Hi,
I want to put new secondary, means low voltage, windings on an old toroid transformer.
In my first attempt to unwind and re-apply the secondaries, I was faced with many challenges.
This is really difficult to do by hand.
I wonder whether anybody put new secondary windings on a toroid transformer already and what was your experience.
In my mind, a bifilar secondary winding would be perfect, but I don't dare to attempt this because I found it so difficult to just apply a single wire.
I guess everybody knows how toroid transformer winding machines work.
I made up my mind how this machines theory of operation could be applied to hand winding and came up with an idea for a hand tool.
I sketched this in CAD:
The idea is to put the tool on the toroid like illustrated, then put the wire onto the tool by just spinning the tool and thereby reeling the wire from the spool onto the tool, cut the wire once it is enough, and finally to apply the wire from the tool onto the toroid by spinning the tool trough the toroid.
Does anybody know whether such a tool exists and where to buy it?
Any other ideas for tools that may be helpful for hand winding toroids?
I want to put new secondary, means low voltage, windings on an old toroid transformer.
In my first attempt to unwind and re-apply the secondaries, I was faced with many challenges.
This is really difficult to do by hand.
I wonder whether anybody put new secondary windings on a toroid transformer already and what was your experience.
In my mind, a bifilar secondary winding would be perfect, but I don't dare to attempt this because I found it so difficult to just apply a single wire.
I guess everybody knows how toroid transformer winding machines work.
I made up my mind how this machines theory of operation could be applied to hand winding and came up with an idea for a hand tool.
I sketched this in CAD:
The idea is to put the tool on the toroid like illustrated, then put the wire onto the tool by just spinning the tool and thereby reeling the wire from the spool onto the tool, cut the wire once it is enough, and finally to apply the wire from the tool onto the toroid by spinning the tool trough the toroid.
Does anybody know whether such a tool exists and where to buy it?
Any other ideas for tools that may be helpful for hand winding toroids?
I have seen home made tools for this.
They mostly consist of an old bicycle wheel with a section cut out and made to be fitted back in after the transformer core is added and held in place.
After adding the removable part of the wheel the wire is wound from the supply spool to the wheel.
The end of the wire is then fixed to the core and the wind motor is reversed to add the winding.
The difficult part is arranging the friction drives to the wheel rim.
They mostly consist of an old bicycle wheel with a section cut out and made to be fitted back in after the transformer core is added and held in place.
After adding the removable part of the wheel the wire is wound from the supply spool to the wheel.
The end of the wire is then fixed to the core and the wind motor is reversed to add the winding.
The difficult part is arranging the friction drives to the wheel rim.
Seems like the basic idea is the same: Using some kind of wheel with a cutout.
Sure I could just 3D print my design, but it would cost a fortune.
I need to make up my mind what kind of wheel I could modify.
I don't plan to add any motors BTW, but do everything by hand.
For reference and entertainment, here is a professional toroid winding machine:
Sure I could just 3D print my design, but it would cost a fortune.
I need to make up my mind what kind of wheel I could modify.
I don't plan to add any motors BTW, but do everything by hand.
For reference and entertainment, here is a professional toroid winding machine:
That shows the wire being wound from the holding spool to the core.
It does not show the wire being wound from the supply spool to the holding spool.
The holding spool and core have to be in place throughout the entire process.
The pro machine also moves the core round to keep the lay of the turns even.
It does not show the wire being wound from the supply spool to the holding spool.
The holding spool and core have to be in place throughout the entire process.
The pro machine also moves the core round to keep the lay of the turns even.
We used to call those a shuttle winder. Universal and Gorman used to make them back in the 70’s-80’s. As Refugee1 said there was also a core support (usually 3 rubberized wheels) that would rotate the core to ensure even layering. The machine I used 40 years ago was a bear to get set up right to ensure that the laying was maintained properly.
Most of the transformers I wound were pulse types or HV switching transformers for power supplies. That usually meant that the wire was fairly small (22AWG or less if I remember correctly). I couldn’t imagine doing this with bigger wire.
Good luck!😀
Most of the transformers I wound were pulse types or HV switching transformers for power supplies. That usually meant that the wire was fairly small (22AWG or less if I remember correctly). I couldn’t imagine doing this with bigger wire.
Good luck!😀
Yes, the video I linked shows only part of the action.
I really started to like the idea with the bicycle wheel. Thanks a lot for mentioning this!
When visualizing a bicycle wheel, I first I had like 28" size in mind, but 10" to 12" wheels seem just right for my core size.
Remove the spokes, add the cutout - ready is the shuttle. Should be easy to do at home using a saw and file.
I guess I might be even succeed with bifilar winding using such a shuttle.
Of course, it takes hours to do what a machine can do in minutes.
My first attempt was a lot of work, but the result wasn't too bad, the layering was somewhat even.
The transformer shall receive four or maybe six secondaries in the end, not sure yet.
I also need to calculate wire diameter, but pretty sure the power windings will use >1.5mm diameter wire.
I'm going to order a wheel and will keep you posted.
I really started to like the idea with the bicycle wheel. Thanks a lot for mentioning this!
When visualizing a bicycle wheel, I first I had like 28" size in mind, but 10" to 12" wheels seem just right for my core size.
Remove the spokes, add the cutout - ready is the shuttle. Should be easy to do at home using a saw and file.
I guess I might be even succeed with bifilar winding using such a shuttle.
Of course, it takes hours to do what a machine can do in minutes.
My first attempt was a lot of work, but the result wasn't too bad, the layering was somewhat even.
The transformer shall receive four or maybe six secondaries in the end, not sure yet.
I also need to calculate wire diameter, but pretty sure the power windings will use >1.5mm diameter wire.
I'm going to order a wheel and will keep you posted.