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Old 1st June 2009, 10:29 AM   #1
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Default DIY Transformer Winding

Since this a very active DIY Audio forum I would expect that here is a few guys winding their own transformers.

I would like to pose a few questions:

Any tips for a new-bee transformer winder?
What can I use to build my own winding jig? What parts are essential?
What external tools are also required?

The reason for this is that here in S Africa the price of proper audio transformers are incredible and there is no real place here that specializes in audio transformer winding. Market is too small I guess.
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Old 1st June 2009, 10:53 AM   #2
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Hi,

Yes, a few of us do actually

Here's my sloppy jig:
http://geek.scorpiorising.ca/GeeK_Zo...p?topic=3476.0

Though I now use a magnet on the wheel and a Hall-effect sensor for the counter.


All you need is something that turns at a controlled rate hooked up to something that counts and voila! Instant roller.

Cheers!
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Old 1st June 2009, 01:04 PM   #3
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I do occasional big (=lots of turns) ones on my metal turning lathe. I made a simple counter from an ICM7217 which can switch the motor off at a preset count. A photodiode "watches" a paint dot on the belt pulley.

Small coils - few enought turns to count in the head - I do on a old fashioned hand-drill, held in a vice.
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Old 1st June 2009, 01:24 PM   #4
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Thanks for the replies so far. It seems that there is no magical mysteries to winding transformers.

I saw on the RS Components site that a simple inductance meter can be bought for under $200.
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Old 1st June 2009, 01:25 PM   #5
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I use a shuttle to wind toroids -- it's a small piece of thin wood, notched at each end.

When I am checking out a transformer I use a signal generator to send a 5kHz signal in one end and measure the ratio of input/output.

I've wound quite a few SMPS transformers this way -- with mystery cores -- life is simpler if you purchase cores from Amidon because you don't have to cut and measure -- works right the first time from the equations given, and you know how much heat it will take.
Attached Images
File Type: jpg shuttle.jpg (15.3 KB, 1259 views)
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Old 1st June 2009, 01:39 PM   #6
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I should probably as if there is any literature on winding techniques of audio transformers that would be a good supplement.

I studied the Hashimoto Electric Co. website with great care trying to absorb the "greatness" of their products - he-he!!
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Old 2nd June 2009, 02:54 AM   #7
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Here's some necessary math from our member mcs:
http://stiftsbogtrykkeriet.dk/~mcs/Transformer.html

Pat Turner of Turner Audio has some super info here (scroll down):
http://www.turneraudio.com.au/education+diy.htm

I have a couple of pages here:
http://geek.scorpiorising.ca/windingtransformers.html
http://geek.scorpiorising.ca/windingchokes.html


Cheers!
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Old 2nd June 2009, 08:19 AM   #8
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Geek! Thank you for all the info. I am now reading your tutorial and it is great!

One thing I need to jog down somewhere is how to calculate the total number of windings and wire thicknesses.
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Old 2nd June 2009, 01:21 PM   #9
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If Pat Turner had a coffee machine in his basement, his wife would never see him.
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Old 6th May 2010, 10:37 AM   #10
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Hi,

I would like to wind a custom audio transformer. The following are the requirement parameters:
> Transformer Type: Audio
> Primary Impedance: 200ohm
> Secondary Impedance: 10kohm
> Turns Ratio: 1:1

How to compute the primary and secondary turns by knowing only the primary and secondary impedances ? I used the formula Xs/Xp and obtained the value as 500. Please confirm.

Best regards,
Bins.

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