Don't use a needle.. You can't get any tension without damaging the wire and making it kinky. Rather look at the method of sewing machines. They tension the string, and use smooth eyelets.
You want the wire to exit a large radius'ed flare. The wire should be restricted before the nozzle/flare. You'll also want a stay of sorts. Imagine doing it by hand. You 'lay' the wire through, then loop it around your finger to keep the tension as you 'lay' it back across. Then you remove your finger, and pull it taut. Now you put your finger on the other side to keep it taut again. Doesn't sound too hard to automate... Roland On 19 September 2014 22:19, Ralph Stirling <ralph.stirl...@wallawalla.edu> wrote: > Nice video. The difficulty we had with the needle winding method > was that the needle won't fit between the teeth of small stators, > especially on the last tooth, where you have two full teeth on either > side. Also, if you try to pack as much wire on as you can, it becomes > very difficult to get the needle in. If you watch a video of a skilled > hand motor winder packing wire in, you will see him (or her) use a > small wooden wedge to help flatten the wire between teeth to make > room for the next layer. That is a tough operation to automate. > > If you do try to do this, look up a place called Cosmos USA, which > makes polished wire nozzles that reduce the abrasion at the tip as > the wire exits at a sharp angle. > > http://www.cosmos-na.com/Coil%20Winding%20Nozzle%20Introduction.html > > -- Ralph > ________________________________________ > From: Rene Hopf [reneh...@mac.com] > Sent: Friday, September 19, 2014 12:20 PM > To: Enhanced Machine Controller (EMC) > Subject: Re: [Emc-users] brushless motor coil winder > > winding a gimbal motor with a 4th axis on a 3d printer. > https://www.youtube.com/watch?v=DCKl3B-guSs > > cpp program for gcode is available on his website. > > Rene > > On 19 Sep 2014, at 19:59, David Armstrong <cncbas...@gmail.com> wrote: > > > Thanks Ralph, > > certianly given me some ideas, and just as i thought not as easy as first > > thoughts > > > > On 19 September 2014 17:59, <p...@wpnet.us> wrote: > > > >> > >> Picture here: > >> http://gympiemodelflyers.wordpress.com/articles/brushless-motors/ > >> > >> ------Original Mail------ > >> From: "Dave Caroline" <dave.thearchiv...@gmail.com> > >> To: "Enhanced Machine Controller (EMC)" < > emc-users@lists.sourceforge.net> > >> Sent: Fri, 19 Sep 2014 17:53:53 +0100 > >> Subject: Re: [Emc-users] brushless motor coil winder > >> > >> I do have one relevant picture already though, this shows they are > >> wound before placing on the armature and field for tis particular > >> design > >> > >> http://www.collection.archivist.info/archive/Lucas/PS/PA11/ps1636.jpg > >> > >> Dave > >> > >> On 19/09/2014, Dave Caroline <dave.thearchiv...@gmail.com> wrote: > >>> Thinking of thick wire, I do have some as yet unscanned pictures of > >>> (Lucas) starter motor winding machines. > >>> > >>> Dave Caroline > >>> > >>> On 19/09/2014, Kirk Wallace <kwall...@wallacecompany.com> wrote: > >>>> On 09/19/2014 09:11 AM, Dave Caroline wrote: > >>>>> I dont think it is much worse than any other, you just join the > groups > >>>>> of coils together differently. > >>>>> > >>>>> Often the coils are wound off the rotor/stator and then mounted and > >>>>> varnished to keep steady. > >>>>> > >>>>> Reverse engineer (unwind) one to see how they did it. > >>>>> > >>>>> > >>>>> Dave Caroline > >>>>> > >>>>> On 19/09/2014, David Armstrong <cncbas...@gmail.com> wrote: > >>>>>> Guys, > >>>>>> iv'e been asked to come up with a coil winder for rc brushless > motors > >>>>>> has anyone done such a winder , specific to rc brushless ,as these > are > >>>>>> 3 > >>>>>> phases > >>>>>> i fear it could get complicated > >>>>>> > >>>>>> Dave > >>>> > >>>> The RC motors I'm familiar with use a few turns of very thick wire and > >>>> would be a bear to wind mechanically. There may be a way to wind a > coil > >>>> off the core then install it to the stator leg, but this not ideal. > >>>> Maybe form C shapes and weld them into a coil after they are > installed? > >>>> > >>>> > >>>> -- > >>>> Kirk Wallace > >>>> http://www.wallacecompany.com/machine_shop/ > >>>> http://www.wallacecompany.com/E45/ > >>>> > >>>> > >> > ------------------------------------------------------------------------------ > >>>> Slashdot TV. Video for Nerds. Stuff that Matters. > >>>> > >> > http://pubads.g.doubleclick.net/gampad/clk?id=160591471&iu=/4140/ostg.clktrk > >>>> _______________________________________________ > >>>> Emc-users mailing list > >>>> Emc-users@lists.sourceforge.net > >>>> https://lists.sourceforge.net/lists/listinfo/emc-users > >>>> > >>> > >> > >> > >> > ------------------------------------------------------------------------------ > >> Slashdot TV. Video for Nerds. Stuff that Matters. > >> > >> > http://pubads.g.doubleclick.net/gampad/clk?id=160591471&iu=/4140/ostg.clktrk > >> _______________________________________________ > >> Emc-users mailing list > >> Emc-users@lists.sourceforge.net > >> https://lists.sourceforge.net/lists/listinfo/emc-users > >> > >> > >> > >> > ------------------------------------------------------------------------------ > >> Slashdot TV. Video for Nerds. Stuff that Matters. > >> > >> > http://pubads.g.doubleclick.net/gampad/clk?id=160591471&iu=/4140/ostg.clktrk > >> _______________________________________________ > >> Emc-users mailing list > >> Emc-users@lists.sourceforge.net > >> https://lists.sourceforge.net/lists/listinfo/emc-users > >> > > > ------------------------------------------------------------------------------ > > Slashdot TV. Video for Nerds. Stuff that Matters. > > > http://pubads.g.doubleclick.net/gampad/clk?id=160591471&iu=/4140/ostg.clktrk > > _______________________________________________ > > Emc-users mailing list > > Emc-users@lists.sourceforge.net > > https://lists.sourceforge.net/lists/listinfo/emc-users > > > > ------------------------------------------------------------------------------ > Slashdot TV. Video for Nerds. Stuff that Matters. > > http://pubads.g.doubleclick.net/gampad/clk?id=160591471&iu=/4140/ostg.clktrk > _______________________________________________ > Emc-users mailing list > Emc-users@lists.sourceforge.net > https://lists.sourceforge.net/lists/listinfo/emc-users > > > ------------------------------------------------------------------------------ > Slashdot TV. Video for Nerds. Stuff that Matters. > > http://pubads.g.doubleclick.net/gampad/clk?id=160591471&iu=/4140/ostg.clktrk > _______________________________________________ > Emc-users mailing list > Emc-users@lists.sourceforge.net > https://lists.sourceforge.net/lists/listinfo/emc-users > ------------------------------------------------------------------------------ Slashdot TV. Video for Nerds. Stuff that Matters. http://pubads.g.doubleclick.net/gampad/clk?id=160591471&iu=/4140/ostg.clktrk _______________________________________________ Emc-users mailing list Emc-users@lists.sourceforge.net https://lists.sourceforge.net/lists/listinfo/emc-users
