Unified Tariff and Qualification Directory of Works and Professions of Workers (UTKS), 2019
Issue No. 21 ETKS
The issue was approved by Resolution of the Ministry of Labor of the Russian Federation dated 03/07/2001 N 23
Reel winder
§ 24. Coil winder of the 2nd category
Characteristics of work. Winding coils (multi-turn, multi-layer, single- and multi-section, regular and non-row with several windings, universal, etc.) with wires various brands and diameters for frames, transformers and other parts of medium complexity on configured machines with automatic laying of wires, laying insulation between rows during winding, sealing and soldering of lead ends, and adjustment of resistances. Winding simple coils with universal winding (in mass production conditions). Progressive bifilar and bifilar winding with sealed lead ends. Pyramidal winding of coils with manual laying of wires (in conditions single production). Adjustment of resistance and inductance of coils for short-circuited turns. Winding of multi-section potentiometers and resistance and self-induction coils. Soldering the ends of samples and wire breaks.
Must know: the operating principle of the serviced equipment and the rules for controlling winding machines and installations; purpose and conditions of use of universal and special devices, control and measuring instruments and devices of average complexity and accuracy; rules and methods for winding frames, transformers and other products of simple and medium complexity; characteristics and methods of setting up equipment with the selection of the most advantageous speeds winding machine; basic properties and technological characteristics of the materials used; basics of electrical and radio engineering.
Work examples
1. Chokes - ordinary winding of wires on a well-established machine.
2. Corrective chokes - "Universal" type winding.
3. Toroidal chokes, coils of electromagnets, delay lines on ferrite rods and coils of type B and OB - winding.
4. Two-section and frameless coils - winding in bulk on a manual machine.
5. Low frequency inductor coils, contour, multi-section for high-voltage devices, on prefabricated frames rectangular section, modulation transformers - winding.
6. Coils of high-frequency circuits - step-by-step winding on a manual machine.
7. Multilayer linear guide filter coils - universal winding.
8. Coils of sectional transformers - winding with a pair of double wires.
9. Coils of power transformers and transformers of Sh and ShL types, electromagnets - ordinary winding.
10. Resistance coils - one- and two-layer winding on a well-established machine.
11. Cellular coils - winding wires on a mandrel with knitting needles and impregnating the turns with varnish.
12. Telephone relay coils - combined winding.
13. Toroidal coils with one or several sections different sizes- winding manually and on machines.
14. Coils of transformers and chokes of the "Gabarit" type - winding with stripping and soldering of the output ends.
15. Wirewound resistors - winding, adjustment.
16. Stator sections - winding.
17. Twisted tape cores, armor and rod type - winding.
18. Transformers - toroidal winding on a special winding machine.
19. Multi-section transformers - winding with an interturn insulation gasket made of capacitor or telephone paper with a screen gasket made of copper or tin-clad foil.
20. Filters - winding on a manual machine.
§ 25. 3rd class coil winder
Characteristics of work. Winding of various types different types and shapes (cylindrical, pyramidal, honeycomb, stepper, row, frameless, etc.) with wires of any brands and diameters onto complex coils, frames, transformers and other parts. Frameless winding of coils with manual laying of wire with insulation of each winding layer and adjustment of resistance. Winding potentiometers with wire onto ring, flat and shaped frames, adjusting the resistance and checking the smoothness of changes in the measured current characteristics.
Must know: device, principle of operation and methods of setting up the equipment being serviced; installation of universal and special devices, control measuring instruments and devices and rules for using them; winding rules and methods various types coils, frames, transformers and other products found in the production of electronic equipment; types of windings and specifications for winding manufactured products; basics of electrical and radio engineering.
Work examples
1. Round adjusting autotransformers - winding.
2. Pulse transformer biscuits - winding with insulation of each even turn with varnished cloth.
3. Biscuit deflection system of the cathode ray tube of the TV - winding on special automatic and semi-automatic machines.
