[SOLVED] is it worth hand-winding a solenoid?

If I need an extremely tiny amount of movement, just enough to move a hair spring let's say, should I consider hand-winding a solenoid? The reason I ask is because then I would just need to buy wire rather than a complete solenoid, and could also end up with something that does not weigh more than I need.

On the other hand, I haven't wound a solenoid so perhaps my expectations regarding what is required are off.

Can someone give me advice on whether I will be successful or what would be involved? Is it a good idea to hand-wind solenoids? what gauge wire etc should I try to use?

All information is appreciated.

[EDIT: this thread is solved and the answer is "No, it is not worth it."]

It is easy to wind solenoids. Wrap a few turns of wire around a nail and you are done.

However, you will have to be much more specific about what this particular solenoid is supposed to do, how much force to exert over what distance, what source is available to power it, etc. before anyone can offer specific advice.

I would say that for purposes of making practical devices and assuming a reasonable value for your time, it is typically not worth it to wind your own coils. Unless it's something with very few turns, or you need something you can't buy on the market, I wouldn't make my own.

jremington:
It is easy to wind solenoids. Wrap a few turns of wire around a nail and you are done.

However, you will have to be much more specific about what this particular solenoid is supposed to do, how much force to exert over what distance, what source is available to power it, etc. before anyone can offer specific advice.

Thanks. Could you give me an example, for example: gauge of wire, number of turns, how much current I would pass through it and what kind of attractive power I should expect?

As I mentioned, I basically want to move a small pawl out of the way, that is otherwise pushed into a gear with a tiny little spring. there should be next to no mechanical resistance to the motion so I think it doesn't need to be very strong. being light is more important. could you give me some examples?

DrAzzy:
I would say that for purposes of making practical devices and assuming a reasonable value for your time, it is typically not worth it to wind your own coils. Unless it's something with very few turns, or you need something you can't buy on the market, I wouldn't make my own.

Assume no value for my time (within reason, obviously not weeks spent on it.)

You say "unless it's something with very few turns" but this might describe what I need. Could you give me some guidance on what kind of forces I could expect out of how many turns, with what gauge, and what kind of voltage/current to pass through it? How would an example circuit diagram look?

I googled "solenoid circuit diagram" but saw circuits that just show 12v going straight through the solenoid, with no resistors or anything. Is that right? Seems like that is like wiring two ends of a battery together - shouldn't there be something limiting the current involved?

Thanks for any advice or an example diagram. (You can just describe it in words if it's a couple of parts.)

curious48:
Thanks. Could you give me an example, for example: gauge of wire, number of turns, how much current I would pass through it and what kind of attractive power I should expect?

what you are saying in so many words is that you have no desire to do any actual research and just want someone to turn you into a robot that follows direction ? then not do the thing because it is beyond your abilities?

it sounds harsh, but this is about the 4th thread you started that has no connection to Arduinos and is mechanicaly bent and you have spent no personal effort.

http://lmgtfy.com/?q=how+to+wind+a+solenoid

solenoid : About 33,900,000 results
pictures, theory, the works.

e-bay, 99 cents free shipping.

Maybe try a reed relay coil.

@dave-in-nj:

I disagree with your characterization, since despite your claim I did do the basic reading. My question was whether it's worth my doing - your links and my searches don't answer that question directly, and also highly expert people have given me conflicting advice. The title says "is it worth hand-winding a solenoid?", which is clearly part of project guidance on my arduino project - just as my previous question about cheaply getting 3D prints is (which I began with "I did the obvious searches:").

But I can see how you are annoyed by this in the project Feasability section, you are right it is somewhat mechanical, albeit part of an Arduino project. I've requested a sub-forum, "General kinematics, dynamics, and statics: the gears and levers between Arduino and the real world":

http://forum.arduino.cc/index.php?topic=414252.0

which I hope you will put your vote behind. (Especially since you've been addressing several questions like this, but sometimes with some annoyance.)

I think we can all agree that these questions are inherent parts of building many types of Arduino projects (for example, just glancing through this sub-forum on project guidance, I see: "grab it and take it somewhere"; "use a servomotor to control the amount of air entering the turbine"; "converting [truck etc] with steerable rear axle."; "rotate the top of a table at a very specific speed"; "water supply (pump) per plant, as they require different amount of water"; "Car wiper as the servo motor"; " various inflatable toy and beds - various air pressure preset and a number of valves so I could blow up maybe 4 things at once "; and that is from just the first couple of pages, and are all mechanical problems in nature, that are part of arduino projects.)

