The old winder that you see in the first pictures, uses a stepper motor controller and two NE555's to drive and control the stepper motor that drives the lead screw. The lead screw is M4 traded rod and is coupled directly stepper motor. The carriage that has the pulleys to guide the wire to the coil former is coupled to the lead screw with a M4 nut. another M4 traded rod has two M4 nuts which has large washers soldered to them, there is one each side of the carriage, when the carriage pushes against one of the washers the rod pushes a micro switch at one end to tell the controler to change direction.
My new setup will be very similar but with a PIC controlling it. This will enable easier setup and more precise movement of the carriage.
I am only starting on this part of the winder but have most of the code wrote for it. I am using a PIC18F4520. I have posted a photo of the progress so far.
I will be using a M6 traded lead screw which has a 1mm pitch, the stepper motor that I am using has 100 steps, so each step will move the carriage by 10um. To get the carriage to move fast enough each step needs to be 2ms this will be approximately equal to 5mm per second movement of the carriage. To drive the stepper motor at 2ms per step and with good toque it needs a supply voltage of 18v, this is far too high a voltage to use as a holding voltage, the motor would overheat very quickly. I use 5V holding voltage and the PIC switches it up to 18V immediately before the motor takes a step.
The PIC also ramps up the speed at the beginning of each movement, first step is 4ms the second is 3ms and all the rest are 2ms, this improves the starting toque.
The first line on the display is the turns counter, the next is the wire diameter in micrometer's and then the number of turns in the last full layer wound (I put it there just because there was a spare line on the display), the last line shows the direction of travel of the carriage. The wire diameter (including insulation) is imputed via up/down switches, the PIC calculates how many steps it needs to take at each turn of the coil former. The old system had to take the same number of steps each time the former turned, the PIC can vary the number of steps for each turn so that errors don't accumulate. At worse every 10 turns it is exactly where it should be, for every time it is not where it should be it is no more than 9um out. This is far better than it needs to be and the mechanical tolerances are far greater than this.
As far as PIC's go I am just a novice this is my second PIC project.
I use Great Cow BASIC
and Great Cow Graphical BASIC. It took a bit of reading up and a lot of trial and error but was worth it. It's unbelievable what these PIC's can do. I am just using there basic functions in this project.
IF you would like the code that I have wrote so far just send me a PM with your email address.