Re: Winding technique

["Tesla list" <tesla@xxxxxxxxxx>]

Original poster: Liviu Vasiliu <teslina@xxxxxxxxx>

I am using this techique to wind the secondaries with
thin magnet wire. The V clamp is made with hard wire
plastic insulated, bent in an appropriate shape. The
mass of the clamp is usually enough to tension the
wire. Here are some pictures (the wire is so thin that
it is not visible):

http://www.geocities.com/teslinasite/cwpage.html
It is very effective.

vasil
>
>
--- Tesla list <tesla@xxxxxxxxxx> wrote:

> Original poster: "Dr. Resonance"
> <resonance@xxxxxxxxxx>
>
>
> One interesting trick large commercial xmfr winders
> use is to route the
> enameled magnet wire through a simple piece of
> cardboard in a "V" shape.  A
> small lightweight clamp allows different tension on
> the cardboard V
> depending on the gauge of wire being wound.  It was
> amazingly simple but
> they used this technique on over 20 winders all hard
> at work winding pole
> xmfrs.
>
> The magnet wire is located on a simple dowel type
> arrangement and is located
> down near the floor.  The V cardboard is up on a
> metal stand at a level even
> with the xmfr being wound.  The magnet wire makes a
> approx 70 degree bend at
> the cardboard V.
>
> The engineer told me they have used this technique
> for over 40 years!
> Simple but effective.
>
> We use a similar arrangement with our lathe.
>
> Dr. Resonance
>  >  >
>  >  > I have a set up to make coils from 1" to 15"
>  >  > diameter up to about 5ft long.
>  >  > How many coils do you want.  I make a few
> coils from
>  >  > time to time and sell
>  >  > them on ebay mostly because it helps out the
> hobby
>  >  > the secondary coils take
>  >  > a long time to wind by hand.
>  >
>  > Well, I am happy that you are helping out the
> hobby,
>  > but I have to differ with you on the contention
> that
>  > secondary coils take a long time to wind by hand.
>  If
>  > you have a wife or partner to help, it can be
> knocked
>  > out in a hurry.  I wound my 6" dia 24" long
> secondary
>  > with a temporary jig set up between two
> collapsable
>  > aluminum saw horses.  I had a cheap wooden dowel
> as
>  > the shaft for the spool of magnet wire, and
> endcaps
>  > with carriage bolt axles in the center for the
> coil
>  > former.  After using masking tape to secure the
> wire,
>  > I spun the form with both hands while my wife
> kept the
>  > rate of spin on the spool constant as well as
> guiding
>  > the angle of the wire.  I was also making sure
> the
>  > wire was tight and flush before putting a piece
> of
>  > temporary tape over each new few inches of
> winding.
>  > We knocked out the whole job in just 45 minutes!
>  > Perfect secondary, no overlaps, kinks, gaps or
>  > problems at all.  I have also wound others since
> then
>  > with equal success.  The great thing too, is that
> you
>  > can start applying coats of polyurethane (or
> whatever)
>  > while the coil is still sitting the the jig.
> Then
>  > after you are done, you can just untape the axles
> and
>  > everything and collapse the sawhorses and store
> them
>  > away for later.  I used aluminum tape for the
> axles,
>  > since it has a much stronger adhesive.
>  >
>  > -Brett
>  >
>  >  > I might be
>  >  > interested in making you some
>  >  > coils.  I can get any size enamel coated
> copper wire
>  >  > it comes in 100 lb
>  >  > rolls.  Tell me what you need.
>  >  >
>  >  > Gary Weaver
>  >
>  >
>  >
>
>
>