4. Glass epoxy frames - winding on a device.
5. Correction coils - sectional toroidal winding with glass tape insulation.
6. Large-sized coils of pulse transformers - multilayer winding.
7. Small-sized microrelay coils - winding.
8. Deflection system coils - toroidal multilayer winding.
9. Symmetrical relay coils for complex equipment and instruments - winding.
10. Rheostatic coils for hardware switchboards - winding.
11. Coils of power and output transformers with more than two windings - winding.
12. Toroidal coils - winding with adjustment of the inductance value of each tap.
13. Toroidal coils - "Universal" type winding.
14. Coils of high-voltage transformers, transformers with more than three taps in one winding and a wire diameter of up to 1.5 mm - combined winding.
15. Transformer coils for sound speakers, 6-section focusing coils, rotors and stators of induction phase shifters - winding.
16. Stabilizing circuits for string multivibrators - winding sections of the "Universal" type.
17. Filters - automatic winding.
18. Pulse transformers - winding on toroidal cores.
§ 26. Coil winder of the 4th category
Characteristics of work. Winding of coils and transformers on various frames of increased complexity simultaneously with two or more wires with complex connections. Winding of coils and transformers of prototypes on automatic, semi-automatic and multi-spindle automatic machines of various types for universal, bifilar, toroidal and step winding. Winding openwork frames with wires of any brands and diameters. Frameless winding and laying up to 14 windings in one reel (with laying thin wires on the top of thick ones with elimination of incursions and maintaining the given shape of the coils) with making up to 28 leads and bends and securing the outer turns of each layer to avoid falling off. Multi-place winding of multi-winding coil ratings on semi-automatic machines with sealing and design of leads and taps, as well as their soldering.
Must know: device, principle of operation and methods for setting up the winding equipment used various models; switching diagrams of the equipment used; basics of electrical and radio engineering.
Work examples
1. Coils of prototypes - toroidal winding.
2. Reels are especially complex - universal winding.
3. Coils complex design for transmitting FOS - winding on templates with manual laying, with “gluing” or “sintering” of turns.
4. Experimental transformers - toroidal multilayer winding.
5. Small-sized toroidal transformers - winding manually and on SNT-1.5 and SNT-3-u machines.
6. Transformers and chokes such as TA, TN, TAN, TPP, TR, DPP, "Factor", "Potential", DVK, high-frequency choke - winding.
§ 27. Coil winder of the 5th category
Characteristics of work. Winding of particularly complex and particularly stable coils for high-voltage and high-frequency transformers and printed circuit transformers with small overall dimensions (winding window - 4 - 5 mm using magnetic core ШЛ5, ШЛ6, ШЛ8 with a large number of windings and leads) with wires various diameters with terminals sealed with mounting wire. Winding of experimental and experimental transformers and chokes on automatic, semi-automatic and multi-spindle machines of various types of all-climate and export performance and with special acceptance. Adjustment of resistance and inductance of transformers, checking for short-circuited turns. Winding on openwork frames with wires of any brands and diameters.
Must know: device, principle of operation, maintenance procedure and methods for setting up the equipment used of various models; purpose and rules for the use of universal and special devices, instrumentation and instruments of any complexity; properties, technical and technological characteristics of the materials used; types of windings and specifications for winding manufactured products; basics of electrical and radio engineering.
Work examples
1. Transformers for printed circuit circuits of the "Malyutka" type - winding on magnetic cores.
2. Transformers are especially stable in export and all-climate versions - coil winding.
3. Transformers - small-sized toroidal converters, small-sized transformers for video equipment - winding coils.
4. High-voltage transformers of the "Potential" type - winding in the conditions of a single, pilot, experimental production.
5. Toroidal transformers, experimental and experimental - multilayer winding in small-scale production.
2nd category
Characteristics of the work. Winding of coils (multi-turn, multi-layer, single- and multi-section, row and non-row with several windings, universal, etc.) with wires of various brands and diameters on frames, transformers and other parts of medium complexity on configured machines with automatic laying of wires, laying insulation between rows at winding, sealing and soldering of output ends, adjusting resistances. Winding of simple coils with a universal winding (in mass production conditions). Progressive bifilar and bifilar winding with sealed lead ends. Pyramidal winding of coils with manual laying of wires (in single production conditions). Adjustment of resistance and inductance of coils for short-circuited turns. Winding of multi-section potentiometers and resistance and self-induction coils. Soldering the ends of samples and wire breaks.
