ABSTRACT

1
ABSTRACT

The main objective of this project is to develop an automatic coil

winding machine which can be used for various winding operations that will
greatly reduce an effort behind the manually operated machines and to
implement the idea of automation in coil winding machines. This method can
also be used to reduce the manufacturing cost and also to increase the rate of
productivity. The winding is done by suitable methodology using various
components. The common applications for a coil winding machine are to wind
coil for transformer and motor.

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 CHAPTER-1

INTRODUCTION

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CHAPTER-1

1.1 INTRODUCTION

A winding machine winds a material such as metal wire, thread, or paper,

onto a core, spool, or bobbin. There are several different types of winding
machines, from simple manual feed machines to complex computer- numeric-
control (CNC) machines. An automated system ultimately aims to reduce man
power and labor task. The common applications for a coil winding machine are
to wind coils for transformer, inductors, motor and chokes. The fabrication of
coil winding machine is done using Arduino controller for automation purpose,
stepper motor for rotation of threaded shaft on which bobbin are mounted and
Pulleys are used for maintaining constant tension.

1.2 PROPOSED TECHNOLOGY

The proposed methodology is based on robust technology meets safety

reliability and fastest in operation. It consists of a sensing system, signal
conditioning electronic circuit, controller. It is installed at the transformer site
and the finding parameters recorded using the analog to digital converter of the
embedded system. The acquired parameters are processed and recorded in the
system memory. System will help the system to run under reliable condition and
identify problems before any failure. For above result we are using a small step
down transformer of 12 V, 1 Amps rating and small bulb are connected as a
load. In this project we are using CT transformer for measuring load current.
Also we are using Temp. Temperature Sensor for giving any rise of
temperature, oil level sensor is also used which detects any fall of oil level. The
values of voltage, current and temperature and level of oil of the transformer is
directly applied to one of the input ports of the microcontroller.

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 Along with this, a display is connected in the input port of the
microcontroller value then the transformer will automatically shut down and in
this way transformer life will be increased. We also designed Two-way
communication here by which we can ask system about given parameter value
just by sending Wireless Data to it so that we can have watch over transformer
For this it is not necessary for the operator to sit in the system premises which
was the case at conventional system.

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 CHAPTER-2

BLOCK DIAGRAM

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CHAPTER-2

BLOCK DIAGRAM

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 CHAPTER-3

EMBEDDED SYSTEM

CHAPTER-3

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3.1EMBEDDED SYSTEM

An embedded system is a combination of computer hardware, software

and additional mechanical parts, designed to perform a specific function .An
embedded system is designed to do a specific task within a given time frame,
repeatedly, without human interaction. Embedded system do not need a
complete operating system, but only the basic functionalities of an operating
system in a real-time environment, that is, a real time operating system.
(RTOS). Frequently, embedded system does not have a user interface.

Application Area of embedded system include aerospace/defense

systems, telecommunication equipments and switches, mobile computing,
broadcast, automotives, industrial process control and monitoring, medical
electronics, consumer electronics, etc. Main hardware components of an
embedded system are microprocessor or micro controller, and supporting ICs.
The combination of micro-controller and ICs are application specific.
Commonly used microprocessors include the following. Motorola 680XX
series, IBM PowerPC series processors, MIPS processors, Intel 386 and
compatible CPUs, ARM processors, Sun SPARC series, etc. Embedded systems
need memory for storing programs and data, and usually programs are stored in
ROM or EPROM. Often these systems have a serial port network interface, I/O
interface for interacting with sensors and actuators in the case of process
controlling systems.

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3.2 MICROPROCESSOR Vs MICROCONTROLLER

Microcontroller is a general-purpose device which has an in-built CPU,

Memory and peripherals, which make it, function as a mini computer.

Both Microcontroller and microprocessor can be employed for designing

products or applications in Embedded System. But Microcontroller has its own
advantages over microprocessor. They are as follows:

 For transfer of data from external memory to the CPU, microprocessor needs
many operational codes. But in Microcontroller, one or two codes are
enough.

