Automatic Solenoid Winder
A mechanism that winds solenoids while counting the number of turns
Project Date: April 2019
Background and Motivation
I wanted to build a coilgun, but I did not feel like winding high inductance solenoids for hours. While I was at Rochester Institute of Technology, I asked my professor if RIT had a 'solenoid winder'. Sadly, they did not. So I designed a mechanism that winds them for me while I was home for Thanksgiving break.
Design Process
I used a stepper motor for its accuracy, as counting the number of turns in a solenoid is critical to the subsequent calculations that go into creating something like a coilgun.
To control this motor, I used the A4988 motor drivers. These interface easily with an Arduino.
To display the turn count, I went with a simple I2C OLED display
Later in the design process, I implemented a potentiometer as a speed controller. This allows the motor to wind a solenoid at any speed, forwards or backwards.
The chassis was made to support a rod for placing wire, 3 tensioner stages of bearings, and a place for a solenoid to be attached to the motor.
Operation
Capabilities
- Wind solenoids with wire gauges of 18-24 gauge so long as they are not too rigid.
- Wind multiple layer solenoids given that the final tensioner is adjusted every layer.
- Display the turn count
- Wind in the clockwise and counterclockwise directions
Parts
- Wood (for chassis)
- A9488 Motor Driver
- Arduino Pro Mini (Any microcontroller with I2C will do)
- 128x64 OLED I2C Display
- Potentiometer
- LM317 Adjustable Voltage Regulator
- Resistors