Must know: the operating principle of the equipment being serviced and the rules for controlling winding machines and installations; purpose and conditions of control and measuring instruments and devices of average complexity and accuracy; rules and methods for winding frames, transformers and other products of simple and medium complexity, characteristics and methods of setting up equipment with the choice of the most advantageous speeds of the winding machine; basic properties and technological characteristics of the materials used; basics of electrical and radio engineering.
Work examples
1. Chokes - ordinary winding of wires on a well-established machine.
2. Corrective chokes - "Universal" type winding.
3. Toroidal chokes, coils of electromagnets, delay lines on ferrite rods and coils of type B and OB - winding.
4. Two-section and frameless reels - winding in bulk on a manual machine
5. Coils of low-frequency chokes, contour, multi-section for high-voltage devices, on prefabricated frames of rectangular cross-section, modulation transformers - winding.
6. Coils of high-frequency circuits - step-by-step winding on a manual machine.
7. Multilayer linear guide filter coils with universal winding.
8. Coils of sectional transformers - winding with a pair of double wires.
9. Coils of power transformers and transformers of type Ш and ШЛ electromagnets - ordinary winding.
10. Resistance coils - one- and two-layer winding on a well-established machine.
11. Cellular coils - winding wires on a mandrel with knitting needles and impregnating the turns with varnish.
12. Telephone relay coils - combined winding.
13. Toroidal coils with one or several sections of different sizes - winding manually and on machines.
14. Coils of transformers and chokes of the "Gabarit" type - winding with stripping and soldering of the output ends.
15. Wirewound resistors - winding, adjustment.
16. Stator sections - winding.
17. Twisted tape cores, armor and rod type winding.
18. Transformers - toroidal winding on a special winding machine.
19. Multi-section transformers - winding with an interturn insulation gasket made of capacitor or telephone paper with a screen gasket made of copper or tin-clad foil.
20. Filters - winding on a manual machine.
Instructions:
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1st category
Characteristics of the work. Winding coils with cheeks of round and rectangular sections with wires of various brands on configured machines with automatic laying of wires. Toroidal basting, regular with one winding (low-turn). Laying insulation between rows during winding with sealing and soldering of output ends with adjustment of resistance. Winding of simple coils with universal winding (in the conditions of in-line mass production). Winding in bulk of single-section relay coils, chokes, etc.
Must know: basic information about the arrangement of the equipment being serviced; name and purpose of its parts; purpose and conditions of use of the most common simple devices and control and measuring instruments and instruments; name and marking of the materials used; coil insulation methods; rules for soldering, tinning and welding when sealing wire ends; types of windings and technical specifications for winding; basic information on electrical engineering in the scope of the full program high school.
Work examples
1. Biscuit deflection system of the cathode ray tube of the TV - winding on special automatic and semi-automatic machines.
2. Chokes - ordinary winding with wire on a well-established machine.
3. Corrective chokes - "Universal" type winding.
4. Toroidal chokes, coils of electromagnets, delay lines on ferrite rods and coils of type B and OB - winding.
5. Two-section and frameless coils - winding in bulk on a manual machine.
6. Low frequency choke coils - winding the wire by hand.
7. Coils of high-frequency circuits - step winding on a manual machine.
8. Resistance coils - one- and two-layer winding on a well-established machine.
9. Cellular coils - winding with wire on a mandrel with knitting needles with the coils impregnated with varnish.
10. Telephone relay coils - winding sections with manual laying of wires.
11. Stabilizing circuits for string multivibrators - winding sections of the "Universal" type.
12. High voltage transformers - layer winding.
2nd category
Characteristics of the work. Winding of coils (multi-turn, multi-layer, single and multi-section, row and non-row with several windings, universal, etc.) with wires of various brands and diameters on frames, transformers and other parts of medium complexity with laying insulation between the rows, with any number of output ends and final sealing them. Progressive bifilar and bifilar winding with sealed lead ends. Pyramidal winding of coils with manual laying of wires (in single production conditions). Adjustment of resistance and inductance of coils for short-circuited turns. Winding of multi-section potentiometers and resistance and self-induction coils. Soldering ends and broken wires.
