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renewableMark Guru Joined: 09/12/2017 Location: AustraliaPosts: 1678
Posted: 08:31am 08 Mar 2018
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Got the primary wound this afternoon, 35 strands of 2mm2.
Cheers Caveman Mark Off grid eastern Melb
Madness Guru Joined: 08/10/2011 Location: AustraliaPosts: 2498
Posted: 08:40am 08 Mar 2018
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If you wind it through the hole with that coil size or little smaller and keep doing that till it is all back in a coil through the hole it is easier to handle. When you do the first turn of the big coil tape the end to the next turn so it keeps threading through on each turn. It pays to pay attention to each corner and get as snug as you can. Also helps to mark out the spacing rather than trying to tidy it after.There are only 10 types of people in the world: those who understand binary, and those who don't.
renewableMark Guru Joined: 09/12/2017 Location: AustraliaPosts: 1678
Posted: 08:52am 08 Mar 2018
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Had to read that a couple of times to get it, but yeah, got it thanks, Mad. BTW average is 13mm diameter.
Being involved with a few 4wd recoveries, I can see this is actually quite a dangerous process, there is a fair amount of weight here and it's under tension, if you do this take great care. A couple of "winch rope dampeners" is a good idea. (the twisting part I meant)Edited by renewableMark 2018-03-09Cheers Caveman Mark Off grid eastern Melb
Madness Guru Joined: 08/10/2011 Location: AustraliaPosts: 2498
Posted: 09:23am 08 Mar 2018
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What internal circumference and how many turns do you have to fit in?There are only 10 types of people in the world: those who understand binary, and those who don't.
renewableMark Guru Joined: 09/12/2017 Location: AustraliaPosts: 1678
Posted: 09:27am 08 Mar 2018
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Looks like 77mm ID and 14 turns to get spot on 26VCheers Caveman Mark Off grid eastern Melb
Tinker Guru Joined: 07/11/2007 Location: AustraliaPosts: 1904
Posted: 09:29am 08 Mar 2018
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Mark, until you are actually *doing* it you won't "get it". But then, when you realise what you thought will be a horrible job, turns out to be quite simple you won't be able to wipe that grin off your face .
How many times did you read that .Klaus
Madness Guru Joined: 08/10/2011 Location: AustraliaPosts: 2498
Posted: 09:36am 08 Mar 2018
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My calculations say you 14mm for each turn.There are only 10 types of people in the world: those who understand binary, and those who don't.
renewableMark Guru Joined: 09/12/2017 Location: AustraliaPosts: 1678
Posted: 09:50am 08 Mar 2018
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I won't be bloody grinning till the bastard works mate. Thanks Mad, reckon I'll just sneak in.Cheers Caveman Mark Off grid eastern Melb
Madness Guru Joined: 08/10/2011 Location: AustraliaPosts: 2498
Posted: 10:54am 08 Mar 2018
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Keep in mind you need to keep the turns in the hole hard against the core or they will have less diametre available. Also it would be a good idea to insulate it, either with heat-shrink of insulation tape before winding it.There are only 10 types of people in the world: those who understand binary, and those who don't.
renewableMark Guru Joined: 09/12/2017 Location: AustraliaPosts: 1678
Posted: 03:39am 09 Mar 2018
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Well it didn't go to plan, when you lever the cable against the inner it seems to flatten it out a bit and takes up more room. Two wires ended up overlapping.
Cheers Caveman Mark Off grid eastern Melb
Warpspeed Guru Joined: 09/08/2007 Location: AustraliaPosts: 4406
Posted: 04:47am 09 Mar 2018
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Overlapping does not matter. As long as it passes through the hole any way it can get through, it counts as one more turn. As long as one bunch of wires does not short to the next bunch next to it, you are winning. I see 13 turns there if my eyes are not deceiving me. One more to go and you can treat yourself to a beer.