 Microcontrollers have many bit-handling instructions, but microprocessors

have only one or two.

 Microcontrollers have built-in peripherals whereas microprocessors lack in-

built peripherals.

 Microcontroller work faster than microprocessor because of rapid movement

of bits within the chip.

 Microcontrollers have simple circuit structure compared to microprocessor.

 Microcontrollers have only 35 instructions whereas microprocessors have

75.

 Microcontrollers are costly when compared with microprocessor.

 Microcontroller can function as a mini computer without any additional

parts.

 Microcontroller instructions are simple, single word instructions.

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 CHAPTER-4
WORKING

CHAPTER-4

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WORKING

In this coil winding machine two stepper motor are use. One is use for
rotation motion and another is use for linear motion. This two stepper motors
runs in synchronization such that one revolution of shaft the slider advances
according to the diameter of bobbin . This help in winding without gap. This is
done by the program set in arduino,
As per the winding i.e. for motor or transformer the program can easily
change.
Initially the coil setup is done i.e., the coil is firstly attached to the armature
manually through the slider assembly. The power supply is connected and
Arduino is started. Then the program is allowed to run. According to the
program this two stepper motor rotate, after one revolution of shaft the slider
linearly advanced. The program helps in synchronizing these two shafts and
slider to obtain accurate rotation.

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 CHAPTER-5
HARDWARE REQUIREMENT

CHAPTER-5

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 5.HARDWARE REQUIREMENT

5.1POWER SUPPLY DESCRIPTIONS

The present chapter introduces the operation of power supply circuits built
using filters, rectifiers, and then voltage regulators. Starting with an ac voltage, a
steady dc voltage is obtained by rectifying the ac voltage, then filtering to a dc
level, and finally, regulating to obtain a desired fixed dc voltage. The regulation is
usually obtained from an IC voltage regulator unit, which takes a dc voltage and
provides a somewhat lower dc voltage, which remains the same even if the input
dc voltage varies, or the output load connected to the dc voltage changes.

A block diagram containing the parts of a typical power supply and the
voltage at various points in the unit is shown in fig 19.1. The ac voltage, typically
120 V rms, is connected to a transformer, which steps that ac voltage down to the
level for the desired dc output. A diode rectifier then provides a full-wave rectified
voltage that is initially filtered by a simple capacitor filter to produce a dc voltage.
This resulting dc voltage usually has some ripple or ac voltage variation. A
regulator circuit can use this dc input to provide a dc voltage that not only has
much less ripple voltage but also remains the same dc value even if the input dc
voltage varies somewhat, or the load connected to the output dc voltage changes.
This voltage regulation is usually obtained using one of a number of popular
voltage regulator IC units.

Transformer Rectifier Filter IC regulator Load

5.2 IC VOLTAGE REGULATORS:

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 Voltage regulators comprise a class of widely used ICs. Regulator IC units
contain the circuitry for reference source, comparator amplifier, control device,
and overload protection all in a single IC. Although the internal construction of
the IC is somewhat different from that described for discrete voltage regulator
circuits, the external operation is much the same. IC units provide regulation of
either a fixed positive voltage, a fixed negative voltage, or an adjustably set
voltage.A power supply can be built using a transformer connected to the ac
supply line to step the ac voltage to a desired amplitude, then rectifying that
ac voltage, filtering with a capacitor and RC filter, if desired, and finally
regulating the dc voltage using an IC regulator.

5.3 THREE-TERMINAL VOLTAGE REGULATORS:

Fig shows the basic connection of a three-terminal voltage regulator IC to

a load. The fixed voltage regulator has an unregulated dc input voltage, Vi,
applied to one input terminal, a regulated output dc voltage, Vo, from a second
terminal, with the third terminal connected to ground. For a selected regulator,
IC device specifications list a voltage range over which the input voltage can
vary to maintain a regulated output voltage over a range of load current. The
specifications also list the amount of output voltage change resulting from a
change in load current (load regulation) or in input voltage (line regulation).