Must know: the operating principle of the equipment being serviced and the rules for controlling winding machines and installations; purpose and conditions of use of universal and special devices and control and measuring instruments and devices of average complexity and accuracy; rules and methods for winding frames, transformers and other products of medium complexity; characteristics and methods of setting up equipment with the selection of the most advantageous speeds of the winding machine; basic properties and technological characteristics of the materials used; basic information on electrical and radio engineering in the scope of high school and industrial training.
Work examples
1. Pulse transformer biscuits - winding with insulation of each even turn with varnished cloth.
2. Eight-section chokes - "Universal" type winding.
3. Coils of low-frequency chokes, contour, multi-section for high-voltage devices, on prefabricated frames of rectangular cross-section, modulation transformers - winding.
4. Multi-section linear guide filter coils - universal winding.
5. Coils of sectional transformers - winding with a pair of double wires.
6. Coils of power transformers and types Ш and ШЛ, electromagnets - ordinary winding.
7. Telephone relay coils - combined winding.
8. Toroidal coils with one or several sections of different sizes - winding manually and on machines.
9. Coils of transformers and chokes of the "Gabarit" type - winding with stripping and soldering of the output ends.
10. Secondary windings of high-voltage transformers - winding with insulation of each layer with cable or fringed electrical insulating paper.
11. Wirewound resistors - winding, adjustment.
12. Stator sections - winding.
13. Twisted tape cores, armor and rod type - winding.
14. Transformers - toroidal winding on a special winding machine.
15. Pulse transformers - winding on toroidal cores.
16. Multi-section transformers - winding with an interturn insulation pad made of capacitor or telephone paper with a shield pad made of copper or tin-clad foil.
17. Filters - winding on a manual machine.
3rd category
Characteristics of the work. Winding of various types and shapes (cylindrical, pyramidal, honeycomb, step, row, frameless, etc.) with wires of any brands and diameters onto complex coils, frames, transformers and other parts. Frameless winding of coils with manual laying of wire, with insulation of each layer and winding and adjustment of resistance. Winding potentiometers with wire onto ring, flat and shaped frames, adjusting the resistance and checking the smoothness of changes in the measured current characteristics.
Must know: the device, principle of operation and methods of setting up the equipment being serviced; arrangement of universal and special devices, control and measuring instruments and instruments and rules for their use; rules and methods for winding various coils, frames, transformers and other products found in production radio-electronic equipment; types of windings and technical conditions for winding manufactured products; general information in electrical and radio engineering within the scope of the industrial training and training program in the vocational school system.
Work examples
1. Round adjusting autotransformers - winding.
2. Glass epoxy frames - winding on a device.
3. Correction coils - sectional toroidal winding with glass tape insulation.
4. Large-sized coils of pulse transformers - multilayer winding.
5. Small-sized microrelay coils - winding.
6. Deflection system coils - toroidal multilayer winding.
7. Rheostatic coils for hardware switchboards - winding.
8. Symmetrical relay coils for complex equipment and devices - winding.
9. Coils of power and output transformers with more than two windings - winding.
10. Toroidal coils - winding with adjustment of the inductance value of each tap.
11. Toroidal coils - "Universal" type winding.
12. Coils of high-voltage transformers, transformers with more than three taps in one winding with a wire diameter of up to 1.5 mm - combined winding.
13. Transformer coils for sound speakers, 6-section focusing coils, rotors and stators of induction phase shifters - winding.
14. Filters - automatic winding.
4th category
Characteristics of the work. Winding of coils and transformers on various frames of increased complexity simultaneously with two or more wires with complex connections. Winding of coils and transformers of experimental and experimental samples on automatic, semi-automatic and multi-spindle automatic machines of various types for universal, bifilar, toroidal and step winding. Winding openwork frames with wires of any brands and diameters. Frameless winding and layout in one coil of up to 14 windings (with laying thin wires on top of thick ones, eliminating incursions and maintaining the given shape of the coils) with making up to 28 leads and taps and securing the outer turns of each layer to avoid falling off. Multi-place winding of multi-winding coil ratings on semi-automatic machines with sealing and design of leads and taps, as well as their soldering.
