Automatic Winder Takes The Drudgery Out Of Tesla Coil Builds

What is it about coil winding automation projects that’s just so captivating? Maybe it’s knowing what a labor saver they can be once you’ve got a few manually wound coils under your belt. Or perhaps it’s just the generally satisfying nature of any machine that does an exacting task smoothly and precisely. Whatever it is, this automatic Tesla coil winder has it in abundance.

According to [aa-epilectrik]’s account, the back story of this build is that while musical Tesla coils are a big part of the performance of musical group ArcAttack, they’re also cool enough in their own right to offer DIY kits for sale. This rig takes on the job of producing the coils, which at least takes some of the drudgery out of the build. There’s no build log, but there are enough details on reddit and Instagram to work out the basics. The main spindle is driven by a gearmotor while the winding carriage translates along a linear slide thanks to a stepper-driven lead screw. The spool holding the fine magnet wire needs to hold proper tension to prevent tangling; this is achieved through by applying some torque to the spool with a small DC motor.

There are some great design elements in this one, not least being the way tension is controlled by measuring the movement of an idler pulley using a linear pot. At top speed, the machine looks like it complete a coil in just about three minutes, which seems pretty reasonable with such neat results. Another interesting point: ArcAttack numbers [Anouk Wipprecht], whom we’ve featured a couple of times on these pages, among its collaborators. Small world.

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Homebrew Coil Winder Makes Toroids A Snap To Wind

Anyone who has ever wound a toroidal coil by hand can tell you that it’s not exactly a fun job. Even with the kinds of coils used in chokes and transformers for ham radio, which generally have relatively few windings, passing all that wire through the toroid time after time is a pain. And woe unto anyone who guesses wrong on how much wire the job will take.

To solve those problems, [Sandeep] came up with this clever and effective toroid winder. The idea is to pass a small spool of magnet wire through the toroid’s core while simultaneously rotating the toroid to spread the windings out as evenly as possible. That obviously requires a winding ring that can be opened up to allow the toroid form to be inserted; [Sandeep] chose to make his winding ring out of plywood with a slit in it. Carrying the wire spool, the winding ring rotates on a C-shaped fixture that brackets the toroid, which itself rotates under stepper motor control on a trio of rollers. An Arduino controls the rotation of both motors, controlling the number of windings and their spread on the form. lacking a ferrite core for testing, [Sandeep] used a plywood ring as a stand-in, but the results are satisfying enough to make any manual coil-winder envious.

We love tools like this that make a boring job a snap. Whether it’s cutting wires for wiring harnesses or winding guitar pickups, tools like these are well worth the time spent to build them. But we suppose when it comes to toroid winding, one could always cheat.

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The FilaWinder


The latest addition to the line of 3D printer accessories is the FilaWinder, a tool for winding your filament neatly onto a spool. If you’ve abandoned buying your filament by the reel in favor of making your own from cheaper pellets—such as the Lyman Extruder, the Filabot Wee, or other alternatives, including the winder’s companion product, the FilaStruder—then you’ve likely had to roll everything up by hand, perhaps after it flopped around on the floor first.

The FilaWinder spools for you while the filament extrudes, using a sensor to adjust the winding the speed to match extrusion rates as well as running it through some PTFE tube to gently coil it as it moves along. Perhaps most important, the FilaWinder provides a guide arm to direct the filament back and forth across the reel as it spools up, to keep it evenly distributed. Swing by their Thingaverse page for a list of printable pieces and their assembly guide can be found here, as well as on YouTube. You can see an overview video of the FilaWinder winding away after the break.

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Guitar Pickup 101

[Dino Segovis] is at it again!  For this week’s installment of his “Hack A Week” series [Dino] is holding a guitar pickup winding 101.  Professional guitar pickups can cost hundreds of dollars, but are all essentially a permanent magnet wrapped in a bunch of wire. Using some cheap headphones, magnet wire, and a spare bolt [Dino] produces his own pickup and throws it in a one string blues guitar. This is a great beginner’s project as it involves only a few very easy to find parts and touches on some interesting concepts such as inductance and magnetic flux.

The premise is really simple:  Sandwich the headphone magnet between two plastic discs to make a spindle, hot glue a 1/4″ bolt to the spindle, connect to a power drill, and wind a few thousand loops of magnet wire onto the thing.  Hook your coil up to an amp and lay down a jam.

We might be tempted to add a counter to the rig using a reed switch connected to the “=” key of a cheap pocket calculator, and a magnet glued to the bolt.  We have also seen a more complicated automated spool winder but [Dino] is keeping it nice and simple.

Check out the video after the jump to hear [Dino] go all Seasick Steve on us.

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Automated Guitar Pickup Winding

[Robert Pickering] shares his automated guitar pickup winder with us. He built it for his senior project at Old Dominion University. Two stepper motors are used to wind the magnet wire around the pickup hardware. The unit is PIC based and about six minutes into the video (embedded after the break) you can see that he used wire wrapping for this build. Curious, one of the comments on our latest Hackaday Links mentioned that wire wrapping was rarely used anymore, but here it is anyway.

We especially like the limiting switches he’s using on the traverse mechanism. There are momentary push buttons on either side of a carriage which are depressed when a drywall screw in the sides of that carriage hits them. This makes for very easy calibration because the screw can be raised or lowered with just a bit of screwdriver work. Well built and documented, we’re sure he’ll get some high marks on this one. Continue reading “Automated Guitar Pickup Winding”