SMALL SCALE AUTOMATED COIL WINDING MACHINE
By Garry 11601010
BACHELOR’S DEGREE in
MECHANICAL ENGINEERING – MECHATRONICS CONCENTRATION FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY
SWISS GERMAN UNIVERSITY The Prominence Tower
Jalan Jalur Sutera Barat No. 15, Alam Sutera Tangerang, Banten 15143 - Indonesia
January 2021
Revision after Thesis Defense on 20 January 2021
Garry STATEMENT BY THE AUTHOR
I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.
Garry
Student Date
Approved by:
Leonard P. Rusli, M.Sc., Ph.D.
Thesis Advisor
Date
Nova Kristian, S.T.
Thesis Co-Advisor Date
Dr. Maulahikmah Galinium, S.Kom., M.Sc.
Dean Date
Garry ABSTRACT
SMALL SCALE AUTOMATED COIL WINDING MACHINE
By
Garry
Leonard P. Rusli, M.Sc., Ph.D., Advisor Nova Kristian, S.T., Co-Advisor
SWISS GERMAN UNIVERSITY
The purposes of this thesis are to design and create a small scale automated coil winding machine system with high accuracy and precision and controlled by simple program in order to control the movement of the stepper motor. Arduino IDE is used in this thesis research for the simple program. In addition, the stepper motor that used in this research is stepper motor NEMA 17. To complete a coil using manual coil winding machine will be inconvenience and waste of time. Therefore, fabrication of coil winding machine will be done in this project which is controlled by two stepper motor using Arduino program.
This machine is inexpensive, easy to operate and build in a small scale size. This project also can be used for training students in winding of small transformers & relay coils.
Keywords: Automated Coil Winding Machine, Stepper Motor NEMA 17, Arduino
Garry
© Copyright 2021 by Garry All rights reserved
Garry DEDICATION
I dedicate this thesis works to my parents,
Anggi Lieman Honggosaputra and Trifena Wangsa Chandra, who offered me their unconditional love and support all the time,
to my elder sister Grace Honggosaputra, to all of my friends,
and to my future self.
Garry ACKNOWLEDGEMENT
First and foremost, I would like to give thanks to God for His guidance and blessings that have been given to me during my hardest time during my thesis writing and make me to be able to finish it on time. In this opportunity, I would like to extend my gratitude and appreciation to:
1. Leonard P. Rusli, M.Sc., Ph.D. as my advisor and Nova Kristian, S.T., as my co-Advisor, for their great help, patience, assistance, guidance, and also their great advices in my research and thesis writing from the very beginning until its completion.
2. Dr. Maulahikmah Galinium, S.Kom., M.Sc., as my dean faculty of Engineering and Information Technology.
3. Mr. Y. Fredhi S, for giving the best consultation session for my thesis works and patiently trained me.
4. My beloved parents, sister and Nico Antonio Santoso who always support me moral and financial during my study and life.
5. Kevin Indra Wijaya who was my partner in crime since PCE (Pre Course English), for his help, support, and accompaniment and sharing the laughter, care, craziness and silly things during the struggle of my thesis works.
6. Levina Nathania who always care about me and gave her encouragement and trust from the beginning until the completion of my thesis work.
7. All my best buddies, Oliver Benedict, Fendi Heryanto, Alvin Tri Hartono, Wilvan Gunawan, Edrick Phoa, Ivan Goldy, Daniel Alvin, Muhammad Ichsan Efendi, Andrian Marcello, Theodorus, Tantolo Rario Peter Gani, Rizki Giovanni, Sebastian Agus Wibowo and Valen for sharing their laughter, support and trust and also my entire Mechatronics class mate at Swiss German University, made me really pleasure to conduct my undergraduate study in the past four years.
