Easiest way to rewind transformer - Page 1
Forum section: electronics / repair

author: 001
author_rank: Super Contributor
timestamp: October 12, 2019, 08:18:10 pm
content: Hiis it possible rewind transformer without winding machine?

author: LateLesley
author_rank: Frequent Contributor
timestamp: October 12, 2019, 08:39:57 pm
content: I think it is, but you would need a lot of time and patience. You could probably make some form of jig to do it. There's plenty of videos on youtube on how to wind transformers. Here's one example.You'd probably be better trying to find one ready made to fit your needs though.

author: wraper
author_rank: Unknown
timestamp: October 12, 2019, 09:01:16 pm
content: Completely possible. Though will require patience and winding quality will be worse unless you want to spend a lot of time to do it neat.

author: TheMG
author_rank: Frequent Contributor
timestamp: October 12, 2019, 11:06:54 pm
content: Toroidal transformer, or E-I core transformer?Toroidal transformer is totally doable, but without a specialized machine will require A LOT of patience as the the entire length of the winding needs to be passed through the core of the toroid every single turn.E-I core can be much easier IF the core can be disassembled so you can remove the bobin from the core. Some transformers the laminations are welded together, but others are held by a crimped outer shell or even nuts and bolts. Almost all are dipped in varnish which will tends to stick the laminations together.So yes, totally doable, but depending on the specific construction of the transformer can range from a fairly easy task to a complete nightmare.If you can free the bobin from the core, you can rig something up to a variable speed drill to accelerate the winding process.

author: 001
author_rank: Super Contributor
timestamp: October 13, 2019, 08:37:51 am
content: YeaI mean EI coresBut I can`t google practic guidelines exept manuals for semiautomatic monstersAll I have is hand drill jig and handsIt is low end technologyHow to make winding outputs right? How to make bobbin from paper? What is the best way to glue? etc

author: PKTKS
author_rank: Super Contributor
timestamp: October 13, 2019, 02:36:36 pm
content: the thicker the gauge the more impractical it is.Although some thin coils can be done ... more or less easilyA small machine does worth the moneyPaul

author: bd139
author_rank: Super Contributor
timestamp: October 13, 2019, 03:05:21 pm
content: My uncle has a winding machine he made himself. It was a drill mount on a bit of plywood, a bit of threaded rod and a couple of chunks of plywood and some wing nuts and washers to clamp the bobbin. He made a turns counter with a microswitch screwed to the base activated with an egg shaped bit of plywood. This was all attached to a simple 4 banger calculator’s equals button. You put 1++ in the calculator and start winding and it accumulates the turns. Must have cost him about $10 in parts.I occasionally wind E cores here. Usually just do it by hand. Takes a while but not impossible.

author: exe
author_rank: Unknown
timestamp: October 13, 2019, 07:31:47 pm
content: Quote from: TheMG on October 12, 2019, 11:06:54 pmI think it's possible to do several windings and connect them in series. Or just make one winding from multiple pieces of wire. Just be sure to insulate it well, and no sharp edges so it won't damage other turns.PS I also compared tight turns with loose ones. No difference in output voltage, even if it's super-loose. But I recommend to make it tight a bit to reduce hum and friction between turns. Friction may damage insulation and cause shorts.

author: wraper
author_rank: Unknown
timestamp: October 13, 2019, 09:24:19 pm
content: Quote from: exe on October 13, 2019, 07:31:47 pmYou don't need to do such stupid shit. Just use netting shuttle with enough wire for entire winding.QuoteOf course there won't be differenceunder no load. However total winding length will be longer = higher resistance. Also you use more space, thus will need to use thinner wire than you could. Again meaning higher resistance.

author: Bud
author_rank: Super Contributor
timestamp: October 13, 2019, 09:50:00 pm
content: I used to do something like in your first photo, with a proper ratio of the transformer circumference to the jig length you can do just fine in terms of convenience and easy of the winding job.

author: jdragoset
author_rank: Frequent Contributor
timestamp: October 14, 2019, 12:20:11 am
content: For smaller ID toroids, I use a pop sickle stick cut with a "V" notch each end as the net needles will be too wide.As a group, the automatic toroid winding machines and operators were exceptional pieces-of-work.Very many, reliably, have gone into orbit and beyond.

author: tautech
author_rank: Super Contributor
timestamp: October 14, 2019, 04:25:40 am
content: Quote from: 001 on October 12, 2019, 08:18:10 pmYep, lathe or cordless drill on slow speeds.Nice overview website:https://ludens.cl/Electron/trafos/trafos.html