Coil Winder

16 11 2008

I’m working on a computer controlled coil winder. I’ve started by using the midpoint circle algorithm to rasterize a circle. Each digit represents a wrap of 22 gauge wire inside a torus with a cross section about the size of a US quarter:


Here is an updated version. The wire is a more realistic 12 gauge. I knocked out the corners, so it’s true only where the coil should be. Now it’s much easier to iterate over. This coil would have 421 turns. With some additional code, I can now calculate the actual length of wire necessary for the coil, and in this case it comes out to ~200 meters! With this new information, I will have to adjust the model. I want to shoot for the same wire gauge and number of wraps as WB6.


Here we have the design for the bobbins. They split down the middle so you can remove the finished coil:



16 11 2008



This iteration of the design is nearly ready for rapid prototyping. The chassis walls are thicker, and there is more room for the coils. Also the joints are hollow now, so the coils can be wired together. Specs:

  • outside_radius: 242.487113059643 mm
  • torus_midplane_radius: 192.693468865964 mm
  • donut_exterier_radius: 107.8 mm
  • torus_radius: 77.0 mm
  • donut_hole_radius: 46.2 mm
  • torus_tube_radius: 30.8 mm
  • torus_tube_hollow_radius: 25.564 mm
  • joint_radius: 21.56 mm
  • joint_negative_radius: 7.546 mm
  • torus_tube_wall_thickness: 5.236 mm


Here is the corresponding array of 12 lids:


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