From Challenge to Innovation: How I Automated Transformer Winding

As a Senior Electronics Engineer at Minipa do Brasil , I've faced numerous technical challenges, but one project particularly stands out – not just for its complexity, but for the innovative solution we developed to overcome it. Today, I want to share a story of problem-solving, engineering creativity, and the power of leveraging open-source technologies.

The Challenge

We needed to develop a high-voltage source of approximately 15 kV, stepping up from just 12 V. The mathematics was clear: our transformer would require over 1,000 secondary turns using incredibly delicate 38 AWG enameled wire – about the thickness of a human hair (0.100 mm). Manual winding wasn't just impractical; it was a potential bottleneck for the entire project.

The Innovation Journey

Rather than outsourcing the transformer prototyping, we made a strategic decision to manufacture prototypes in-house. This choice would prove crucial, allowing us to make rapid adjustments. But we needed to solve the winding challenge first.

The solution came from an unexpected source: the GRBL project, an open-source G-code interpreter typically used in CNC machines. Here's how we built our automated winding system:

1. Software Stack: Gcoil (mega link, for download) for winding pattern generation; Universal G-code Sender (UGS) for command interface; and GRBL for core control
2. Hardware Implementation: Adapted GRBL for #STM32 (Bluepill) with #USB communication Integrated stepper motors with microstepping capability. Built mechanical assembly using linear guides, trapezoidal spindle, and precision components

Results That Speak Volumes

The impact was immediate and significant:

• Reduced winding time from hours to minutes
• Achieved consistent, high-quality results
• Completed over 100 transformers in record time
• Extended utility to support other projects, including my master's degree research

Key Learnings

This project reinforced several crucial principles:

1. Sometimes the best solution comes from adapting existing technologies in novel ways
2. In-house development capabilities can be a game-changer for specialized manufacturing
3. Investment in automation pays dividends far beyond the initial project scope

Looking Forward

This experience has fundamentally changed how we approach similar challenges. The winding machine served not just for the company but has also supported academic research and collaborative projects.

What started as a technical challenge evolved into a testament to engineering creativity and the power of practical innovation. It's a reminder that in engineering, the most elegant solutions often come from thinking outside the conventional toolbox.

What challenges have you automated in your engineering journey? I'd love to hear your stories and insights in the comments below.

#Engineering #Innovation #Automation #Manufacturing #ElectricalEngineering #TechnicalLeadership #Magnetics #PowerElectronics #OpenSource