Fixed Positive Voltage Regulators:

IN OUT

UNREGULATE 7805
D DC
VOLTAGE

GND

The series 78 regulators provide fixed regulated voltages from 5 to 24 V.

Figure 19.26 shows how one such IC, a 7812, is connected to provide voltage
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regulation with output from this unit of +12V dc. An unregulated input voltage
Vi is filtered by capacitor C1 and connected to the IC’s IN terminal. The IC’s
OUT terminal provides a regulated + 12V which is filtered by capacitor C2
(mostly for any high-frequency noise). The third IC terminal is connected to
ground (GND). While the input voltage may vary over some permissible
voltage range, and the output load may vary over some acceptable range, the
output voltage remains constant within specified voltage variation limits. These
limitations are spelled out in the manufacturer’s specification sheets. A table of
positive voltage regulated ICs is provided in table

Positive Voltage Regulators in 7800 series

IC Output Voltage Minimum Vi (V)

Part (V)
7805 +5 7.3
7806 +6 8.3
+8 10.5
7808
+10 12.5
7810
+12 14.6
7812
+15 17.7
7815
+18 21.0
7818

5.4 LCD DISPLAY

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 The most commonly used Character based LCDs are based on Hitachi's
HD44780 controller or other which are compatible with HD44580. In this
project document, we will discuss about character based LCDs, their interfacing
with various microcontrollers, various interfaces (8-bit/4-bit), programming,
special stuff and tricks you can do with these simple looking LCDs which can
give a new look to your application.

Usually these days single controller LCD modules are used more in the
market. So in the project document we will discuss more about the single

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controller LCD, the operation and everything else is same for the double
controller too.

5.5 MICRO CONTROLLERS

The ATMEGA-328 is a modified Harvard architecture 8-bit RISC

single chip microcontroller which was developed by Atmel. It uses on-chip
flash memory for program storage, as opposed to one-time
programmable ROM, EPROM, or EEPROM used by other
microcontrollers at the time.

FEATURES:

32KB of flash memory for program storage.

2KB of SRAM for data storage.

1KB of EEPROM for non-volatile data storage.

23 general-purpose I/O pins.

6 channels of 10-bit Analog-to-Digital Converter (ADC).

Several communication interfaces including UART, SPI, and I2C.

Internal oscillator and the ability to use an external crystal for clocking.

Development Tools:

To program the ATmega328P, you'll typically use an in-circuit serial

programmer (ICSP) or a bootloader. Popular development environments for

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programming the ATmega328P include Atmel Studio, Arduino IDE, and
various third-party IDEs that support AVR microcontrollers.

You can use various hardware platforms for programming and development,
such as the Arduino Uno, Arduino Nano, or custom-made development boards.

PROGRAMMING:

Write your code in C/C++ or assembly language using the chosen development
environment.

Compile the code into a hex file.

Program the ATmega328P using an ICSP programmer or upload the hex file
using a bootloader and a USB-to-serial adapter.

You can also program the ATmega328P using the Arduino IDE by selecting the
appropriate board (e.g., Arduino Uno) and uploading your sketch via USB.

PERIPHERAL INTERFACING:

Utilize the GPIO pins for interfacing with external components such as sensors,
actuators, displays, and communication modules.

Configure the ADC to read analog sensor values.

Implement serial communication protocols (UART, SPI, I2C) to communicate

with other devices.

POWER MANAGEMENT:

The ATmega328P can operate at voltages ranging from 1.8V to 5.5V,

making it suitable for battery-powered applications. Utilize sleep modes and
low-power techniques to minimize power consumption and prolong battery life.

APPLICATION EXAMPLES:

Embedded systems: IoT devices, home automation, data loggers, etc.

Robotics: Motor control, sensor interfacing, etc.

