[Solarbotics] shared a video of their DIY winder, which uses OpenBeam hardware and some 3D printed parts to perfectly wind the wire, regardless of whether the pipeline shaft size matches. Connecting wires from one spool to another can be trickier than it sounds, especially when the physical size of one spool is larger than the other. This is because continuously moving the wires between spools of different sizes requires them to rotate at different rates. Most importantly, the ideal rate will change as one spool empties and the other spool becomes larger. When moving from one spool to the next, the wire must remain taut; any slack is a winding problem. At the same time, the wire should not be too tight, so as not to put unnecessary pressure on it or the motor at the other end.

There are no construction details, but the video embedded below provides a good overview and understanding of the entire system. In the middle is a pull rod with pulleys at both ends through which the wire is fed. The rod rotates in the center and remains slack, while the position is encoded by turning the pot with a 3D printed gear. Both spools are driven by motors, and the speed of the source spool is controlled by the position of the lever. Therefore, the rod will automatically absorb any slack while dynamically slowing down or accelerating the feed rate to match any needs.

There is nothing more appropriate than facing repetitive and lengthy tasks to get a good solution. This reminds us of another DIY automation solution that meets wire-related needs: a device that cuts 1,000 wires.

Well, I have been designing my mother's sewing machine since 1887.

Somehow, I don’t think your mother’s sewing machine can handle such a large bobbin or bobbin. Just because he re-used an existing concept and expanded it for his application does not make it less useful or noteworthy.

You make this sound like a bad thing. Most inventions of hackers or anything are iterative, or rediscover things that already exist. Sewing machine technology and thread/3d filament winding is a strange logical leap for some people, while others are "nonsense of course". Oops, the chip manufacturer "stole" the traditional lithography technology used for newspaper photo reproduction to better produce the chip... Then you accept the idea, you can jump to the resin curing in laser-based 3D printing... ...Just use light instead of plastic and "slice" printing with heating elements stolen from the toaster.

Or you can be rash, but Aristotle did this to Plato in 347 BC.

I believe that the tensioning arm will provide feedback to the wind drive to prevent overrun or underrun. This prevents pulling in the wire harness, which would kink or break the wire when the wire is unwound, and prevent bird nests, which may require cutting off tangles and wasting the wire.

I guess your sewing machine has the same tension system as mine: friction on the spool to reduce spillage, and a friction disc on the thread for needle tension.

Similar concepts may already be used in existing industrial winding equipment, and it is certain that they are-or were :-)-used in tape drives.

It's really smart. Does the electromagnetic winding machine along these lines work?

A clever solution, but I am not sure if I understand the problem. Why does the wire need to be on the small spool instead of the big spool? Are they selling it, packing for a trip, or part of a small pick-and-place facility? Why is spool shifting so common that the time to develop a fixture is reasonable? Is it equally convenient to use the main spool for the average store? If it's a "because I can" project is cool, but the problem with this solution is not well explained.

Suppose he wants to wind a lot of coils for his maglev home robot project?

Maybe, but why is it a spool? Isn’t the magnetic levitation coil usually installed on a dedicated spool? This looks like refilling the spool for some purpose. Most of the time, lathes or drills are fine. All of their other products are wearables or solar-powered BEAMbots. I don't see what this is for, so it's the motivation to build it.

40 strands of 0.08 mm super-flexible heat-resistant casing. Don't knock it before you try it (by the way, we will give away samples in every order).

it. Makes PVC-coated wires dwarfed. For the same reason, I do not use "KrazyGlue" on high-quality cyanoacrylates. Both are effective, but it is much better to use one of them.

It may be suitable for installation in the housing of a prefabricated printer.

I know that if I really want to, I can rewind the spool in the davinci cartridge, because I have a professional version and there is no drm on the filament, but because I don’t want to bother me printing a spool holder that can be installed outside, allowing almost Any spool size can be used.

I'm sure it can be used for that, but they designed it for wires. Especially the "noodle thread", which is a certain high-purity copper insulated by a very flexible coating. It seems to be very popular in RC and wearable devices.

We fell in love with silicone wire not long ago and wanted to buy some for our own projects. We couldn't find anyone selling a 100M length product, so after a lot of searching, we found that we need an investment of 50,000M (50 kilometers-31 miles!) to get the number of lines and colors we want. When you buy 50km, they will (try to) do Pantone matching and even custom print on the side. Cool.

Sooo, what about the extra? Spool and sold as a separate and 7-color set! We thought about winding the spool for us, but since we didn’t know exactly how much to convert to a spool, we decided to wind the spool ourselves. Yes, we considered buying a commercial unit, but this is too much. The sewing bobbin is too light. Therefore, the natural conclusion is to construct it yourself.

Very satisfied with most design choices. The PID loop of the tensioner was investigated, but a simple lookup table of PWM and resistance turned out well. We are very happy to feed PWM through a beautiful sturdy FET driving a cordless screwdriver with a 3D printed spindle mount.

We have a stack of cable bearing/pulley sets from PCB feeders for fixed pick-and-place machines that perfectly fit the wires, and 3D printed brackets with semi-fixed channels to keep the wires on the pulleys when fully slack.

The only idea I really want to change is feedback fine-tuning. This should be optical gray coding to avoid wiper wear, but I think this audio taper fine-tuning will wear less than traditional hobby servers. Oh, I have to put a spring instead of using that (doomed to fail) rubber band to return.

Again, OpenBeam makes it so easy to build and adjust. Like these things.

The mandrel on the variable speed hand drill and the take-up spool, the vertical screwdriver is fixed in the vise, and the supply spool rests on the rag friction brake on the vise. complete. simple.

When laying down the sounding line used to determine the depth of the Atlantic Ocean before laying the first cable, the sounding line must be re-wound. Then set sail and do it again. They have a spool of more than two miles. When reeling from a deep place for the first time, the reel imploses due to the accumulated pressure on its core. So they developed slack control. When it turns and is dragged away, all the pressure of that line is added to the drum. Therefore, the winch is responsible for traction, and the drum runs with slight tension without traction pressure, just like a tape recorder.

When winding fine enameled wire on a magnetic coil, it is important to maintain very low tension during the winding process. This is why most of these things disappear or short-circuit. This is a miniature version of a ship that is dragging a sounding line.

How about a cheap and easy-to-build version of the horizontal wind mechanism used by the open bait fishing reel? Those whose reels are perpendicular to the rods have a thread guide loop that runs back and forth to ensure that it is not tangled.

I have some printer filament spools, which must be allowed to loosen when filling. The filament crossed a lot under itself, and I had to keep pulling it out. For long hours of work, I have to untie a bunch and then carefully roll it up.

A device that can take out the filament from a heavily wound spool, with enough pulling force to pull it out of the overlapping coil, and then correctly wind it onto another spool, which will be a very good thing. Especially if it does not require any electronic equipment. In this case, the feed spool can run freely, just apply some tension on the take-up spool to ensure that the filament does not wind the overlapping coils in the wrong way.

Because that mechanism will twist the wires. For fishing lines, this is no problem, but copper has poor flexibility.

Not bad. What if I want to maintain a fixed/required tension during winding...any ideas...

What about spring arms, such as bicycle chains?

Use air cylinders to preload the floating arms/beams.

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