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This project was inspired from UK CNC winding machine, development started in 2018 and it was originally designed based on Mega but it had issue keeping up with high RPM and so the project upgraded to a Arduino Due with the main Console written in Microsoft Visual Basic. It took me more than 4 years to reach the current stage of development.
*Recommended using Arduino Due as the 84mhz clock speed is able to keep up with the high rpm rate and smaller lead screw pitch.
The Precision of the winding will largely depends on your hardware:
- Using Closed Loop Stepper motor
- High Grade Precision Ball Screw for the feeder
- SKF Linear bearing and ball bearing
- CNC machined bearing housing and parts with dowel pin positioning
Other features include:
- SDCard to store microstep, leadscrew size and gear ratio settings
- Pushing of data back and forward from Console to Arduino Due
- Added honeycomb winding(Not fully tested)
1 / 10 • Main Winding Console
Facebook group: https://www.facebook.com/groups/804317050166139
Posting in diyaudio: https://www.diyaudio.com/community/threads/diy-voice-coil-winding-machine.320505/
Winding diagram(Visio): https://drive.google.com/file/d/1_6f2hie3eDf1MylQuOxnzkuoEMLCf04q/view?usp=sharing
Visual Basic Source Code: https://drive.google.com/file/d/1AOmF5mqrvjK27zb0kKF-ql0HPubnvbuI/view?usp=sharing
Winding Machine Console EXE: https://drive.google.com/file/d/15WdvWJgELRgZkiP6f_SSHOrFwHynDfkr/view?usp=sharing
Arduino Code: https://drive.google.com/file/d/1J7EjuvvNr1K7UUrEQVwOqorbTNrljsDC/view?usp=sharing
#include <AccelStepper.h>
#include <Wire.h>
#include <SPI.h>
#include <SD.h>
// Stepper Motor Setup
AccelStepper Winder_Stepper(AccelStepper::DRIVER, 3, 4);
AccelStepper Feeder_Stepper(AccelStepper::DRIVER, 7, 8);
//SD Card CS Pin
const int CS = 53;
bool SD_Check = false;
String Config = "";
File Load_Config;
//Firmware
String Firmware_V = "v0.3.1.8:";
//Enable SW for Stepper Motor
int w_en = 2;
int f_en = 6;
//Limit switch
int L_SW = 5;
int R_SW = 9;
//E-Stop Switch
int E_Stop = 13;
//Analog Buttons
int Left_Button = A0;
int Right_Button = A1;
int Winder_DisableButton = A2;
int Feeder_DisableButton = A3;
int Speed_Pot = A5;
//Toggle Switch Contol
int Winder_Toggle = 11;
int Feeder_Toggle = 12;
//Serial Data Input
String Serial_Input;
String EStop_Input;
//Visual Basic Pause
bool Pause = false;
//Pot Speed Input
int Pot;
//Winding Parameters
long Winding_Steps;
int Winding_Speed;
int Feeder_StepsWidth;
long Feeder_Steps;
int Feeder_Speed;
int LayersCounter;
int FDir = 0;
bool FDir0;
bool FDir1;
int WDir = 0;
bool WDir0;
int Winding_StepsA;
//Variables for the serial input array
int ct[9];
int gt[9];
//Homing
bool Home_L = false;
bool Home_R = false;
bool Home_ = false;
//Feeder and Winder Check
bool F_CH = true;
bool W_CH = true;
bool A_CH = true;
//E-Stop Check
bool E_CH = true;
//Manual Feeder speed to compensate for the microsteping
int MicroStepF;
int MicroStepW;
float Fn;
float Wn;
int LeadS;
float FeederRatio;
float WinderRatio;
//Counters
int StepW_Counter = 0;
bool T_CH = true;
void setup()
{
Serial.begin(115200); // USB serial port 0
