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'[OT]:Toroidal coil winder'
2002\10\21@150603 by fred jones

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Hi all,
I am experimenting with winding some larger diameter toroid coils.
Approximately 2"ID and 6"OD with a couple thousand turns of magnet wire.  I
started looking and found plans to build a coil winder (solenoidal) but I
couldn't find any plans to build a toroidal winder.  Does anyone know where
there are any plans to build one?  My online searches have shown some Asian
companies that make suitable machines but I'm sure they are out of my hobby
budget.  Again, thanks for any help.
Fred

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2002\10\21@152356 by Roman Black

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fred jones wrote:
>
> Hi all,
> I am experimenting with winding some larger diameter toroid coils.
> Approximately 2"ID and 6"OD with a couple thousand turns of magnet wire.  I
> started looking and found plans to build a coil winder (solenoidal) but I
> couldn't find any plans to build a toroidal winder.  Does anyone know where
> there are any plans to build one?  My online searches have shown some Asian
> companies that make suitable machines but I'm sure they are out of my hobby
> budget.  Again, thanks for any help.


Wow! Now that's an ambitions project. I've seen
one of these in a factory doing similar sized
toroids, the machine was the size of a small truck.
:o)
-Roman

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2002\10\21@160927 by Peter L. Peres

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On Mon, 21 Oct 2002, fred jones wrote:

*>Hi all,
*>I am experimenting with winding some larger diameter toroid coils.
*>Approximately 2"ID and 6"OD with a couple thousand turns of magnet wire.  I
*>started looking and found plans to build a coil winder (solenoidal) but I
*>couldn't find any plans to build a toroidal winder.  Does anyone know where
*>there are any plans to build one?  My online searches have shown some Asian
*>companies that make suitable machines but I'm sure they are out of my hobby
*>budget.  Again, thanks for any help.

A toroidal winder is a very complicated and clever piece of machinery. I
doubt you can build one 'simply'. The manual way involves a bobbin that is
long and slender with the wire spooled on it, and with a retainer that
does not allow the wire to come off too easily. The bobbin must be able to
pass through the hole when the toroid is fully wound.

Toroidal winders are of several types. The 'simplest' kind has a lot of
limitations but the complex kind is more like building a Jacquard loom.

The simple kind works like this: A toroidal spinner has an outer groove
that can spool wire on it and a spinner head (think bicycle wheel without
tyre and spokes, and fishing line brake affixed to its rim for the head).

The spinner splits open to thread it through the center of the toroid to
be wound, then it is closed (the spinner is itself a toroid). Now two
cycles happen: First the spinner spins and loads itself with wire from a
bobbin, solenoid like into the groove (where the tyre would be). Then the
wire is cut from the supply reel and the start is fixed to the toroid and
the spinner spins backwards, now putting the wire on the toroid to be
wound, through the spinner head which ensures constant wire tension
together with the drive.

When the spinner is empty it is split to be removed from the toroid or
reloaded with wire to put on another winding. This sounds simple but it
isn't really. There are lots of nasty details like what happens if the
wire jams, how to ensure that the toroid is spun evenly while being wound,
how to hold down the ends of the wire and the wire proper on the spinner
that goes a few hundreds of rpm, and how to make this automatic. Note that
the spinner head revolves around the toroid in a non-circular orbit but
the wire tension must be the same all the time, and adjusted for 'inside'
and 'outside' toroid dynamically. The price tags of these machines reflect
this very clearly. Professional ones can have several spinners working at
the same time, some putting on wire, others putting on insulation tape
etc. They are fun to watch ;-)

If you are really really good with fine mechanics then you could build a
semiautomatic toroid winder that will not eat your wire for lunch every
300 turns or so (semiautomatic means you turn the toroid by hand over a
set of wheels while a motor turns the spinner).

Peter

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2002\10\21@160935 by Tim McDonough

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On Mon, 21 Oct 2002 14:03:55 -0500, fred jones wrote:
>Hi all, I am experimenting with winding some larger diameter toroid
>coils.

I'm not sure what he uses but there's a guy who sells pre-wound toroids for some of the ham radio kits. The email address I saw for him is spam_OUTtoroidguyTakeThisOuTspambigfoot.com

Tim

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2002\10\21@162842 by Tom Messenger

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Excellent description, Peter! I've seen these close up at trade shows and
conventions but never had a clue as to how they work. Now I do.  Thanks.
Tom M.

>
>The simple kind works like this:

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2002\10\21@193112 by David Minkler

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Hi Fred,

Big project.  I use a shuttle when winding onesies or twosies.  Usually
works quite well.  For quantity work I have it done commercially.  Try
Energy Transformation Systems http://www.etslan.com I've had good luck
with them.

Best regards,
Dave

fred jones wrote:
{Quote hidden}

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2002\10\21@201344 by fred jones

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Thanks to all for the advice.  It sounds like I'll need to pay to have them
made.
Thanks,
Fred

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