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DIY Voice Coil Winding Machine
DIY Voice Coil Winding Machine
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Old 23rd March 2018, 02:51 AM   #1
ghemml is offline ghemml  Singapore
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Default CNC Winding Machine

A CNC Winding Machine using Arduino Mega as the Microcontroller and Microsoft Visual Basic for the User Interface


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Microcontroller: Arduino Mega
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PIN Assignment

Winder Stepper Motor Driver Pin:
Stp = 7
Dir = 8

Feeder Stepper Motor Driver Pin:
Stp = 3
Dir = 4

Microstepping for Winder:
ms1 = 5;
ms2 = 6;
ms3 = 9;

Microstepping for Feeder:
ms1 = 10;
ms2 = 11;
ms3 = 12;

Enable SW for Stepper Motor:
Winder EN = 2;
Feeder EN = 13;

Limit switch:
L_SW = 44;
R_SW = 45;

E-Stop Switch:
E_Stop = 46;

Analog Buttons:
Left_Button = A0;
Right_Button = A1;
Winder_DisableButton = A2;
Feeder_DisableButton = A3;
Speed_Pot = A5;

Probably DUE will have more digital PINs compared to MEGA. And all the analog pins except for the speed pot can be reassigned to digital pins on a Arduino Due.
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Share drive downloadable contain:

-Codes and executable
-Part Lists
-AutoCAD Files(dwg)

CNC Winding Machine Shield - Google Drive
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User Interface(Visual Basic): Executable file "Winding Machine GUI.exe"

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Version 1 - Stepper Motor
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Version 2 - Closed Loop Hybrid Motor
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TMC2208 Stepper Motor Driver
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DRV8825 Stepper Motor Driver
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Parts:


Nema 23 Stepper Motor NEMA 23 CNC Stepper motor 57x82mm 3A 2.2N.m D=8mm 6.35mm 315Oz in Nema23 CNC Router Engraving milling machine 3D printer-in Stepper Motor from Home Improvement on Aliexpress.com | Alibaba Group

Proximity Sensor Switch Inductive Switches M12 4mm DC 5V NPN NO LJ12A3 4 Z/BX 5V Inductive Proximity Sensor Switch Inductive Switches-in Switches from Lights & Lighting on Aliexpress.com | Alibaba Group

ER25 or ER32 collet Motor shaft Chuck - 12mm bore ER20 collet Motor shaft Chuck ER ER11 ER16 ER25 ER32 spindle Extension Rod tool holder CNC Milling drill chuck B10 12 18 JT2 6-in Milling Cutter from Tools on Aliexpress.com | Alibaba Group

M8 60mm Clamping Lever M8 16mm to 60mm Clamping Lever Machinery Adjustable Handle Locking External Male Thread Knob Hex Screws Tools Accessory-in Screws from Home Improvement on Aliexpress.com | Alibaba Group

SFU1204 400mm rolled ball screw https://www.aliexpress.com/item/SFU1204-200-250-300-350-400-450-500-550-600mm-rolled-ball-screw-C7-with-1204/32677353331.html

New linear guide rail HGR20CC https://www.aliexpress.com/item/Free-shipping-new-linear-guide-rail-HGR20-400mm-long-with-1pcs-linear-block-carriage-HGH20CA-HGH20/32825473369.html

10-20pcs/lot M5*L(10-35) +8 stainless steel 304 hex socket spacer standoffs - 25mm https://www.aliexpress.com/item/10-20pcs-lot-M5-L-10-35-8-stainless-steel-304-hex-socket-spacer-standoffs-male/32841917721.html

SCS10UU Linear Ball Bearing Block https://www.aliexpress.com/item/4pcs-lot-Free-shipping-SC8UU-SCS8UU-8mm-Linear-Ball-Bearing-Block-CNC-Router/32318993714.html



Sliding V-groove nylon pulleys https://www.aliexpress.com/item/Sliding-V-groove-nylon-rollers-pulleys-wheels-626zz-bearing-bore-6mm-and-Applicable-angle-V-groove/32853711067.html

