Toroid winding cheat

torroid-winding-cheat

When you need a toroid the easiest source is often to wind it yourself. The problem being that placing a few hundred windings around a ferrite ring is a real drag, especially if you have to make several of them. This cheat developed by [Jim W.] will save a lot of time. He cuts the ring in half for the winding and reassembles it afterward.

Here you can see that he has half of the core mounted in a drill chuck. To get to this point he scored the ferrite before clamping half in a vice and whacking the extruding half with a block of wood and a hammer. He hasn’t found a perfect solution for scoring the material (a utility knife or a triangular file both work but have drawbacks). Leave a comment if you’ve got any bright ideas.

Once the core is in two pieces he used some copper pipe with one end flattened and bent to the shape of the ring segment. With it hot glued in place he takes it for a spin (shown in the clip after the break). Once the windings are done a bit of super glue recombines the halves. This sort of thing is great for monitoring power use.

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Homemade toroid winder

toroid_winder_172

[eclipsed78], built an automatic toroid winder. The drum splits in order to load the toroid. Then wire is wound on the drum, much like any other coil would be wound. The drum rotates as a slider pulls the wire off the drum, while revolving in and out of the toroid. A side tension keeps the slack out of the wire during operation. The winding coil is stepped as the drum rotates, in order to control the turns ratio. [eclipsed78] created a stepper driver from a schematic, so he could drive the motors. You can watch the winder in operation  as a series of videos. The first of which is embedded below. If you have ever needed to wind a massive toroidal transformer, this is the project for you. Continue reading “Homemade toroid winder”