Wire counter parts for Z96F Length Counter

2/26/2023 - This is still a work in progress.  Specifically the measurement wheel may be updated if full scale testing indicates a need.

3/3/2023 - added a base version with 608RS bearings in the wear areas. This version of the base probably has the potential for a longer useful life if use is frequent.

3/5/2023 - Simplified measurement wheel and trimmed content here.  Current measurement wheel was designed with a 31mm contact diameter.  I ended up emperically testing wheel variations and the best I could do was a repeatable measurement error of roughly 1% - 1.4%.  I believe I am running up against limitations associated with the print process.   I recomment you test accuracy on any assembled configuration using a known length of wire & determine the correction factor needed for that particular build.   

Old Stuff

The Z96F is an inexpensive, mechanical, textile length measurement tool counting meters of textile, film, or other sheet material.  It has two wheels sized so that three revolutions equals one meter of distance.   It has five digits for counting meters, the fifth being 1/10 meter increments.

The two parts described here were used to adapt this counter to for measuring 14 awg THHN wire length in foot and  1/10 foot increments for use in construction of large loop antennae. The first part is base with holes to mount the counter using 4mm screws with nuts and wire guides to constrain the wire to pass under the measurement wheel during use.  The measurement wheel is sized so that three revolutions measure one foot of length.  

I printed the base with PLA + and the wheel with 95A TPU.  Both were printed with a high wall count (5 layers).  The base was printed with 20% infill, the wheel with 33% infill.

New Stuff

A second version of the base is included which uses 608RS type bearings in the wear areas. An axle pin is also included for mounting the bearings.  

The measurement wheel has been simplified for quicker printing, easier wire loading and optimized for least error with my printer, yours may differ. If desired, alternative diameters could be produced and included.

I printed the axle pins with 99 walls and concentric lines, a solid print in case I want to remove them by twisting with pliers.