Assembly Process: Jig Preparation + Coiling

A project log for Portal Point Generator

An efficient and compact generator that can be coupled with wind turbines or water wheels to produce upwards of 100W

VijayVijay 07/13/2018 at 13:590 Comments

Jig Preparation:

The winding jig is used to wind the coil. The Jig and the Jig holder are fastened together using M3 fasteners.

Figure 1: Both jigs affixed together along their shape and their elevations facing each otherPrint 2 Jigs,  fix them along their shape, and elevations facing each other.

Figure 2: Jig handle attached to the jigs on one faceAttach the 3DP Jig Holder on one of the faces. I recommend marking this face, and you should use the same convention when winding all the coils., and the winding direction should match. 

Figure 3: Jig handle attached to the jigs on one faceFasten everything togehter

Figure 4: Wire inserted through hole in the jig to help the wire sit in the grooveThere is a small hole in the jig through which you can slot the wire, to keep it in place while winding.  Put the 30 AWG wire into this from the inside of the jig, coming out.

Figure 5: Attach kapton tape to the face of each edge in a reverse manner to help get the coil out of the grooveAttach kapton tape in the 3 slots . Once the coiling is done, the kapton will be folded onto the finished coil to hold its shape.

Coil Preparation:

The jig is mounted on a power screw driver/drilling machine using a HEX bit. There is a notch on the jig to indicate when the maximum number of coils are reached.

Try and maintain a constant level of tension on the coils to get a roughly same number of coils. 6 coils will need to me made like this.

Use kapton tape to keep the cool from unwinding. Keep the kapton in place on the inside of the coil, and wind on top of it.

There is a hole on the jig where the start of the coil is placed. As long as you use the same convention for winding, and placing into the coil holder, you should be alright, only the polarity of the DC would change.

To Do: Automate this process with a encoder and counter to be more accurate.

Figure 7: Wire being wound around the jig with the help of a hand drill and drill bit

 If you have the patience, you can hold the handle and wind by hand, or use a drill/power driver to make this faster. You need 6 coils.

Figure 8: Unscrewing the jig handle

Fold the Kapton tape over the coil to hold it in place. Now work backwards to remove the coil.

Figure 9: Removing the jig handle