300mm Digital Linear Readout Scale Ruler https://www.aliexpress.com/item/300mm-200mm-Digital-Linear-Readout-Scale-Ruler-Vertical-Horizontal-scale-Magnetic-Remote-External-Display-Ruler-Machine/32948847385.html

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Last edited by ghemml; 12th July 2019 at 08:48 AM.
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Old 24th March 2018, 08:06 AM   #2
K.A.B is offline K.A.B  Sweden
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Nice i got some broken hard to get drivers hows need repair, I see in the link it need some nozzels here, in fly tying are some tools you can convert, See my link Fly Tying Bobbin / Super-Smooth Bobbins -- Orvis there are cheaper to buy

Anders

Last edited by K.A.B; 24th March 2018 at 08:09 AM.
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Old 24th March 2018, 08:45 AM   #3
simon7000 is offline simon7000  United States
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Normally to get a good wind you want the wire feed tension point to be thirty times the wind diameter away from the coil form edge or more.
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Old 25th March 2018, 05:20 AM   #4
ghemml is offline ghemml  Singapore
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Quote:
Originally Posted by K.A.B View Post
Nice i got some broken hard to get drivers hows need repair, I see in the link it need some nozzels here, in fly tying are some tools you can convert, See my link Fly Tying Bobbin / Super-Smooth Bobbins -- Orvis there are cheaper to buy

Anders
Looks interesting, worth a try since they are not super expensive, and I also found this while doing some research online

Low cost mechanical wire tensioners for coil winding machines




Quote:
Originally Posted by simon7000 View Post
Normally to get a good wind you want the wire feed tension point to be thirty times the wind diameter away from the coil form edge or more.
Yeah, will keep that in mind making the wire guide adjustable. And as for the wire tension, I planning to use this as a solution:

MTB-03 Wire Coiling Binding Machine Torque Controller Mechanical Tension | eBay

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I did bought some 10mm and 22mm V-Grove pulley for the feeder
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Last edited by ghemml; 25th March 2018 at 05:32 AM.
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Old 25th March 2018, 05:22 AM   #5
ghemml is offline ghemml  Singapore
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Some ideas I been exploring to make the wire guide modular, like interchangeable for thicker wire gauge

Thin wire 0.05 to 0.5
DIY Voice Coil Winding Machine


1mm and above(Mainly for winding electromagnet)
DIY Voice Coil Winding Machine
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Old 7th August 2018, 04:04 AM   #6
ghemml is offline ghemml  Singapore
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Some updates on the winding machine clone built.



Still have quite a few stuff still pending fabrication. But the mind winder is completed, but need to cut down the linear shaft to a proper length.
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Old 24th September 2018, 10:12 AM   #7
Gadgety is offline Gadgety
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Thank ou ghemml for publishing this. Really interesting!
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Old 24th September 2018, 11:37 AM   #8
JMFahey is offline JMFahey  Argentina
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Location: Buenos Aires - Argentina
I wind my own voice coils and built a dedicated variable diameter bobbin former holder which I insert in my regular transformer winding machine, but since voice coils are just 2 layers and typically around 100 turns only, I just hand guide and tension them.
Way faster than you imagine and very precise, because I guide wire from far away, as suggested above, and just provide some sideways tension, no need for an advance screw since wire "self accomodates" against the previously wound one.

Just be careful on the first turn and then it self guides.

Winding machine itself is only half the problem, you need variable diameter/expansible form holders or you will never be able to pull the wound coil smoothly out of it.

You will also need to solve the wire adhesive problem.

Nowadays you have many solutions, usually dry adhesive precoated wire, which you either activate with heat or wiping it with a mild solvent (alcohol), I have been doing this for decades and still use the messy old "wet wire winding" system, since precoated wires simply did not exist and today getting them into Argentina is a mess, so .....
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Old 17th October 2018, 05:47 AM   #9
ghemml is offline ghemml  Singapore
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I using self-bonding enamel wire with a Nichrome wire are heating agent, then pre-coated again



Off shelf winding machine doesn't suits my need which I need easy changing from voice coil winding to field coil winding.


It is more fun to design and build your own, give me more flexibility in capability expansion for future.
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Old 1st February 2019, 12:58 PM   #10
ghemml is offline ghemml  Singapore
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Some updates to the winding machine that I building
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