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Registered Member #2939
Joined: Fri Jun 25 2010, 04:25AM
Location:
Posts: 615
I wanted litz wire for my tesla coil build but thought the price on Ebay was a bit much. So I dug out a 1kg roll of 0.08mm wire I bought many, many years ago (surplus) and set about making my own litz. 0.08 mm copper wire is ridiculously thin and fragile - this was not going to be an easy project.
First off I built a rotating platform to hold seven spools of wire, driven by the motor and gearbox off a cheap battery drill. This gave me the ability to do a seven strand twist. Loading the little spools with such fine wire proved incredibly difficult - fortunately a workmate owns a coil winding lathe, and I got him interested in the project (always a good trick!). His lathe was able to fill the spools, reasonably evenly, then the lathe and my spinner were used for the first twisting operation. Resulting in about 900g of 7 strand wire. Or not. It was certainly 7 at the start, but only 5 strand at the end - damn. Took 3 days to do this wind - the lathe was running very slow to avoid breakage.
Next step was to convert the 7 (5) strands into litz. I chose a 6 +1 configuration : one solid strand of 0.25mm as the core, with 6 x 7 strands on the outside. Got my mate to split the 7 (5) strand twist into 6 spools - ended up with 2 spools of 5 strand twist, and 4 of seven strand twist (yeah, he found the transition and elected not to waste the 5 strand - fine by me!). After running the twisting process again I now have a fat roll of litz: 4 x 7s + 2 x 5s +1s ! Theres a couple of joins in there somewhere (wire snagged and broke), but I can work around that.
An interesting project, but I can now see why Litz costs as much as it does!
Registered Member #2431
Joined: Tue Oct 13 2009, 09:47PM
Location: Chico, CA. USA
Posts: 5639
This shoiuld be on the project forum, as it is a project as worthy as any other... perhaps you should have a microcontroller based tensioner rack and pulleys', like for photo processing, that nmight limit the breakage better.
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Homebrew Litz