Must know: the structure, operating principle of equipment of various models; kinematics, electrical diagram and methods for setting up the winding equipment used; interaction of units of winding machines of various types; equipment switching diagrams; basic information on electrical and radio engineering in the scope of the industrial training and training program in the vocational school system.
Work examples
1. Coils of complex design for transmitting FOS - winding on templates with manual laying, with “sizing” or “sintering” of the turns.
2. Reels are especially complex - universal winding.
3. Coils of prototypes - toroidal winding.
4. Experimental transformers - toroidal multilayer winding.
5. Transformers and chokes such as TA, TN, TAN, TPP, TR, DPP, "Factor", "Potential", DVK, high-frequency choke - winding.
6. Small-sized toroidal transformers - winding manually and on SNT-1.5 and SNT-3-u machines.
5th category
Characteristics of the work. Winding of particularly complex and particularly stable coils for high-voltage and high-frequency transformers and printed circuit transformers with small overall dimensions (winding window 4 - 5 mm using magnetic core ShL5, ShL6, ShL8 with big amount windings and terminals) with wires of various diameters with terminals sealed with mounting wire. Winding of experimental and experimental transformers and chokes on automatic, semi-automatic and multi-spindle machines of various types of all-climate and export performance and with special acceptance. Adjustment of resistance and inductance of transformers, checking for short-circuited turns. Winding on openwork frames with wires of any brands and diameters.
Must know: the structure, principle of operation, maintenance procedures for the equipment used of various models; kinematics, electrical diagram and methods for setting up the winding equipment used; purpose and use of universal and special devices and control - measuring instruments and tools of any complexity; properties, technical and technological characteristics of the materials used; types of windings and technical conditions for winding manufactured products; basic information on electrical and radio engineering in the scope of the industrial training and training program in the vocational school system.
Work examples
1. High-voltage transformers of the "Potential" type - winding in the conditions of a single, pilot, experimental production.
2. Transformers for printed circuit circuits of the “Malyutka” type - winding on magnetic cores.
3. Toroidal transformers, experimental and experimental - multilayer winding in small-scale production.
4. Transformers - small-sized toroidal converters, small-sized transformers for video equipment - winding coils.
5. Transformers are especially stable in export and all-climate versions - coil winding.
This job description has been automatically translated. Please note that automatic translation is not 100% accurate, so there may be minor translation errors in the text.
Preface to the job description
0.1. The document comes into force from the moment of approval.
0.2. Document developer: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _.
0.3. The document has been approved: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _.
0.4. Periodic check of this document carried out at intervals not exceeding 3 years.
1. General Provisions
1.1. The position "4th category transformer coil winder" belongs to the "Workers" category.
1.2. Qualification requirements- vocational and technical education. Advanced training and work experience as a 3rd category transformer coil winder - at least 1 year.
1.3. Knows and applies in practice:
- structure and principle of control of a horizontal winding machine, a carriage for installing drums with wire;
- winding technology of the above coils, requirements for windings and insulating parts, quality control methods.
1.4. A transformer coil winder of the 4th category is appointed to the position and dismissed from the position by order of the organization (enterprise/institution).
1.5. The winder of coils of transformers of the 4th category is directly subordinate to _ _ _ _ _ _ _ _ _ _ .
1.6. The 4th category transformer coil winder controls the work of _ _ _ _ _ _ _ _ _ _ .
1.7. The winder of coils of transformers of the 4th category during absence is replaced by a person appointed in in the prescribed manner, which acquires the corresponding rights and is responsible for the proper fulfillment of the duties assigned to it.
2. Characteristics of work, tasks and job responsibilities
2.1. Winds coils of cylindrical multilayer windings from round and rectangular wires of transformers of the third size, winds screw windings of transformers of the third size with a number of parallels of more than 12 hectares of screw single-pass windings of transformers of the fourth size.
2.2. Winds continuous coils of transformers of the first, second and third dimensions, winds disk coils of transformers of the fourth and fifth dimensions.
2.3. Winds cylindrical, multilayer winding blocks with round and rectangular wires, round and oval shapes, transformers of the first and second dimensions.
2.4. Knows, understands and applies current regulations relating to his activities.
2.5. Knows and complies with the requirements of regulations on labor protection and environment, complies with the standards, methods and techniques of safe work performance.
