Delta Printer Morphs into CNC Flat Coil Winder

Anyone who has ever wound a coil by hand has probably idly wondered “How do they do this with a machine?” at some point in the tedious process. That’s about when your attention wanders and the wire does what physics wants it to do, with the rat’s nest and cursing as a predictable result.

There’s got to be a better way, and [Russ Gries] is on his way to finding it with this proof-of-concept CNC flat coil winder. The video below is a brief overview of what came out of an intensive rapid prototyping session. [Russ] originally thought that moving the coil would be the way to go, but a friend put him onto the idea of using his delta-style 3D-printer to dispense the wire. An attachment somewhat like a drag knife was built, but with a wire feed tube and a metal roller to press the wire down onto an adhesive surface. The wire feed assembly went through a few design iterations before he discovered that a silicone cover was needed for the roller for the wire to properly track, and that the wire spool needed to be fed with as little friction as possible. Fusion 360’s CAM features were used to design the tool paths that describe the coils. It seems quite effective, and watching it lay down neat lines of magnet wire is pretty mesmerizing.

We’ve seen a couple of cylindrical coil winding rigs before, but it looks like this is the first flat coil winder we’ve featured. We can’t help but wonder about the applications. Wireless power transfer comes to mind, as do antennas and coils for RF applications. We also wonder if there are ways to use this to make printed circuit boards. Continue reading “Delta Printer Morphs into CNC Flat Coil Winder”

Snazzy Balun Lets Ham Use Off-The-Shelf Coax

It’s a dilemma many hams face: it’s easy to find yourself with a big spool of RG-11 coax cable, usually after a big cable TV wiring project. It can be tempting to use it in antenna projects, but the characteristic impedance of RG-11 is 75 Ω, whereas the ham world is geared to 50 Ω. Not willing to waste a bounty of free coax, one ham built a custom 1:1 current balun for a 75 Ω dipole.

Converting between balanced and unbalanced signals is the job of a balun, and it’s where the device derives its name. For hams, baluns are particularly useful to connect a dipole antenna, which is naturally balanced, to an unbalanced coax feedline. The balun [NV2K] built is a bifilar 1:1 design, with two parallel wires wound onto a ferrite core. To tweak the characteristic impedance to the 75 Ω needed for his antenna and feedline, [NV2K] added short lengths of Teflon insulation to one of the conductors, which is as fussy a bit of work as we’ve seen in a while. We appreciate the careful winding of the choke and the care taken to make this both mechanically and electrically sound, and not letting that RG-11 go to waste is a plus.

With as much effort as hams put into antenna design, there’s a surprising dearth of Hackaday articles on the subject. We’ve talked a bit about the Yagi-Uda antenna, and we’ve showcased a cool magnetic loop antenna, but there’s precious little about the humble dipole.

[via r/amateurradio]