Design And Construction Of A Microcontroller Based Winding Machine

In this project “microcontroller based automatic coil winding machine” mainobjective is to bring out a machine which can implement the idea of automation in Transformer winding or any type of coil windings. The proposed system controls the speed of a winding machine in order to obtain the optimum stop point in terms of security and fast production. The system is based on a microcontroller and an extremely simple hardware. The system has been tested for two years and results evince a very good mean time between failures.

TABLE OF CONTENTS

COVER PAGE

TITLE PAGE

APPROVAL PAGE

DEDICATION

ACKNOWELDGEMENT

ABSTRACT

CHAPTER ONE

INTRODUCTION

1.1      BACKGROUND OF THE PROJECT

• PROBLEM STATEMENT
• PURPOSE OF THE PROJECT
• OBJECTIVE OF THE PROJECT
• SIGNIFICANCE OF THE PROJECT
• APPLICATION OF THE PROJECT
• TYPES OF COIL WINDING MACHINES
• DEFINITION OF TERMS
• PROJECT ORGANISATION

CHAPTER TWO

LITERATURE REVIEW

• OVERVIEW OF THE STUDY
• REVIEW OF DIFFERENT KINDS OF COIL
• TYPES OF WINDING MACHINE
• REVIEW OF AUTOMATIC COIL AND TRANSFORMER WINDING MACHINES

CHAPTER THREE

3.0      METHODOLOGY

• BASIS OF AN AUTOMATIC WINDING MACHINE
• AUTOMATIC COIL WINDER CONTROL UNIT SCHEMATIC DIAGRAMS
• PRINCIPLE OF OPERATION
• CONSTRUCTION NOTES
• POWER SUPPLY UNIT

CHAPTER FOUR

4.0      TEST AND RESULT ANALYSIS

• CONSTRUCTION PROCEDURE AND TESTING
• CASING AND PACKAGING
• ASSEMBLING OF SECTIONS
• TESTING OF SYSTEM OPERATION

CHAPTER FIVE

• CONCLUSION
• RECOMMENDATION
• REFERENCES

CHAPTER ONE

1.0                                                        INTRODUCTION

1.1                                         BACKGROUND OF THE PROJECT

Coil winding machine allows you to make an electromagnetic coil that can be used for a variety of purposes. A coil winding machine takes a copper or aluminum wire and winds it around a core or sometimes around air. The coils are usually wound around reels. During this process, the wires can be coated with a variety of materials that can provide some form of insulation. The types of wire, coiling, and insulation needed depends upon the particular application.

Automatic coil winding machine main objective is to bring out a machine which can implement the idea of automation in Transformer winding or any type of coil windings. A transformer changes (transforms) an alternating voltage from one value to another. It consists of two coils, called the primary and secondary winding, which are not connected electrically. The windings are either one on top of the other or are side by side on an iron, iron-dust or air core.

A transformer works by electromagnetic induction: a.c. is supplied to the primary and produces a changing (alternating) voltage in the secondary. It is important that as much as possible of the magnetic field produced by the primary passes through the secondary. A practical arrangement designed to achieve this in an iron-cored transformer. In which the secondary is wound on top of the primary. You should also notice that the induced voltage in the secondary is always of opposite polarity to the primary voltage.

Too large a current in a transformer causes magnetic saturation of the core i.e. the magnetization of the core is a maximum and it is no longer able to follow changes of magnetizing current. Particular care is required when there is a d.c. component.

In block consists of keypad, Microcontroller, display, Stepper motor, Stepper driver circuit, coil winding machine. This demo works on the basis that the keypad provided is for entering the set values that is the number of windings can be given In case of transformer the primary winding and secondary winding can be entered. All the interfacing with Microcontroller is done through its I/O lines.

The aim of this project is to develop a microcontroller based automatic coil winding machine to wind coils for Transformers, condensers, Coil rolls etc. This machine is needed to wind coils of copper wires up to hundreds of gauges. The operation of coil winding machine is performed automatically by microcontroller – which is the heart of the machine and by using a Motor – which controls the winding movement.

1.2                                                  PROBLEM STATEMENT

Traditional or manual method of winding copper or aluminum wire waste much time, leads to miscalculation of number of coil ( which leads to under or over number of turns), and also can cause scratching the coat of the wire – which can cause flux leakage and electric shock during the device operation. The invention of an automatic winding machine led to overcoming these problems associated with the traditional method of winding coil.

