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Winding coils for motors, transformers, inductors, and chokes requires the usage of electrical coil winding equipment. Applications like wire winding, wire welding, and wire bonding all use coil winding machinery.

I made a coil winding machine at home for this instructable. The machine is incredibly easy to construct and does the wire winding task practically perfectly.

Construction 

• Take some cardboard that is approximately 8 by 5 inches.
• Cut the cardboard as illustrated in the image above using a stationary knife.
• The cardboard H features a centre piece that is about 1.5 inches long.
• Mark the points and position the bearing at the top of the side parts.
• Create holes at the indicated locations that are the same size as the bearing.
• Place the bearing in the holes and glue it in place.
• Create two side walls with such identical components.

Prepare Base Platform

• Take a piece of cardboard that is about 9 by 8 inches.
• Cut 4 pieces of cardboard that are around 2 by 1.5 inches.
• Attach two pieces to the cardboard base’s two corners with super glue.
• Hot glue the side wall (with bearings) into position in the middle of the smaller parts. (See the picture above)
• Place the other two smaller cardboard pieces at the platform’s remaining corners.
• The other side wall should be positioned in the middle of the cardboard pieces.
• Super glue is used to affix the side wall to the cardboard corner pieces.
• Be careful not to glue the corner pieces to the platform’s foundation.

Make The Second Side Wall’s Frame

• Mark the location of the second Side wall with a pencil.
• As seen in the image above, cut two cardboard pieces into the shape of an L.
• Place the L-shaped cardboard piece on the designated position’s outer edge.
• The cardboard L-shaped shape was used to measure the length of the wooden tongue depressor.
• Attach the tongue depressor to the cardboard’s L-shaped edges using super glue.
• Make sure the tongue depressor and slit in the base of the opposite side wall can be readily slid together.
• Move on to the next stages if everything looks to be in order.

Make Rotary Mechanism

• Take two wooden sticks that are approximately 9″ long.
• To place the wooden stick in the bearing, remove the side wall.
• By applying tape on the wooden stick, you can make it thicker.
• Make sure that the bearings of the fixed side wall can accommodate both sticks.
• Because it will be challenging to remove it repeatedly after winding, the wooden sticks in the bearing of the removable side wall shouldn’t be too tight.

Prepare Electronic Components

• Consider a strong DC motor.
• Connect a little plastic pulley to the motor shaft if you have one.
• If not, then cover the motor shaft with tape.
• Carefully cut the tape with a knife so that a slit appears between the layers.
• Connect a switch and a battery to the motor as shown in the above schematic.
• For this project, a straightforward ON/OFF switch will do; however, I used a DPDT switch to regulate the motor in both directions.
• Attach the motor to one of the wooden sticks using hot glue.
• Super glue and a cardboard piece should also be used to secure the motor because hot glue will melt if the motor becomes hot.
• See the image above and copy the switch and battery holder as well.

Note:For charging the Li-ion Battery, you may also refer to my DIY -Battery Charger tutorial or watch the Video; I used the 18650 Li-ion battery because it can deliver a very high power.

Finish the Project

• Rubber bands are used to secure the motor shaft and wooden stick together so that the stick rotates along with the shaft.
• To prevent the rubber band from coming out while turning, tape the edge of the stick.
• To place the copper wire spool over one of the sticks, remove the free side wall.
• You can attach any cylindrical pipe to the other stick.
• Tape makes it simple to enhance the thickness of a wooden stick so that the pipe fits snugly.
• A black spool holder can be seen in the image. I used a 3D-printed spool holder, but any cylindrical pipe will suffice; just make sure to add thickness to the side edges with cardboard or tape to prevent the wire from coming loose from the pipe’s sides.

Test and Improvements

• As you turn the switch ON, use your hand to guide the wire along the pipe.
• A uniformly wound coil can be created by moving your hands in a to and fro motion from one end to the other.
• Apply tape after winding to keep the wire from unrevealing.

Some individuals find this machine to be quite helpful for a variety of jobs, but after using it for a time, I believe that a few changes may significantly enhance this machine.

• It will be considerably more useful if fueled by a wall adapter than than a battery.
• To regulate the motor’s speed, add a potentiometer to the circuit.
• The motor’s RPM will be reduced and the torque will be greatly increased by attaching a big pulley to the wooden stick, giving you more control during winding.

Hope all of you find this article informative. We Superkitz will be back soon with more informative blogs. Thank You Bye.