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Thread: Ideal DIY Pickup Winder Features?

  1. #1
    Supporting Member Robert Technology's Avatar
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    Ideal DIY Pickup Winder Features?

    I am new to pickup winding but am looking for a fun project to take on with an extra PLC (programmable logic controller) and HMI that I have laying around.

    I'm hoping to get some insight into what features the ideal pickup winder would have. Is there anything that would be useful outside of things like:

    • Rotation direction (CW Vs. CCW)
    • Total rotation count
    • Speed up/Slow Down at startup/stop
    • Lateral movement for programmable scatter and coil distribution


    That's basically what I have seen on commercial and DIY units online and seems easy enough to accomplish with a programmable unit. Anyone have any other advice that I may not find from basic research? I'm going to order some pickup parts from Mojotone to figure out the best way to mount to the motor shaft, but it seems like a PLC, an HMI for control/dispaly and a motor should get me most of the way there.

    Thanks!

  2. #2
    Senior Member jack briggs's Avatar
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    All the above

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    CNC Trial by Fire kayakerca's Avatar
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    You may want to include:
    - Traverse start position option to be either left side or right side (top or bottom) of the bobbin.
    - Bobbin height/traverse distance (distance between the inside top and inside bottom of the bobbin).
    - Lateral movement distance parameter to accurately align the wind start position setup (in predefined increments [e.g. .0028/.028/.125/.125/Bobbin height itself]).
    Robert Technology likes this.
    Take Care,

    Jim. . .
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    In the immortal words of Dr. Johnny Fever, “When everyone is out to get you, paranoid is just good thinking.”

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    Supporting Member Robert Technology's Avatar
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    Quote Originally Posted by kayakerca View Post
    You may want to include:
    - Traverse start position option to be either left side or right side (top or bottom) of the bobbin.
    - Bobbin height/traverse distance (distance between the inside top and inside bottom of the bobbin).
    - Lateral movement distance parameter to accurately align the wind start position setup (in predefined increments [e.g. .0028/.028/.125/.125/Bobbin height itself]).
    This is good stuff that I wouldn't have thought of! Thanks!

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    CNC Trial by Fire kayakerca's Avatar
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    Quote Originally Posted by Robert Technology View Post
    This is good stuff that I wouldn't have thought of! Thanks!
    Anytime. Spent a few months on that same road a number of years back. The result was well worth the few bumps in the road during the journey.
    Take Care,

    Jim. . .
    ____________________________________________________
    In the immortal words of Dr. Johnny Fever, “When everyone is out to get you, paranoid is just good thinking.”

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    ken
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    If you use automatic traverse wire feed (selffeeding) instead of always having to sit in front of it...

    A 'broken wire detector' and automatic 'bobbin full shutoff' is always a good thing if you decide to let the winder run by itself. Then it can run in the background as you do other things. It's almost like having another helper for free

    What PLC and boards are you planning to use?

    Following this one...

    Ken

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    You might want to read through the old thread that Elepro started when he began designing his automated winder's architecture. His was all about repeatability vs randomization in the tpl. He used stepper motors for both the spindle and the wire feed traverse so that he could completely sync up the two. Basically a PIC to a 60 char display that went through a series of "conversational" questions to determine the desired variables and constraints. It has a very simple interface. A number of us got the PIC and PCB and then organized a group purchase of BOM kits from Mouser. I still have mine assembled and ready to run but no time to design the perfect hardware compliment I'd envisaged.
    Last edited by David King; 02-12-2018 at 08:05 AM.

  8. #8
    Supporting Member Robert Technology's Avatar
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    Very interesting! I'll have to check out the Elepro thread on this topic to see what other people have done in the past. I don't have any experience with pickup winding so I appreciate all of the details you are sharing.

    I definitely like the idea of some sort of automation related to a "broken wire detector" and that shouldn't be too hard to add in. I'm planning on using cheap servo motors for the positioning automation, and possibly for the drive of the winding as well.

    For the actual automation I'll be using a "cheap" Koyo Click PLC from Automation Direct. It's what most of my students typically use for our PLC class so I'm hoping to get something similar to them. I've used the Allen-Bradley MicroLogix 1100 in the past, but that unit is being phased-out of production, so it's time for me to switch to what the bulk of my students will be using. Control and setup will be accomplished through a C-More HMI (probably just the cheapest touch-screen unit that Automation Direct offers).

    I'm not entirely proficient with text-based coding but will share what I end up with in case someone wants to translate it to a language that can be used with a PIC, otherwise I'll take that on this Summer to finally get the hang of some C Language!

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