Re: Winding technique

["Tesla list" <tesla@xxxxxxxxxx>]

Original poster: "Scott Hanson" <huil888@xxxxxxxxxxxx>

Wrong - there most certainly IS a 360 degree twist imparted to the wire if
it is "unspooled" from a stationary roll by drawing the wire up over the
spool flange (vs unspooling the wire by allowing the spool to rotate on a
spindle of some sort). If you can't visualize this in your head,  just look
at any spool of wire that has lengthwise printing on the jacket (household
THHN, etc). Remove a few feet of wire from a stationary spool by pulling it
off over an end flange and you'll immediately see there is one complete
"twist" of the wire for every turn removed from the spool.

With copper magnet wire larger than about #30 AWG, this "twisting" usually
poses no problem. However, with #32 AWG or smaller wire it poses a serious
problem with the wire "kinking" every chance it gets. I have personally
wound at least half a dozen secondaries using #32 or smaller wire, and I can
assure you the problem is real.

I eventually developed a technique of setting a plastic funnel over the top
flange of a stationary spool of wire (spout facing up), and feeding the wire
up through the spout and thence off to the secondary coilform. If more wire
tension if required than the weight of the funnel can provide, add a few
small chunks of modeling clay to the funnel to add weight. This, plus a
foot-pedal motor speed control, an extremely low inertia DC drive motor, and
a very sensitive slip-clutch on the secondary coilform drive allow me to
very quickly wind secondaries using very fine wire with no breakage,
kinking, or stretched wire.

Regards,
Scott Hanson

----- Original Message -----
From: "Tesla list" <tesla@xxxxxxxxxx>
To: <tesla@xxxxxxxxxx>
Sent: Sunday, January 02, 2005 8:52 PM
Subject: Re: Winding technique


> Original poster: "Dr. Resonance" <resonance@xxxxxxxxxx>
>
>
> Wire alignment does not change.  No 360 degree twist.  There is no stress
on
> the insulation.
>
> Dr. Resonance
>
>
>  >
>  > It doesn't effect the insulation at all. I've had no insulation
problems.
>  >
>  > Claude.
>  > ----- Original Message ----- From: "Tesla list" <tesla@xxxxxxxxxx>
>  > To: <tesla@xxxxxxxxxx>
>  > Sent: Monday, January 03, 2005 1:29 AM
>  > Subject: Re: Winding technique
>  >
>  >
>  > >Original poster: Rob Maas <robm@xxxxxxxxx>
>  > >
>  > >At 1/2/2005 05:11 AM, you wrote:
>  > >>Original poster: "claudio masetto" <claudmas@xxxxxxxxxxxxxxx>
>  > >>
>  > >>The clamp is clamping the winding wire and therefore tension can
>  > >>maintained while winding resulting in a nice tight coil. This can be
a
>  > >>simple peg arrangement with a couple of pieces of felt or it can be
made
>  > >>adjustable so that tension can be adjusted to suit the gauge of wire.
It
>  > >>is mounted on an arm which is in turn mounted on a lead screw which
>  > >>guides the wire along the length of the coil.
>  > >>Another thing I have noticed is that a lot of coilers who wind their
>  > >>coils place the spool with the winding wire horizontal to the
secondary
>  > >>they are winding supported with some sort of bar. This is not
necessary.
>  > >>The spool can be sat upright and the wire will just unwind
beautifully.
>  > >>No problems with an overunning spool.
>  > >>
>  > >>Claude.
>  > >
>  > >But each unwound turn from the spool will add a 360 degr. twist
>  > >to the wire, which is not good for the isolation.
>  > >
>  > >Rob
>  > >
>  > >
>  > >
>  >