Criss Cross Winding Machine for a Wire Having Spring Back.

Can you try writing this again with paragraphs?

At the outset, thank you very much for your interest. Within three to four days time only I am sending the photographs of the end product so that you will you get clear concept of the exact requirement. Please bear with tiil then. Regards! Devchand

Thanks for the status report.

This should be interesting.

Do a rough sketch of what you want and what it's final use is,ie, is it to surround a tube something like a high pressure flexible pipe that has a steel sleeve around it?

Bazzer

Dear Bazzer, Thank you very much for the interest shown. Within three to four days time only I am sending you the photographs of the end product so that you will have a clear conceptual idea of the same. Till then please bear with me. Regards! Devchand

I agree a bit with Wal that some separation into paragraphs would make it much more readable.

Please define the Criss Cross part. Does this mean that it is NOT just back and forth windings laid parallel from one end to the other?

I gather this coil is for temporary storage of the coil of wire, with the wire later being pulled out from the inside. 1. How do you propose to hold the coil together during storage and withdrawal of the wire? 2. The wire will be twisting as it exits the coil; do you plan on mounting the coil so it can spin during withdrawal?

Have you done the calculations? Does that 1.00 mm diameter include the nylon? In fact it better include a lot of nylon. You say diameter, which means round wire. A round wire of 1.00 mm diameter has a cross section of 0.785 mm², or 0.00785cm². 25,000 meters, or 2,500,000 cm of material of that cross section has a volume of 19,630 cm³. Copper has a density of 8.96 g/cm³, so that much copper has a mass of 176,000g, or 176kg. This stuff must be mostly nylon with a tiny copper wire inside, if the coil is to weigh 30 kg. Even pure monofilament nylon of that size would have a mass of 22.6 kg, more or less depending on the kind of nylon.

Excellent bit of math there mate. I'm sure it's spot on....

...but that still leaves why and what to be answered.

I managed to read through the OP again and the image that came to my mind was, as you say, a bobbin or shuttle of some sort or not.

What will it be used for?

OP?

I couldn't resist doing one more calculation:

The OP specified an average ID of 75 mm, and an average OD of 175 mm, which gives a median diameter of 125 mm, and a core thickness of 50 mm, or 50 layers of perfectly wound wire. This means each turn has approximately 393 mm, or 0.393 meters of wire. 25,000 m of wire will thus require 63,700 turns of wire. Divide by 50 layers, and each layer must have 1273 turns. Perfectly wound, this would be 1273 mm long. His specifications seem to indicate close to perfection in winding.

Obviously no coil is perfectly wound, so the actual length (which the OP calls height) would be somewhat more, but not likely the 1500 - 1750 mm indicated, unless the 1.00 mm is the diameter of the copper, with the nylon occupying the rest of the volume, but then we get back to the mass problem.

Of course it could be wound to a specified length, letting the OD be what it may, but there is going to have to be something, perhaps shrink-wrap, placed on the OD to hold the coil together during storage and use. Unless the intention is to wind up the coil and leave it on the machine until deployment. Even in that case, whatever supported the ID during winding will have to be withdrawn to allow the wire to exit, so it must be supported on the OD and ends during removal of the wire.

One other thing. All the coils of wire I've ever seen, where the intention was to withdraw the wire from the inside of the coil, were relatively large diameter and small height/length. I have a pretty hard time visualizing the wire being withdrawn from this long, thin coil without tangling; especially so at a speed of 200 meters/minute.

Thank you very much for the interest shown. You are right. The nominal Dia of bare copper alloy wire is 0.24mm.Rest is all Nylon coating. The weight of coil is approx.30kg. The coil shall be kept stored in as wound condition . The workmanship of winding shall be such that during withdrawal of the wire, wire shall not get entangled at all and for this purpose the likely spin/sag shall get taken care by passing the wire though suitable device . Within three to four dys time only I am sending you the photographs of the coiled wire so that you will get a clear idea about the requirement. Till then please bear with. Regards, Devchand /

Further to my reply, what is important is that entire length of 25 ,000 metre of 1.00mm Dia wire shall get wound. Length dimension mentioned to be of 1500mm may be considered as indicative . It is to take care of practical issues like , use of plus toleranced wire size or unavoidable voids between wire layers etc. etc The machine deign shall take care of the withdrawal speed of wire @ 200 metre per minute. Regards! Devchand

Nylon-coated wire at this speed is going to give you some issues with static electricity buildup...