Author Topic: Coil winder  (Read 539 times)

Timber_MG

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Re: Coil winder
« Reply #15 on: December 13, 2011, 10:19:40 am »
Here a quic pic of the measurement to determine the horizontal mis-alignment of the tailstock that explains the process in far less time than text ever could. The dial indicator is attached via a magnetic base to the cross slide which I adjust to zero the reading before moving the slide table towards the tailstock to read the total misalignment.






After cleaning up the lathe ways with some 360 wet paper and Q20 for lube on a aluminium plate backer the measurements have become much more repeatable and the motion is also a little smoother. The error still hovers around 0.4mm - 0.5mm in 100mm though :-| I have to choose whether I mill/file/lap/scrape the V-ways of the tailstock base or whether I'll file away at the tailstock and shim up the difference.


Timber_MG

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Re: Coil winder
« Reply #16 on: December 14, 2011, 09:03:14 am »
I am building two of these units as the work involved doesn't change much from a single unit to building a spare.

Yesterday I bored open the bearing hole on my mill to 38 mm, drilled and tapped the bolts to take M8 bolts at either end (note to self: do not use high tensile bolts when performing machining operations on them) and finally one can see this thing taking shape.

To follow are bearing retaining plates and stepper motor mounts. I might use MDF to save on time here as the forces are very low. When painted MDF holds up surprisingly well and with some CA glue even threads can be used reliably.

The first winder I'll simply clamp to my Z-slide for the linear motion. For the second unit I am thinking of MDF and drawer slides. I have a plan to make a trapezoidal thread nut out of acetal that should have very low backlash (ball screws are used on the Z-slide). I have a steel nut and 10mm trapezoidal thread to use in the interim, but Screwman's trapezoidal thread nuts are costly and not centered well.

On to the pics:

This is the bearing plate after I opened up the hole from 25mm to 38mm:


Here I am putting a tap through the face of the bolt (faced off to mount a pulley):


This is the look from the front. A stainless M20 half nut retains the bolt and provides a shoulder for the bobbin:


This is the end where the stepper will drive the spindle with a toothed belt. Stepper mounting and bearing retainer plates are to follow:


This is the view from the side:



Timber_MG

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Re: Coil winder
« Reply #17 on: January 05, 2012, 12:25:24 pm »
I have tested the stepper driver and it still works (thanks Johan for the power supply). I now only require one more bracket to fit the motors to the plate and then then I have the mechanics sorted. Unfortunately most aluminium suppliers seem to be closed still, so I'll have to wait for next week for a permanent motor mount.

What's needed now is the bobbin fixture for the first transformer to be wound on (40mmx60mm). I'll take a milling machine to an M20 bolt to make up a rudimentary tap. I have some maple off-cuts that I'll probably size, drill and tap.


Apocalypse Boy

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Re: Coil winder
« Reply #18 on: January 05, 2012, 01:24:17 pm »
I have tested the stepper driver and it still works (thanks Johan for the power supply). I now only require one more bracket to fit the motors to the plate and then then I have the mechanics sorted. Unfortunately most aluminium suppliers seem to be closed still, so I'll have to wait for next week for a permanent motor mount.

What's needed now is the bobbin fixture for the first transformer to be wound on (40mmx60mm). I'll take a milling machine to an M20 bolt to make up a rudimentary tap. I have some maple off-cuts that I'll probably size, drill and tap.

If you tell me what you nees I might be able to help

Timber_MG

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Re: Coil winder
« Reply #19 on: January 05, 2012, 01:55:36 pm »
The mount is about 40-50mm thick to fit a Nema23 Stepper motor (approx. 65mm x 65mm with a pocket and four holes either side). I don't have spare stock that size currently except if I were to canabalize squared and sized stock of another project (not going to happen as that piece is squared by hand scraping and lapping). The Aluminium traders like NFM will re-open next week I guess.