Load_File();
//Winder Direction
Winder_Stepper.setPinsInverted(true,false,false);
pinMode(L_SW, INPUT_PULLUP); // Left Limit Switch
pinMode(R_SW, INPUT_PULLUP); // Right Limit Switch
pinMode(E_Stop, INPUT_PULLUP); // E Stop Pin
// Stepper Motor Driver Enable Pin
pinMode(w_en, OUTPUT); // Winder Stpper Motor Enable Pin
pinMode(f_en, OUTPUT); // Feeder Stpper Motor Enable Pin
// Stepper Motor Driver Enable Mode
digitalWrite(w_en, HIGH);
digitalWrite(f_en, HIGH);
// Control Buttons
pinMode(Left_Button, INPUT);
pinMode(Right_Button, INPUT);
pinMode(Winder_DisableButton, INPUT);
pinMode(Feeder_DisableButton, INPUT);
pinMode(Speed_Pot, INPUT);
// Toogle Control
pinMode(Winder_Toggle, INPUT_PULLUP);
pinMode(Feeder_Toggle, INPUT_PULLUP);
Winder_Reset();
Feeder_Reset();
Initial_FDir();
Home_Reset();
Input_Reset();
}
void Load_File()
{
Config = "";
if (!SD.begin(CS))
{
Serial.print("Error: Memory card initialization failed.");
SD_Check = false;
}
else
{
SD_Check = true;
}
if (SD_Check == true)
{
Load_Config = SD.open("Config.ini");
if (Load_Config)
{
while (Load_Config.available())
{
Config += (char)Load_Config.read();
}
Load_Config.close();
}
gt[0] = Config.indexOf(':');
MicroStepF = Config.substring(0, gt[0]).toInt();
gt[1] = Config.indexOf(':', gt[0]+1);
MicroStepW = Config.substring(gt[0]+1, gt[1]).toInt();
gt[2] = Config.indexOf(':', gt[1]+1);
LeadS = Config.substring(gt[1]+1, gt[2]).toInt();
gt[3] = Config.indexOf(':', gt[2]+1);
FeederRatio = Config.substring(gt[2]+1, gt[3]).toInt();
gt[4] = Config.indexOf(':', gt[3]+1);
WinderRatio = Config.substring(gt[3]+1, gt[4]).toInt();
Winding_StepsA = MicroStepW * WinderRatio;
}
}
void Winder_moveTo(int W_Steps)
{
Winder_Stepper.moveTo(W_Steps);
}
void Feeder_moveTo(int F_Steps)
{
Feeder_Stepper.moveTo(F_Steps);
}
void Feeder_SpeedSetup(int FSpeed) //Setting Speed for Feeder
{
Feeder_Stepper.setMaxSpeed(FSpeed);
Feeder_Stepper.setAcceleration(FSpeed);
}
void Winder_SpeedSetup(int WSpeed) //Setting Speed for Winder
{
Winder_Stepper.setMaxSpeed(WSpeed);
Winder_Stepper.setAcceleration(WSpeed);
}
void Winder_Reset()
{
Winder_Stepper.setMaxSpeed(0);
Winder_Stepper.setAcceleration(0);
Winder_Stepper.setCurrentPosition(0);
Winder_Stepper.moveTo(0);
}
void Feeder_Reset()
{
Feeder_Stepper.setMaxSpeed(0);
Feeder_Stepper.setAcceleration(0);
Feeder_Stepper.setCurrentPosition(0);
Feeder_Stepper.moveTo(0);
}
void Input_Reset()
{
Winding_Steps = 0;
Winding_Speed = 0;
Feeder_StepsWidth = 0;
Feeder_Steps = 0;
Serial.flush();
}
void Initial_FDir()
{
if (FDir == 0)
{
FDir0 = false;
FDir1 = true;
}
else if (FDir == 1)
{
FDir0 = true;
FDir1 = false;
}
Feeder_SetDir(FDir0); //Feeder Dir //false : Left to Right //true : Right to Left
}
void Initial_WDir()
{
if (WDir == 0)
{
WDir0 = true;
}
else if (WDir == 1)
{
WDir0 = false;
}
Winder_SetDir(WDir0); //Winder Dir //false : Clockwise //true : Counter Clockwise
}
void Feeder_SetDir(bool DirSet)
{
Feeder_Stepper.setPinsInverted(DirSet,false,false);
}
void Winder_SetDir(bool DirSet)
{
Winder_Stepper.setPinsInverted(DirSet,false,false);
}
void Home_Reset()
{
Home_L = false;
Home_R = false;
if (Home_L == false && Home_R == false && Home_ == true)