3. Rights
3.1. The 4th class transformer coil winder has the right to take action to prevent and eliminate the occurrence of any violations or non-conformities.
3.2. A 4th category transformer coil winder has the right to receive all social guarantees provided for by law.
3.3. The winder of transformer coils of the 4th category has the right to demand assistance in the performance of its job responsibilities and exercise of rights.
3.4. A 4th category transformer coil winder has the right to demand the creation of organizational and technical conditions necessary for the performance of official duties and the provision necessary equipment and inventory.
3.5. A 4th category transformer coil winder has the right to get acquainted with draft documents relating to his activities.
3.6. A 4th category transformer coil winder has the right to request and receive documents, materials and information necessary to perform his job duties and management orders.
3.7. A transformer coil winder of the 4th category has the right to improve his professional qualifications.
3.8. A 4th category transformer coil winder has the right to report all violations and inconsistencies identified in the course of its activities and make proposals for their elimination.
3.9. A transformer coil winder of the 4th category has the right to become familiar with the documents defining the rights and responsibilities of the position held, and the criteria for assessing the quality of performance of job duties.
4. Responsibility
4.1. The winder of the coils of transformers of the 4th category is responsible for failure to fulfill or untimely fulfillment of the requirements of this job description obligations and (or) non-use of granted rights.
4.2. The winder of transformer coils of the 4th category is responsible for non-compliance with internal labor regulations, labor protection, safety regulations, industrial sanitation and fire protection.
4.3. The 4th category transformer coil winder is responsible for disclosing information about the organization (enterprise/institution) that is a trade secret.
4.4. The winder of transformer coils of the 4th category is responsible for failure to fulfill or improper fulfillment of internal requirements regulatory documents organization (enterprise/institution) and legal orders of management.
4.5. The winder of transformer coils of the 4th category is responsible for offenses committed in the course of its activities, within the limits established by the current administrative, criminal and civil legislation.
4.6. The coil winder of class 4 transformers is responsible for causing material damage organization (enterprise/institution) within the limits established by current administrative, criminal and civil legislation.
4.7. The 4th category transformer coil winder is responsible for the unlawful use of the granted official powers, as well as their use for personal purposes.
For all radio amateurs or enthusiasts interested in sound-reproducing equipment, a winding machine is an extremely popular piece of equipment. Such devices are used for winding single-layer and multi-layer cylindrical coils for transformers.
In this article we will study the design and operating principle of the winding machine, and also consider step by step instructions, following which you can make such equipment with your own hands.
1 Design and principle of operation
The winding machine is indispensable in the production of similar products. There are two types of such units - automatic and manual, while the latter are practically not common in the industrial sector due to limited functionality.
However dimensions, the heavy weight and cost of automatic winders make them inapplicable in everyday life, so it is better to get a manual machine for your home. Standard design such a device consists of the following elements:
- a supporting frame made of two vertical posts made of metal or wood, between which horizontal axes are fixed (on the central post - for the plates with a wheel, on the outer one - for the coil itself);
- large and small gears that transmit torque to the reel;
- a handle fixed on a large gear, through which the axis with the reel rotates;
- fastening elements - screws and nuts.
The principle of operation of such a device is extremely simple - rotating the handle leads to winding a wire or cable onto a rotating frame; the stacker guide, which moves the wire in a horizontal plane, is responsible for the uniformity of winding.
Monitoring the number of turns can be done both visually and using special counters, the simplest of which is a regular bicycle odometer. In more advanced machines, a special magnetic reed sensor is used as a counter.
1.1 Magazine machines
Among industrial winding units, the cable winding machine SRN-05M3 is widely popular. This model was put into operation during the Soviet era, and since then has proven itself well due to its high reliability and performance. On the secondary market, SRN-05M3 can be found for 15-20 thousand rubles.
SRN-05M3 is made of cast iron, the weight of the equipment is 80 kg, the dimensions are 877 * 840 * 142 cm. The machine allows you to wind single-layer, double-layer and toroidal coils in automatic laying mode. Minimum diameter cable - 0.05 mm, maximum - 0.5 mm. The unit is equipped with a single-phase electric motor of the UL-62 type, the power of which is 0.18 kW. The highest rotation speed during winding is 5100 rpm.