Garry TABLE OF CONTENTS
STATEMENT BY THE AUTHOR ... 2
ABSTRACT ... 3
DEDICATION ... 5
ACKNOWLEDGEMENT... 6
TABLE OF CONTENTS ... 7
LIST OF FIGURES ... 10
LIST OF TABLES ... 12
CHAPTER 1 – INTRODUCTION ... 13
1.1 Background ... 13
1.2 Research Problems ... 15
1.3 Research Objectives ... 15
1.4 Research Questions ... 16
1.5 Hypothesis ... 16
1.6 Thesis Overview ... 16
CHAPTER 2 – LITERATURE REVIEW ... 18
2.1 Coil Winding ... 18
2.1.1 Manual Coil Winding Machine ... 19
2.1.2 Automatic Coil Winding Machine... 19
2.2 Principles of Coil Winding ... 19
2.2.1 Orthocyclic Winding ... 20
2.2.1.1 Position and Size of the Crossover Section ... 22
2.2.1.1.1 Equal Number of Turns per Layer ... 23
2.2.1.2 Fabricating Orthocyclic Winding ... 23
Garry
2.2.1.3 Design of an Orthocyclic Winding ... 25
2.4 Comparison between Round and Rectangular Bobbin ... 25
2.4 Methods of Winding Coil ... 26
2.5 Importance of Tension in Coil Winding Machine ... 26
2.6 Stepper Motor ... 27
2.6.1 NEMA 17 Stepper Motor ... 28
2.6.2Functions and Advantage of Stepper Motor ... 28
2.7 Types of Arduino ... 29
2.7.1 Arduino Mega 2560 ... 30
2.7.2Arduino with Stepper Motor ... 30
CHAPTER 3 – RESEARCH METHODS ... 31
3.1 System Overview ... 31
3.2 Machine Block Diagram ... 32
3.3 Design Justification ... 32
3.3.1 Mathematical Modelling ... 32
3.4 Components of Design ... 35
3.4.1 Mechanical Design ... 36
3.4.2 Electrical Design ... 36
3.4.3 Programming ... 37
CHAPTER 4 – RESULTS AND DISCUSSIONS ... 39
4.1Design of Small Scale Automated Coil Winding Machine ... 39
4.2 Program to Control Stepper Motor ... 41
4.3 Performance Test ... 45
4.3.1 Performance Test on 10 cm Bobbin ... 45
4.3.2 Performance Test on 5 cm Bobbin ... 47
4.3.3 Troubleshooting in Programming ... 49
Garry
CHAPTER 5 – CONCLUSIONS AND RECOMMENDATIONS ... 50
5.1 Conclusions... 50
5.2 Recommendations ... 51
GLOSSARY ... 52
REFERENCES ... 53
APPENDICES ... 54
APPENDIX 1 DataSheet ... 54
APPENDIX 2 Technical Drawing ... 69
APPENDIX 3 Program Code ... 75
CURRICULUM VITAE ... 79
Garry LIST OF FIGURES
Figure 1. Manual Coil Winding ... 14
Figure 2. Automatic Coil Winding Machine ... 14
Figure 3. Round Coil Winding ... 18
Figure 4. Scheme of Winding Fill Factor ... 20
Figure 5. Polished Cut of Winding ... 20
Figure 6. Scheme of Orthocyclic Winding ... 21
Figure 7. Orthocyclic Wound Coil ... 22
Figure 8. Cross Section of Orthocyclic Winding... 22
Figure 9. Equal Number Turns per Layer ... 23
Figure 10. Acceleration due to the changing wire path length during winding ... 25
Figure 11. Basic winding speed tension control system ... 27
Figure 12. Stepper Motor NEMA 17 ... 28
Figure 13. Speed – Torque Characteristics ... 28
Figure 14. Types of Arduino ... 29
Figure 15. Arduino Mega 2560 ... 30
Figure 16. System Overview Block Diagram... 31
Figure 17. Machine Block Diagram... 32
Figure 18. Torque Formula ... 33
Figure 19. Assembly of Mechanical Design ... 35
Figure 20. Simple Schematic of Electrical Wiring ... 36
Figure 21. Program Flowchart ... 37
Figure 22. Front Side of Small Scale Automated Coil Winding Machine... 39
Figure 23. Top Side of Small Scale Automated Coil Winding Machine ... 39
Figure 24. Left Side of Small Scale Automated Coil Winding Machine ... 40
Figure 25. Right Side of Small Scale Automated Coil Winding Machine ... 40
Figure 26. First Program Sequence ... 42
Figure 27. Second Program Sequence ... 42
Figure 28 Third Program Sequence ... 43
Figure 29. Fourth Program Sequence ... 44
Garry Figure 30. Result of the winding ... 45 Figure 31 Troubleshoot on the winding ... 49 Figure 32. Catchup code... 49
Garry LIST OF TABLES
Table 1. Performance Test on 10 cm Length Bobbin and 0.3 mm Wire Diameter ... 45
Table 2. Performance Test on 10 cm Length Bobbin and 0.5 mm Wire Diameter ... 46
Table 3. Performance Test on 5 cm Length Bobbin and 0.3 mm Wire Diameter... 47
Table 4. Performance Test on 5 cm Length Bobbin and 0.5 mm Wire Diameter... 48
