The wire length counter relies on a QTR-1A reflectance sensor at https://www.pololu.com/product/2458. The same reflectance sensor is used for the winding turn counter, which is an RC version converted to analog. A different resistor requires adjusting the analog values in the code when using original pololu sensors. White tape reflects IR light on a strip, with 4 on the wire length counter. A standard 16*2 LCD displays options and progress, while settings are entered with a rotary encoder. The main processor is an Arduino Pro Mini, with all connections available from the Arduino code (.ino file). Less common ball bearings include two 626ZZ and a tiny one with a 4mm inner diameter and 8mm outer diameter on the wire guiding/length counter wheel. The code is still in its early stages, coded with just enough precision to wind axial flux alternator coils reasonably well.