For household use best choice will manual machine NZ-1 (China). Despite the country of origin, the NZ-1 is quite reliable and functional equipment. The unit is designed for winding coils with a diameter of up to 150 mm, with a maximum width of no more than 100 mm. The gear ratio is 1:08 in fast mode winding and 1:0.1 in slow. Maximum speed- no more than 1000 rpm.
NZ-1 is equipped with a revolution counter mechanical type. The body is made of metal, the supporting frame is made of cast iron. The machine is equipped with a pulley, which allows you to connect an electric motor to it via a belt drive and operate in automatic mode. The cost of such equipment varies between 4-5 thousand rubles.
1.2 Homemade winding machine (video)
2 Making a winding machine with your own hands
The cable winding machine presented in this section of the article allows you to work with coils on a square, round and rectangular frame with a diagonal of up to 200 mm; it can be equipped with different pulleys, which will allow you to change the winding pitch within 0.3-3.2 mm.
The diagram below shows the frame of the machine. To assemble the frame are used metal sheets thickness 15 mm (for the base) and 5 mm (for the side sections). Saving on metal thickness is not welcome, as it leads to a decrease in the weight of the unit and, as a result, a deterioration in its stability.
You will need to cut out the frame blanks (the dimensions are observed) and drill two through holes, then the sides are welded to the base plate. You need to mount 2 bearings in the lower hole, and bushings for the rotation shaft in the upper hole.
As a shaft, you can use a 12 mm smooth reinforcement bar, which must first be sanded and painted. For the stacker sleeve, you can take a rod with a diameter of 10 mm, along the entire length of which a thread of standard M12 * 1.0 is cut.
It is better to make triple pulleys, but keep in mind that their total thickness should not exceed 20 mm. With greater thickness, it will be necessary to additionally increase the length of the shafts by a similar size. The combination of pulleys indicated in the diagram allows the use of 54 different winding steps. If you need to work with wires with a diameter of less than 0.31 mm, you will need an additional 12/16/20 mm pulley, with which you can wind 0.15 mm wires.
For construction manual drive you will need a large gear and handle that are held in place by a collet on the top shaft. Thanks to the use of a collet, you can, if necessary, interrupt the winding by fixing the handle, thereby preventing the reel from unwinding.
The thread counter for the winding machine is made from a regular calculator. You will also need a magnet with a reed sensor (can be bought at any radio equipment store), the leads of which must be connected to the contacts of the calculator on the “=” button.
2.1 How to work on a homemade machine?
So, the equipment is ready, how to work on it? To install the winding frame, it is necessary to extend the upper shaft from the mounting socket to a length equal to the length of the frame. Next, the right disk and the coil mandrel are mounted on the shaft, on top of which the coil itself is put on. The next step is to install the left disk and screw on the nut, after which everything is installed in its original position.
A nail is placed in the hole on the upper shaft and the frame is centered, after which the frame is clamped with a nut. Further operations are performed in the following sequence:
- A pulley of suitable diameter is placed on the feed shaft.
- By rotating the pulley, the stacker moves to the extreme position, to one of the sides of the reel.
- A wire belt is put on the pulley - in a ring or figure eight. The end of the wire must be threaded under the middle shaft, placed in the stacker chute and secured to the frame. The wire tension is adjusted using clamps on the handler.
- At the beginning of winding, the combination “1+1” is typed on the calculator, after which the handle is rotated. With each full revolution of the shaft, the calculator will independently increase the number on the screen by one, thereby counting the number of turns of the wire.
Since this equipment has an extremely simple device that does not have any kind of winding machine control controller, during operation you will need to constantly monitor the reel and, if necessary, adjust the cable on the frame manually.
If you want to make the machine more functional, you will need to complicate the design by adding a controller to it. This will allow you to automate the workflow, however, for fully mechanical pairing, you need to install a stepper motor in the controller (a regular 24-volt drive operating in 44-60 steps per revolution mode will do). Power transistors for this kit are selected based on the characteristics of the motor. The ATmega8 device is ideal as a controller; you can buy it for 150-200 rubles.