{
Serial.print("HOME_END");
Serial.flush();
Home_ = false;
}
}
void Home_Toggle()
{
Home_L = false;
Home_R = false;
if (Home_L == false && Home_R == false && Home_ == true)
{
Serial.print("HOME_TOGGLE");
Serial.flush();
Home_ = false;
}
}
void Feeder_Dir()
{
if (Feeder_Stepper.currentPosition() == Feeder_StepsWidth * LayersCounter && LayersCounter % 2 != 0)
{
LayersCounter++;
Feeder_SetDir(FDir1);
}
else if (Feeder_Stepper.currentPosition() == Feeder_StepsWidth * LayersCounter && LayersCounter % 2 == 0)
{
LayersCounter++;
Feeder_SetDir(FDir0);
}
}
void loop()
{
// Input Read Visual Basic Input from Serial
if (Serial.available() > 0)
{
Serial_Input = Serial.readString();
if (Serial_Input.substring(0,8) == "RUN_CODE")
{
ct[0] = Serial_Input.indexOf(',');
ct[1] = Serial_Input.indexOf(',', ct[0]+1);
Winding_Steps = Serial_Input.substring(ct[0]+1, ct[1]).toInt();
ct[2] = Serial_Input.indexOf(',', ct[1]+1);
Winding_Speed = Serial_Input.substring(ct[1]+1, ct[2]).toInt();
ct[3] = Serial_Input.indexOf(',', ct[2]+1);
Feeder_StepsWidth = Serial_Input.substring(ct[2]+1, ct[3]).toInt();
ct[4] = Serial_Input.indexOf(',', ct[3]+1);
Feeder_Steps = Serial_Input.substring(ct[3]+1, ct[4]).toInt();
ct[5] = Serial_Input.indexOf(',', ct[4]+1);
Feeder_Speed = Serial_Input.substring(ct[4]+1, ct[5]).toInt();
ct[6] = Serial_Input.indexOf(',', ct[5]+1);
FDir = Serial_Input.substring(ct[5]+1, ct[6]).toInt();
ct[7] = Serial_Input.indexOf(',', ct[6]+1);
WDir = Serial_Input.substring(ct[6]+1, ct[7]).toInt();
LayersCounter = 1;
Winder_Reset();
Feeder_Reset();
Initial_FDir();
Initial_WDir();
Home_Reset();
Winder_SpeedSetup(Winding_Speed);
Feeder_SpeedSetup(Feeder_Speed);
Winder_moveTo(Winding_Steps);
Feeder_moveTo(Feeder_Steps);
StepW_Counter = 0;
T_CH = false;
Home_L = false;
Home_R = false;
Pause = false;
delay(1500);
}
else if(Serial_Input.substring(0,1) == "Z")
{
Winder_Reset();
Feeder_Reset();
Input_Reset();
Home_Reset();
T_CH = false;
Home_L = false;
Home_R = false;
Pause = false;
Load_File();
Serial.print("#:" + Config + Firmware_V);
Serial.flush();
}
else if(Serial_Input.substring(0,4) == "SAVE")
{
T_CH = false;
Home_L = false;
Home_R = false;
Pause = false;
if (!SD.begin(CS))
{
Serial.print("Error: Memory card initialization failed.");
SD_Check = false;
}
else
{
SD_Check = true;
}
if (SD_Check == true)
{
SD.remove("Config.ini");
Load_Config = SD.open("Config.ini", FILE_WRITE);
if (Load_Config)
{
Load_Config.println(Serial_Input.substring(5, Serial_Input.lastIndexOf(":") + 1));
Load_Config.flush();
Load_Config.close();
}
Load_File();
Serial.print("@:" + Config);
Serial.flush();
}
}
else if(Serial_Input.substring(0,6) == "CANCEL")
{
Winder_Reset();
Feeder_Reset();
Input_Reset();
Home_Reset();
T_CH = false;
Home_L = false;
Home_R = false;
Pause = false;
Serial.print("CANCEL");
Serial.flush();
}
else if(Serial_Input.substring(0,5) == "PAUSE")
{
Pause = true;
}
else if(Serial_Input.substring(0,6) == "RESUME")
{
Pause = false;
Winder_moveTo(Winding_Steps);
Feeder_moveTo(Feeder_Steps);
}
else if(Serial_Input.substring(0,6) == "HOME_L")
{
Home_L = true;
Home_R = false;
Home_ = true;
}
