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Old 11th January 2012, 04:29 PM   #1
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Default Winding transformers using a flangeless bobbin

Hi,

in another tread there was a link to C-cores by Alpha Core. They also sell rectangular phenolic tubes fitting to their cores. But I'm wondering how one manages winding the second etc. layer without seeing the magnet wire falling off the edges? What's the secret?

Best regards!
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Old 11th January 2012, 04:44 PM   #2
djQUAN is offline djQUAN  Philippines
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there is a step by step picture of winding a transformer in here:
Practical Transformer Winding

although the example was a huge 10kVA transformer.
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Old 11th January 2012, 11:47 PM   #3
AJT is offline AJT  Philippines
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Quote:
Originally Posted by Kay Pirinha View Post
Hi,

in another tread there was a link to C-cores by Alpha Core. They also sell rectangular phenolic tubes fitting to their cores. But I'm wondering how one manages winding the second etc. layer without seeing the magnet wire falling off the edges? What's the secret?

Best regards!
no secret, just give some clearance to the edge say 2mm at least......using a thins sheet of fish paper or Mylar for inter-layer insulation....
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Old 15th January 2012, 02:05 PM   #4
tvrgeek is offline tvrgeek  United States
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Temporary flanges protected with wax paper, so you can slop on some varnish as you wind it up to hold everything nice and vibration free. My method, others may have different views.
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Old 15th January 2012, 06:08 PM   #5
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djQ: Thanks for the link, very good! E
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Old 15th January 2012, 09:35 PM   #6
pski is offline pski  United States
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Quote:
Originally Posted by djQUAN View Post
there is a step by step picture of winding a transformer in here:
Practical Transformer Winding

although the example was a huge 10kVA transformer.
As the previous user of a three phase 10kVA UPS, huge doesn't come close. The word is also DENSE and heavy as hell. <Then you add the batteries.>

p
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Old 15th January 2012, 10:10 PM   #7
AJT is offline AJT  Philippines
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before the advent of plastic formed bobbins, i used to wind traffo coils rhis way:

Click the image to open in full size.
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Old 16th January 2012, 05:11 PM   #8
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Very good looking, Tony!

But how did you avoid the wire's falling off the edges? Did you increase the clearance from layer to layer? And how did you fix the terminal endings?

Best regards!
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Old 16th January 2012, 10:34 PM   #9
AJT is offline AJT  Philippines
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Quote:
Originally Posted by Kay Pirinha View Post
Very good looking, Tony!

But how did you avoid the wire's falling off the edges? Did you increase the clearance from layer to layer? And how did you fix the terminal endings?

Best regards!

i try to get he same winding width from layer to layer, the ends are fixed with tapes, for smaller gauge wires, this is not hard to do and tape is sensually not needed.....

Click the image to open in full size.

please look here: http://www.diyaudio.com/forums/power...ffo-build.html
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