Automatic Coil Winder

This project involved the design and development of a compact automated coil winding machine designed to produce consistent and accurately wound electrical coils. The system integrates a stepper motor–driven bobbin with a threaded rod mechanism that moves a wire guide back and forth to evenly distribute the copper wire during winding. A magnetic trigger and proximity sensor are used to count each rotation of the bobbin, allowing the machine to precisely track the number of coil turns. The device includes a simple control interface for setting the desired number of turns and is enclosed within a transparent polycarbonate casing for safety and visibility. The design utilises readily available components such as stepper motors, bearings, and microcontroller-based electronics, while incorporating mechanical, electrical, and manufacturing considerations to create a cost-effective and functional automated winding system.