1.3                                            OBJECTIVES OF THE PROJECT

The objective of this work is to construct a microcontroller winder which is used for winding copper or aluminum wire.

1.4                                              PURPOSE OF THE PROJECT

The purpose of this work is to have a fast, easy, displayable and reliable means of winding coils for Transformers, condensers, Coil rolls

1.4                                         SIGNIFICANCE OF THE PROJECT

This machine has the ability of UP or DOWN counting. In case number of turns is more than required value, the count can be reduced to required value by rotating the coil in reverse direction. The other advantage of an automatic winding machine are:

1. It can greatly reduce employee fatigue strength, improve work efficiency, saving tie.
2. PLC program control, text display set parameters, and easy operation.
3. can adjust the length of the winding, winding coils set tie line length, number of laps setting  can yield count.
4. for the AC power cord, DC power cord, USB data number, video cable, HDMI high-definition  cable, and other various types of transmission lines using plastic bag tied into bundles core twisted  purposes.

1.5                                          APPLICATION OF THE PROJECT

1. It is very useful in Transformer manufacturing Company, to wind the transformer quickly.
2. To wind the stator or rotor in motor or submersible pump company.

• To wind the condensers coil and fan coils quickly.

1. It is very useful in small scale industries where ever winding coils are used.

1.6                                    TYPES OF COIL WINDING MACHINES

There are different types of coil winding machines available.

Coil Winders

Coil winders are generally used for smaller jobs. They can be hand operated or have a winding drive that is controlled by a foot pedal. These coil winding machines are used in the production of solenoid coils, multi-section coils, and other such complex coils. Though they are small, they can reach up to speeds of 9000 RPM.

Medium-Duty Coil Winding Machines

These machines are more powerful than coil winders and take on higher production demands. Most of them are driven by potentiometers. They can wind various types of wires.

Heavy-Duty Coil Winding Machines

Heavy-duty motor coil winding machines are able to take care of extremely large amounts and are also very versatile in nature. For higher precision, most of these machines are equipped with LCD touch-screen monitors. These screens allow operators to have more control over speed.

1.7                                                  DEFINITION OF TERMS

COIL(s): The end result of a wire, tube, or bar in a continuous loop referred to as “turn” to create a Helix spiral.

COIL ASSEMBLY: Is when parts (ex: plastic) are added to the coil to be considered complete.

COIL BENDING: Is when the end of a coiled material is curved or bent in different directions.

COIL WINDING: “coil” in this sense refers to the wire or conductor and “winding” is the turn/loop of the wire to create the end result.

Over Winding: The winding of a second coil on top of another coil.

TOROIDS: Is a ring-shaped core that can be made of ferrite (magnetic) or out of dust-iron that is used to wind wires inductors.

TOROID COIL: Is sometimes known as “Toroid Inductor” and is used for low frequencies.  It is a coil that is wire wound on a toroid.

TUBE BENDING: Is when a hollow tube of various sizes and material (such as copper) is bent to form a specific shape.  The tube can be curved or angled to create a unique shape based on the functionality and need of the project. The tube size and thickness can vary to ensure the curve or angle follows the original OD of the tube.

TUBE WINDING: Is when a hollow tube of various sizes and material (such as copper) are wound in a continuous loop/turn. A coil is created when tube is wound on a custom mandrel creating a spiral like shape with or without spacing, thus creating a coil. These tubes are utilized in many different industries to create a path for energy or used to heat or cool liquid.

TURNS:  Is the number of loops in a coil(s).

1.9                          PROJECT WORK ORGANISATION

The various stages involved in the development of this project have been properly put into five chapters to enhance comprehensive and concise reading. In this project thesis, the project is organized sequentially as follows:

Chapter one of this work is on the introduction to a microcontroller based winding machine. In this chapter, the background, significance, objective limitation and problem of a microcontroller based winding machine were discussed.

Chapter two is on literature review of a microcontroller based winding machine. In this chapter, all the literature pertaining to this work was reviewed.

Chapter three is on design methodology. In this chapter all the method involved during the design and construction were discussed.

Chapter four is on testing analysis. All testing that result accurate functionality was analyzed.

Chapter five is on conclusion, recommendation and references.