else if(Serial_Input.substring(0,6) == "HOME_R")
{
Home_L = false;
Home_R = true;
Home_ = true;
}
Serial_Input = "";
}
if (digitalRead(E_Stop) == HIGH)
{
if (E_CH == false)
{
Serial.print("ESTOP_N");
Serial.flush();
}
E_CH = true;
//Main Winding Sqeuences Starts//
if(Winding_Steps != 0 || Feeder_Steps != 0)
{
if (Pause == false && digitalRead(Feeder_DisableButton) == LOW && digitalRead(Winder_DisableButton) == LOW && digitalRead(w_en) == HIGH && digitalRead(f_en) == HIGH)
{
// Feeder position where both Limit Switch sensor are off
if (digitalRead(R_SW) == HIGH && digitalRead(L_SW) == HIGH)
{
Winder_Stepper.run();
Feeder_Stepper.run();
Feeder_Dir();
}
// Feeder position is moving Left to Right(Dir == 0), Right Limit Switch is Off and Left Limit Switch is On
else if (digitalRead(R_SW) == HIGH && digitalRead(L_SW) == LOW && FDir == 0 && Feeder_Stepper.currentPosition() < 400)
{
Winder_Stepper.run();
Feeder_Stepper.run();
Feeder_Dir();
}
// Feeder position is moving Right to Left(Dir == 1), Right Limit Switch is ON and Left Limit Switch is Off
else if (digitalRead(R_SW) == LOW && digitalRead(L_SW) == HIGH && FDir == 1 && Feeder_Stepper.currentPosition() < 400)
{
Winder_Stepper.run();
Feeder_Stepper.run();
Feeder_Dir();
}
else
{
Winder_Reset();
Feeder_Reset();
Home_Reset();
Input_Reset();
Serial.print("$");
Serial.flush();
}
//Winder Counter
if (StepW_Counter % Winding_StepsA == 0 && Winder_Stepper.currentPosition() > StepW_Counter)
{
Serial.print(StepW_Counter);
Serial.flush();
}
else if (StepW_Counter == Winding_Steps - 1 && T_CH == false)
{
Serial.print(Winding_Steps);
Serial.flush();
T_CH = true;
}
StepW_Counter = Winder_Stepper.currentPosition();
}
else if (Pause == true)
{
Winder_Stepper.stop();
Feeder_Stepper.stop();
}
if (Winder_Stepper.distanceToGo() == 0 && Feeder_Stepper.distanceToGo() == 0)
{
Winder_Reset();
Feeder_Reset();
Home_Reset();
Input_Reset();
Serial.print("%");
Serial.flush();
}
else if (digitalRead(Feeder_DisableButton) == HIGH || digitalRead(Winder_DisableButton) == HIGH)
{
Winder_Reset();
Feeder_Reset();
Home_Reset();
Input_Reset();
Serial.print("!");
Serial.flush();
}
}
//Manual Control//
else if (Winding_Steps == 0 && Feeder_Steps == 0)
{
//Get Pot input speed
Pot = analogRead(Speed_Pot);
Input_Reset();
///////////////////////////////////////////////////////////////////////////////////////////////
if (digitalRead(Feeder_DisableButton) == LOW) //Feeder is enabled
{
if (A_CH == false)
{
Serial.print("ENABLED_ALL");
Serial.flush();
}
if (F_CH == false)
{
Serial.print("FEEDER_ENABLED");
Serial.flush();
}
F_CH = true;
A_CH = true;
digitalWrite(f_en, HIGH); //Enable Feeder
if (digitalRead(Feeder_Toggle) == HIGH && digitalRead(Winder_Toggle) == LOW)
{
Fn = MicroStepF / 200; //Factor Multipler for FEEDER stepper motor with different microstep values
if (digitalRead(Left_Button) == HIGH && digitalRead(Right_Button) == LOW && digitalRead(L_SW) == HIGH)
{
Feeder_SpeedSetup(Pot * Fn);
Feeder_SetDir(true); //Right to Left
Feeder_moveTo(1800000);
Feeder_Stepper.run();
}
else if (digitalRead(Left_Button) == LOW && digitalRead(Right_Button) == HIGH && digitalRead(R_SW) == HIGH)
{
Feeder_SpeedSetup(Pot * Fn);
