Stepper motor solution for a coil winding machine.

[christinescoms]

Hello all,
I'm currently putting together a coil/transformer winding machine, and stepper motors seem to be the obvious choice
for driving the magnet wire guiding system.
I've searched on google for solutions but I haven't been able to find anything useful yet.
A coil/transformer winder of course needs a motor and a shaft to turn the bobbin, and a magnet wire guiding system which usually
consists of some kind of mechanical system, usually gears to drive the guiding shaft, which in turn is driven from the main shaft,
-much like a feed screw on a metal lathe.
A better solution would be a guiding system that moves the wire guiding mecanism in steps every time the main shaft has completed a full turn,
and in the case of a wire let's say, of 1mm. diameter this step would also be 1 mm.
So, what I'm asking,-is it possible to control a stepper motor driver to do steps by receiving, let's a pulse generated by the rotation
of the main shaft? -The steps would of course need to be varied according to a magnet wire diameter of choice.
All I have found so far are controllers/drivers that need to be programmed.
In this instance this would be both overkill and not practical for my use.

 

[christinescoms]

Hello all,
I'm currently putting together a coil/transformer winding machine, and stepper motors seem to be the obvious choice
for driving the magnet wire guiding system.
I've searched on google for solutions but I haven't been able to find anything useful yet.
A coil/transformer winder of course needs a motor and a shaft to turn the bobbin, and a magnet wire guiding system which usually
consists of some kind of mechanical system, usually gears to drive the guiding shaft, which in turn is driven from the main shaft,
-much like a feed screw on a metal lathe.
A better solution would be a guiding system that moves the wire guiding mecanism in steps every time the main shaft has completed a full turn,
and in the case of a wire let's say, of 1mm. diameter this step would also be 1 mm.
So, what I'm asking,-is it possible to control a stepper motor driver to do steps by receiving, let's a pulse generated by the rotation
of the main shaft of automatic motor winding machine? -The steps would of course need to be varied according to a magnet wire diameter of choice.
All I have found so far are controllers/drivers that need to be programmed.
In this instance this would be both overkill and not practical for my use.

thanks in advance for any help

 

[rjenkinsgb]

My first thought would be to use a high resolution pulse generator on the main winding shaft, eg. a slotted disc and optical sensor, then a TTL/CMOS programmable divider to generate step pulses at any needed frequency.

Use mechanical or optical limit switches to toggle a bistable / S-R latch at each end of the feed system travel and use the output from that to control the stepper driver Direction input.

That would allow you to use such as an L297 + L298 stepper driver module.

eg.

https://www.aliexpress.com/item/1272116331.html

 

[Nigel Goodwin]

All I have found so far are controllers/drivers that need to be programmed.
In this instance this would be both overkill and not practical for my use.

It's neither overkill, nor impractical - and by far the most obvious solution.

It would be simpler, cheaper, and far more versatile - the days of crude fixed logic system are long gone.

Here's a simple example, with everything done for you:

Coil Winder Using Arduino

Coil Winder Using Arduino: Why this project was built?I work at Prabal Learning Innovations, an educational startup. One of our educational kits contains a 3D printed part that is wound with a copper coil to demonstrate electromagnetic induction. Winding the 3d printed part u…

www.instructables.com

Interestingly it uses a servo to spread the winding across the bobbin.

 

[rjenkinsgb]

I thought the OP was referring to this type of thing, "intelligent" stepper drivers - rather than possibly using a microcontroller generally?

DS-OLS4-FPD - Stepper motor driver by Jiangsu DINGS' Intelligent Control Technology Co., | DirectIndustry

Preparations to Operate 1.Recommend to use appropriate power supply [20~50VDC] 2.Controller, PLC or controller block [High speed pulse] 3.Recommend to use 2 phase, 4 lead wire of steppers. Power supply connection 1.Power supply range is 20~50VDC but recommend to select 24V available under Size 17...

www.directindustry.com

 

[JimB]

I have no direct experience of them, but look for "electronic lead screw" for lathes.
They use stepper motors to drive the lathe leadscrew to enable the lathe to cut threads of any pitch without having to change the gearing between the lathe spindle and the leadscrew.

JimB

 

[rjenkinsgb]

If using an MCU, one very simple approach for relating one movement to another is to use Bresenham's line algorithm.

That only needs integer math and no trig functions, to provide any ratio from one value to another.
I've used that for machine tool interpolation routines.

Bresenham's line algorithm - Wikipedia

en.wikipedia.org

 

[MaxHeadRoom78]

Roman Black site is still up, he had one project that used the Bresenham's algorithm.

PIC project DC motor like crystal clockwork!

PIC project, xtal locked DC motor, DC motor crystal clockwork

www.romanblack.com