Spulenwickler - Coil winder

This text is still to be completed!
A modular set to build a coil winder. I use it to unwind and wind delicate high voltage coils for retro projects (like 22.000 windings of 80um copper wire). For lower voltages (i.e. less windings) your electric screwdriver might be sufficient.

The concept is to use hex rods as rails and 3D-printed things, either sliding on them or to attach them with screws to a baseplate and setscrews to the rails. These things can accomodate a stepper motor or a ball bearing for 5mm axles. There is one source axle/rail (or pair of rails) with a sensor to count each unwinding turn)and one target axle/rail (with the stepper motor). A linear drive (like the one that holds a DVD reading head) moves the wire slowly to be wound evenly onto the target spool. and a microswitch to detect its home position. Handwired off-the-shelf stepper drivers and a step-down converter to produce 5V for the electronics and the linear drive from the 12V overall supply that is used directly for the stepper motor and its driver. A Cheap Yellow Display is used as a touch console for the whole system, a pushbutton is used to soft-start.

So, this project is not for the faint of heart, as you need to find some extra components in your DIY-cupboard or buy them and combine all this with some creativity. The winding itself is also a risky procedure. But with quality wire and an Aliexpres account you will certainly master it!

3D-printed components:

• 4 "lager": A combined thing for holding either a stepper motor, or an insert with a large ball bearing (see below). Comes with protrusions to fit small ball bearings on (as needed if you want to use a very large source spool.
• 2 "insert": An insert plate that fits into a "lager" with some adjustment space to have huge tolerances for the whole system.
• 2 "mini-lager": Just the lower part of "lager, if you just want to attach the hex rails to the baseplate.
• 1 "arm": A long arm to ensure source counting (add metall sticker for optimum reflection) and balancing (add M3 screw and some small weight to adjust)
• 4+ "kegel klein": Small cone that slips onto the 5mm rod to clamp source or target spools
• 1 "kegel komplett": Bigger cone that can be added for larger spools
• 1 "kegel oben unten": Ditto in two pieces, one of them fits over the motor axle adapter
• "stand": This is just a hacked version of the stand from LeifA's Yet another Case for the Cheap Yellow Display to add a mounting hole, please load the other files from there. I should do this as a remix, sorry.

Components to purchase:

• 1 "Cheap Yellow Display": ESP32/Touchscreen module for control, for a description cf. https://randomnerdtutorials.com/cheap-yellow-display-esp32-2432s028r/
• 8 Small 6x10x3mm ball bearings: To put a large source spool on the "lager" component, E.g. https://www.aliexpress.com/item/1005007668446060.html
• 3+ Large 5x11x5mm ball bearings: To hold the 5mm axles for the target spool and the source spool. E.g. https://www.amazon.de/dp/B07W679Y3S
• 20+ M3 set screws to lock positions of cones and hex rods
• 20+ 5.5mmx1.8mm M3 square nuts
• 1 adapter to connect the stepper motor axle to a 5mm rod
• 2 200mm or 120mm pieces of 5mm round rods as axles for source and target spools
• 2 or 4 200mm pieces of 1/4" hex rods
• 1 IR reflection sensor module
• 1 Buck converter module (12V -> 5V)
• 1 Small stepper motor driver module for linear drive (5V)
• 1 Big stepper motor driver module for target spool motor (12V)
• 1 micro switch for home-detection of linear drive
• Some flexible wires, plugs (recommended), small piece of prototype board to wire up the small driver and the other connections
  I did not succeed to upload videos, so please use these external videos of mine for illustration:
• Rewinding an odd-shaped target spool from a large source spool
• Unwinding an odd-shaped source spool to a wobbly scrap spool (better use ScrapSpoolV3 from above):