Feeder_SetDir(false); //Left to Right
Feeder_moveTo(1800000);
Feeder_Stepper.run();
}
//Home to Left
else if (Home_L == true && Home_R == false && digitalRead(Left_Button) == LOW && digitalRead(Right_Button) == LOW && digitalRead(L_SW) == HIGH)
{
Feeder_SpeedSetup(Pot * Fn);
Feeder_SetDir(true); //Right to Left
Feeder_moveTo(1800000);
Feeder_Stepper.run();
}
//Home to Right
else if (Home_L == false && Home_R == true && digitalRead(Left_Button) == LOW && digitalRead(Right_Button) == LOW && digitalRead(R_SW) == HIGH)
{
Feeder_SpeedSetup(Pot * Fn);
Feeder_SetDir(false); //Left to Right
Feeder_moveTo(1800000);
Feeder_Stepper.run();
}
else
{
Feeder_Reset();
Initial_FDir();
Home_Reset();
}
}
else if (Home_ == true)
{
Home_Toggle();
}
}
if (digitalRead(Feeder_DisableButton) == HIGH && digitalRead(Winder_DisableButton) == LOW) //Disable Feeder & Winder is enabled
{
digitalWrite(f_en, LOW);
Feeder_Reset();
Home_Reset();
if (F_CH == true)
{
Serial.print("FEEDER_DISABLED");
Serial.flush();
F_CH = false;
}
}
///////////////////////////////////////////////////////////////////////////////////////////////
if (digitalRead(Winder_DisableButton) == LOW) //Winder is enabled
{
if (A_CH == false)
{
Serial.print("ENABLED_ALL");
Serial.flush();
}
if (W_CH == false)
{
Serial.print("WINDER_ENABLED");
Serial.flush();
}
W_CH = true;
A_CH = true;
digitalWrite(w_en, HIGH); //Enable Winder
if (digitalRead(Feeder_Toggle) == LOW && digitalRead(Winder_Toggle) == HIGH)
{
Wn = (float)MicroStepW / 400; //Factor Multipler for Winder stepper motor with different microstep values
if (digitalRead(Left_Button) == HIGH && digitalRead(Right_Button) == LOW)
{
Winder_SpeedSetup(Pot * Wn);
Winder_SetDir(false);
Winder_moveTo(180000);
Winder_Stepper.run();
}
else if (digitalRead(Left_Button) == LOW && digitalRead(Right_Button) == HIGH)
{
Winder_SpeedSetup(Pot * Wn);
Winder_SetDir(true);
Winder_moveTo(180000);
Winder_Stepper.run();
}
else
{
Winder_Reset();
Initial_FDir();
}
if (Home_ == true)
{
Home_L = false;
Home_R = false;
Home_ = false;
Serial.print("HOME_END");
Serial.flush();
}
}
}
if (digitalRead(Winder_DisableButton) == HIGH && digitalRead(Feeder_DisableButton) == LOW) //Disable Winder & Feeder is enabled
{
digitalWrite(w_en, LOW);
Winder_Reset();
Home_Reset();
if (W_CH == true)
{
Serial.print("WINDER_DISABLED");
Serial.flush();
W_CH = false;
}
}
if (digitalRead(Winder_DisableButton) == HIGH && digitalRead(Feeder_DisableButton) == HIGH) //Both Winder & Feeder Disabled
{
digitalWrite(w_en, LOW);
digitalWrite(f_en, LOW);
Winder_Reset();
Home_Reset();
if (A_CH == true)
{
Serial.print("DISABLED_ALL");
Serial.flush();
A_CH = false;
}
}
}
}
else
{
Winder_Reset();
Feeder_Reset();
Input_Reset();
Home_Reset();
if (digitalRead(E_Stop) == LOW)
{
if (E_CH == true)
{
Serial.print("ESTOP_A");
Serial.flush();
E_CH = false;
}
}
}
}
Winding Machine Console Source v0.3.4 Beta.zip
VB.NETVisual Basic Source Code
No preview (download only).
Winding Machine Console Executable
VB.NETExecutable file of the Winding Machine Console. Requires at least a Windows 7 OS with .Net 4.0 installed
No preview (download only).
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