For my Linear Induction motor project, I need to be able to consistently produce uniform coils. While it is possible to make coils by hand, I am not very skilled in hand coil winding, so I elected to build a CNC coil winder instead. This coil winder is built such that it can build a wide array of coil geometries, supporting coil diameters up to 75mm and lengths of up to 175mm.
Here is a photo of the completed first iteration of the coil winder. Although it does not have a built in wire tensioner it should do the trick!
This is a view of the finished first iteration from the front of the system.
Here the control system is visible. The control is based on an Arduino Uno running an open source GRBL interpreter for Arduino. The Arduino then sends signals to the two stepper driver boxes to control the stepper motors.
Here is the complete V1 of the system without the second layer for the electrical control. The Wire guide has been installed, and a second plate has been installed on the other side.
Here is a mostly put together prototype of the coil winder. It uses a plate made on a waterjet cutter and 80/20 extrusion as the frame, and has both the stepper for the rotary axis and linear to control the feed installed.
Here is an image of the first prototype partially assembled. A second plate needs to be added to the left end, and collects and wire guides need to be installed.