What is it about coil winding automation projects that’s just so captivating? Maybe it’s knowing what a labor saver they can be once you’ve got a few manually wound coils under your belt. Or perhaps it’s just the generally satisfying nature of any machine that does an exacting task smoothly and precisely. Whatever it is, this automatic Tesla coil winder has it in abundance.
According to [aa-epilectrik]’s account, the back story of this build is that while musical Tesla coils are a big part of the performance of musical group ArcAttack, they’re also cool enough in their own right to offer DIY kits for sale. This rig takes on the job of producing the coils, which at least takes some of the drudgery out of the build. There’s no build log, but there are enough details on reddit and Instagram to work out the basics. The main spindle is driven by a gearmotor while the winding carriage translates along a linear slide thanks to a stepper-driven lead screw. The spool holding the fine magnet wire needs to hold proper tension to prevent tangling; this is achieved through by applying some torque to the spool with a small DC motor.
There are some great design elements in this one, not least being the way tension is controlled by measuring the movement of an idler pulley using a linear pot. At top speed, the machine looks like it complete a coil in just about three minutes, which seems pretty reasonable with such neat results. Another interesting point: ArcAttack numbers [Anouk Wipprecht], whom we’ve featured a couple of times on these pages, among its collaborators. Small world.