🚀 go-pugleaf

I built a machine to wind wire on a core evenly. I used a sewing machine
motor and foot controller for the operator to have complete control over the
start, stop and hesitation during the operation. But I added a screw onto
which I put Teflon fingers to tension and guide the wire from left to right,
right to left. The machine could handle wires from #26 through #36 and all
that was required was a screw adjustment on a flywheel I put between the
bearing holding the winder shaft, which has a Jacob's chuck to hold whatever
mandrel selected for a particular job.

Think of two microswithces at each end of travel which trigger a simple
latching relay. Connect the screw to a stepper motor to a Minarik 230 Series
Modular Translator drive - now link a punched round disk connected to the
flywheel so it moves in or out thus giving you the control for the pitch
diameter of the wire. Connect an optical sensor so that each time the
punched hole opens it passes one signal to the stepper controller which will
turn the screw driver one pulse.... make your setup match the number of
stepper pulses needed to advance the saddle exactly the distance of the wire
diameter for each winding shaft revolution. You can do this with accuracies
of .0001" or better.

Total cost of the machine was less than $1,000 and is still running after
five years in operation.