*Edit* If you can fit one extra additional 15th turn in there at this stage do it, overlap does not matter. You can always remove that extra turn later on, after some testing.
That is always a lot easier than trying to figure out how to add an extra turn after you have cut and stripped your wires to final length.
Give yourself the option of having that extra turn already on there to remove.........Edited by Warpspeed 2018-03-10Cheers, Tony.
Madness Guru Joined: 08/10/2011 Location: AustraliaPosts: 2498
Posted: 05:53am 09 Mar 2018
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Not sure if it is the angle of the camera but it looks like you spacing around the outside is uneven electrically that does not matter but it has effect of the wire position it the hole.
Looks like you have 13 turns through the hole, I used a couple tyre levers to squeeze out a gap to get the last turn or 2 in.There are only 10 types of people in the world: those who understand binary, and those who don't.
brucedownunder2 Guru Joined: 14/09/2005 Location: AustraliaPosts: 1548
Posted: 05:59am 09 Mar 2018
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Yep,that’s fine ,Mark.
Overlapping was my concern also ,many yers back when I wound my Torodial.
Makes no difference,apparently.
I left an extra turn or two on for the testing ,until I was happy with the final voltage.
Looks like you are doing everything correct ,so a pat on the back ,you deserve another beer..
When will the new one for me be ready, haha,put that scanner down ,I,m a defenceless old man,?.
BruceBushboy
Warpspeed Guru Joined: 09/08/2007 Location: AustraliaPosts: 4406
Posted: 06:01am 09 Mar 2018
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No reason to use tyre levers or any force. Fourteen (or fifteen) turns through the hole is the only requirement when you are working near the middle. Even spacing is only a aesthetic thing, and you can fiddle that when you have all the turns on.Cheers, Tony.
Madness Guru Joined: 08/10/2011 Location: AustraliaPosts: 2498
Posted: 06:09am 09 Mar 2018
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It is a hell of a lot easier to mount the thing if you can get all the wires against the core and it does not take make much create the space needed.There are only 10 types of people in the world: those who understand binary, and those who don't.
Warpspeed Guru Joined: 09/08/2007 Location: AustraliaPosts: 4406
Posted: 06:09am 09 Mar 2018
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Bruce, we posted simultaneously.
Its always best to plan your secondary for full windings with minimal gap or overlap, because these windings are very close to the core.
When you are working much closer to the middle of the hole, as you will be with a huge monster primary, the effect of bunching the turns unevenly becomes unavoidable, and it really has no effect anyway.
Mark, what you have will be fine and will work wonderfully well. Time for a beer.Cheers, Tony.
Warpspeed Guru Joined: 09/08/2007 Location: AustraliaPosts: 4406
Posted: 06:13am 09 Mar 2018
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Yes, its a physical mounting and aesthetic thing only. But a lumpy primary will work perfectly well.
Much better to have a few humps and bumps than try forcing it and fatally damaging the insulation between the turns.Cheers, Tony.
Madness Guru Joined: 08/10/2011 Location: AustraliaPosts: 2498
Posted: 06:25am 09 Mar 2018
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It does not take that much force from my experience.There are only 10 types of people in the world: those who understand binary, and those who don't.
renewableMark Guru Joined: 09/12/2017 Location: AustraliaPosts: 1678
Posted: 06:33am 09 Mar 2018
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Just seem to run out of room, the end will sit pretty flat for mounting so no big deal I suppose. Cheers Caveman Mark Off grid eastern Melb
Warpspeed Guru Joined: 09/08/2007 Location: AustraliaPosts: 4406
Posted: 06:38am 09 Mar 2018
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That is fine Mark.
By the time you have fitted a "top hat" and a bloody big through bolt, and fudged the outer windings for even spacing (for looks only) it will be a perfectly functioning masterpiece.
Notice. New forum software under development. It's going to miss a few functions and look a bit ugly for a while, but I'm working on it full time now as the old forum was too unstable. Couple days, all good. If you notice any issues, please contact me.
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