DIY projects: LED displays, temperature sensors, motion detectors, etc.

RESOURCES:

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The datasheet for the ATmega328P provides detailed information on its
features, electrical characteristics, and programming.

Online communities and forums, such as the Arduino forums and AVR Freaks,
offer support, tutorials, and code examples for working with the ATmega328P.

Overall, the ATmega328P is a versatile microcontroller suitable for a wide

range of embedded applications, from simple hobby projects to more complex
commercial products. Its popularity in the maker community is largely due to its
ease of use, extensive documentation, and robust ecosystem of development
tools and resources.

5.6 RELAY

The first step involves selecting the appropriate relay based on factors
such as voltage and current ratings, switching speed, and the type of load to be
controlled, whether it's AC or DC. Once the relay is chosen, it needs to be wired
to the microcontroller and the device you want to control. This typically
involves connecting the relay coil to a digital output pin of the microcontroller
and wiring the relay's switch contacts to the load.

In programming, you'll use digital output commands to control the relay.

By setting the appropriate digital pin as an output and toggling its state, you can
activate or deactivate the relay as needed. Additionally, you may implement
conditional logic to control the relay based on specific conditions or user input,
adding flexibility and functionality to your project.

5.7 STEPPER MOTOR

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Nema 17 (Bipolar) Current (A): 0.5
Step angle: 1.8° Torque (kg.cm): 4.2
Voltage (V): 8 Control Wires: 4

A stepper motor is an electromechanical device it converts electrical power into

mechanical power. Also it is a brushless, synchronous electric motor that can
divide a full rotation into an expansive number of steps. The speed of stepper
motor can be controlled easily by changing step angle. stepper motor haveself
starting torque and the efficiency of stepper motor is more than synchronous
motor.
The process begins with selecting a suitable stepper motor based on
factors like torque, speed, and step resolution, ensuring compatibility with the
project's requirements. Once the motor is chosen, it needs to be wired to the
microcontroller and power supply. This typically involves connecting the
motor's coils to dedicated driver modules, such as the popular A4988 or
DRV8825, which are in turn controlled by digital output pins of the
ATmega328P.
In programming, the microcontroller sends step and direction signals to
the driver modules to control the stepper motor's movement. By pulsing the step
pin and setting the direction pin appropriately, the microcontroller can rotate the
motor in precise increments and directions. Additional logic can be
implemented to control the motor's speed, acceleration, and positioning,
allowing for complex motion sequences and tasks.

5.8 L293D

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 The L293D is an integrated circuit commonly utilized for motor control
applications, particularly in robotics and other projects involving DC motors.
Functioning as a quadruple high-current half-H driver, it facilitates bidirectional
control of up to two DC motors. Employing an H-bridge configuration, it allows
motors to operate in both clockwise and counterclockwise directions by
manipulating the polarity of applied voltage. With a peak current handling
capacity of up to 600mA per channel (1.2A peak), it suits a broad spectrum of
low to medium-power motors. Featuring built-in clamp diodes for inductive
load protection, it mitigates voltage spikes during motor deactivation. Its control
inputs accept low-level signals (TTL or CMOS), enabling precise manipulation
of motor direction and speed. Operating within a voltage range of 4.5V to 36V,
it accommodates various power sources, including batteries and power supplies.
Available in different package types like DIP and SOIC, it offers versatility and
ease of integration into diverse circuit designs, making it a favored choice for
motor control solutions.

5.9KEYPAD

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HEX keypad is a standard device with 16 keys connected in a 4×4 matrix,
giving the characters 0-9 A-F. Interfacing of Hex key pad to Atmega32 is
essential while designing embedded system projects which requires character or
numeric input or both. For example projects like digital code lock, numeric
calculator etc. Here we are using this to enter numeric password for turn
ON/OFF the circuit breaker. This can be easily interface with ant kits
Microcontroller Development Board. It is a four pin tactile switch and four
mounting holes 3.2mm each

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 CHAPTER-6
PROGRAMMING

CHAPTER-6

6.PROGRAMMING

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 The Arduino Uno can be programmed with the (Arduino Software
(IDE)).The ATmega328 on the Arduino Uno comes preprogrammed with a
bootloader that allows you to upload new code to it without the use of an
external hardware programmer. It communicates using the original STK500
protocol.

