Winding a Toroid

[W1RKW]

I've always wondered how toroid cores were wound with wire.  Out of curiosity, Youtube became my friend.
For those who've wondered like me: http://www.youtube.com/watch?v=6lvm3FGTHSI

There are a few other videos that show other details that this doesn't show. It can be a brain teaser.

[ei9ju]

Isn't it easy when you've the proper tools 

[WD5JKO]

Did anybody think there were safety issues with that video of the coil winding machine?

Here is a method that even I might be able to do. But why is the guy in the video sitting on the floor like that? If I wound a toroid like that while on my knees, I doubt I could get up afterward...

http://www.youtube.com/watch?v=zL51M-0ebXc

[KF1Z]

Looks like he didn't want you to see the rest of his room.

 


Or his camera tripod isn't tall enough to get a shot over his shoulder if he sat in a chair....

[K9ACT]

Well, now I almost understand it and suspected it had something to do with a sewing machine which has a similar problem.

In both cases, you have to plan ahead and get the right amount of wire on the bobbin first.

The second method is known as a stick shuttle in weaving which also requires loading up a bobbin first.

Thanks for the link.

js

[KF1Z]

Those machines show up on ebay quite often...

Usually $2k +

[W1RKW]

Well, now I almost understand it and suspected it had something to do with a sewing machine which has a similar problem.

In both cases, you have to plan ahead and get the right amount of wire on the bobbin first.

The second method is known as a stick shuttle in weaving which also requires loading up a bobbin first.

Thanks for the link.

js

Yep, a little bit of engineering would need to be used.

I have always been curious how toroids were machine wound. I couldn't imagine them being done by hand on a mass production basis. And with Stu experimenting with toroidal transformers as mod transformers, figured this would be a good primer for some of the inventive and craftsmen types here on the forum.

[kb2vxa]

Oh good grief, that could have been me on my last job! Toroid winding by machine is easy, try it with a home made clamping jig and crochet hook sometime. Yeah, production work is done that way too, UGH! How about winding bobbins, done that too on a lathe. Here's the rub, I screwed up so bad they finally decided to put me in the test department as a tech, the position I originally applied for.

Now that was a learning experience and a half, I went in a tech and came out pretty close to an engineer. Like they say on TV; "Transformers, more than meets the eye."