6.2 POWER

The Arduino Uno board can be powered via the USB connection or with
an external power supply. The power source is selected automatically.

External (non-USB) power can come either from an AC-to-DC adapter

(wall-wart) or battery. The adapter can be connected by plugging a 2.1mm
center-positive plug into the board's power jack. Leads from a battery can be
inserted in the GND and Vin pin headers of the POWER connector.

Arduino Power Supply

6.3 MEMORY

The ATmega328 has 32 KB (with 0.5 KB occupied by the bootloader). It also

has 2 KB of SRAM and 1 KB of EEPROM

6.4 ARDUINO DEVELOPMENT "IDE"

The Arduino integrated development environment (IDE) is a cross-

platform application written in Java, and is derived from the IDE for the
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Processing programming language and the Wiring projects. It is designed to
introduce programming to artists and other newcomers unfamiliar with software
development. It includes a code editor with features such as syntax highlighting,
brace matching, and automatic indentation, and is also capable of compiling and
uploading programs to the board with a single click. There is typically no need
to edit make files or run programs on a command-line interface

Developer(s) Arduino Software

Stable release 1.0.3 / December 10, 2012; 3months ago

Written in Java, C and C++

Operating system Cross-platform

Type Integrated development environment

Website arduino.cc

Arduino programs are written in C or C++ The Arduino IDE comes with
a software library called "Wiring" from the original Wiring project, which
makes many common input/output.

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Operations much easier. Users only need define two functions.

To make a run able cyclic executive program:

 Setup (): a function run once at the start of a program that can initialize
settings.

 Loop (): a function called repeatedly until the board powers off

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 CHAPTER-7

CONCLUSION

CHAPTER-7
CONCLUSION

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 The earlier method of coil making is manual coil winding and it was
hectic and time consuming. The time required for making the coil is very low,
even space between two consecutive winding could not be achieved and tight
coil formation also not achieved. While the Automatic coil making machine. Is
less costly, tight coil formation and increase the coil production rate The main
aim of this Automatic coil winding machine is to replace the required manual
labour and minimize the time required for making coils. It was found that this
machine can wind coils of 48 turns turns in just 20 sec. The main objectives of
this machine is to replace the worker or a labour and also the hard work. The
increases rate of production and time required for the work is saved by the
machine.

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 CHAPTER-8
REFERENCES

CHAPTER-8
REFERENCES

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Bindu B, Hemasuganya K, Srilekha V, "Design of Automated Coil Winding
Machine" International Jo.
[2] Sundar Ganesh CCS, Minu S, Niveta R, NivethithaAC,Padmini R, Gokul
Krishna K, Joe Breslin J, “Automatic Coil Winding Machine" pp. 6-8.
[3] Nishad S. Joshi, Chetan B. Bulbule, Sagar D.Domale. Prof.Jayashree Deka,
"Design of Automatic Transformer Winding Machine" International Journal for
Research in Applied Science & Engineering Technology, Volume 3 Issue 4,
April 2015, page no. 942-947.
[4] R. Harisudhan, M. Ganesh Kumar, A. Udhaya Prakash, P. Sathya, "Stepper
Motor Control using ARDUINO ATMEGA - 328 MicroController,"
International Journal for Scientific Research & Development, Vol. 2, Issue 12,
2015, page no. 778 -780
[5] Priya Ikhankar, Rakhi Golhar, Ankita Kamdi, Trupti Banarase, Sanjeet S.
Kashyap, "Automation in Manufacturing of Winding " International Journal for
Scientific Research & Development, Vol. 4, Issue 2, 2016, pp. 453-456.

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