I hope this addresses your concern! :slight_smile:

curious48:
I think we can all agree that these questions are inherent parts of building many types of Arduino projects

Please don't include me in the "all"

...R

curious48:
@dave-in-nj:

I disagree with your characterization, since despite your claim I did do the basic reading. My question was whether it's worth my doing - your links and my searches don't answer that question directly, and also highly expert people have given me conflicting advice. The title says "is it worth hand-winding a solenoid?", which is clearly part of project guidance on my arduino project -

it is clearly NOT part of your 'arduino' project.

as for you saying your question if it is worth doing, I call Bull S-!t....

you asked
"Can someone give me advice on whether I will be successful or what would be involved? Is it a good idea to hand-wind solenoids? what gauge wire etc should I try to use?'

and the answer from the list was that it was not worth doing. unless you needed a specific thing you could not buy.
there was ZERO conflicting advise from the highly expert people who gave responses.

as you said in another post, you ask questions in a way to get people to offer answers.

the answer to it if is worth doing is absolutely not. I would explain why, but you would not comprehend the answer.
once you try to make one, you will discover the answer for yourself.

From what I have seen, you ask questions like a pro, then praise people for answering, but criticize and dismiss anything that is above your skill level.
my brother calls that mental masturbation.

did you order any of those 99 cent/free shipping solenoids ?
did you make a solenoid ? spend the 60 seconds of your time doing something one of the brightest folks and a highly expert person on this list offered to you ?

@Robin you say I shouldn't include you, but you've helped me with questions on kinematics, dynamics, and statics as part of this very Arduino project!!! :smiley: I agree that you and others have been a bit annoyed by some of the mechanical questions - which is why it would be great to have the subforum for discussing them where people who don't like those questions can ignore them :D.

@dave-in-nj you were helpful previously, so I will take 10 minutes to reply to you point by point but you and I both have better things to be doing! In the future please be constructive and helpful (as you have in the past) :slight_smile:

NOT part of your 'arduino' project

I'm sorry that I didn't link to it explicitly, you are not the first person to ask me to talk about which project a post is part of. Here was my answer: advice on how to build a first model from a completed design. - #14 by curious48 - Project Guidance - Arduino Forum -- So, I will link to it, but in exchange PLEASE don't derail the thread to say "This is not possible!!! It will never work!!!" since I have NO questions about it at the moment, it is COMPLETELY solved, there is no NO guidance needed on that part of the project. The Arduino is used to activate solenoid based on input from a button that is in the user's reach and fix the position in place until the button is pressed again.

as for you saying your question if it is worth doing, I call Bull S-!t....
Why? Why would I give it a subject like "is it worth hand-winding a solenoid?" if I didn't want to know this? What other motivation would I possibly have except to determine if I would receive benefits. When you saw the subject line "is it worth hand-winding a solenoid" did you think this thread would have anything in it other than me asking whether it is worth hand-winding a solenoid?

You said this:

the answer from the list was that it was not worth doing

But actually the first REPLY was:

It is easy to wind solenoids. Wrap a few turns of wire around a nail and you are done.

This is actually a highly misleading reply, and it ended up confusing me. In fact I've since found out that you need thousands of turns of wire as thin as a hair to make a good solenoid, and so this was a highly misleading first reply. Rather than saying "it is easy to wind solenoid" the reply perhaps should have stated "No, for the application you have stated, just buy one".
I don't believe it's possible for me to have more clearly stated my goal with the question than: If I need an extremely tiny amount of movement, just enough to move a hair spring let's say, should I consider hand-winding a solenoid?
And the answer to that question is "No" (rather than "It is easy - wrap a few turns of wire around a nail and you're done", which was the first reply.)

So please don't rewrite history to show me doing something else or receiving a different order of responses. Your accusation that asking about whether I should do something is "mental masturbation" is completely inappropriate.

Finally, although you state that I should not hand-wind my solenoid, I have also received the following responses on another forum, all of which give extreme amounts of information:

It takes a lot of wire, and you'll want to build a machine to spin the bobbin while winding or it'll take you weeks.

I didn't know this. It's not included in this thread you'll notice.

Quite a lot, and those ones are pretty nicely engineered. You need to set them up so the piston doesn't stick to the side. Plus you need to buy the correct wire, build a core, etc.
On the other hand, it would be fun and educational.

I think it will be a project in itself to make it work right. But certainly not impossible. You need a fixed coil, and an iron shaft with magnet attached. And a way to hold them in place. And a spring return. And...
If you're just looking to learn then by all means go for it. I thought you were looking to get a pawl moving and by that standard I would buy one.

Also clearly answers my question. At the same time I had disagreements:

In my opinion you should hand wind a solenoid. Not to have something that has any benefits over buying but to see first hand what it entails. You'll loose about three fifty in the process.

And:

Unless you have a need to wind one yourself, it is cheaper and usually better quality to buy one already wound. Rarely, I have come across the need to make one myself, but that has been very rare.

And I asked what those usages were:

I've made literally hundreds (a braille output pad costs a large fortune) plus repurposed many from old laser printers, etc. The problem is making the metal frame - you need just a small "air gap" with the rest of the magnetic circuit being iron. I have an nc lathe and milling machine, so this is easier for me than for many.
Winding the spool is trivial in comparison. Mount it on a hand-drill, or electric drill, or lathe centre. Keep an even tension (via a bendy arm works) and it will almost wind itself.
Notice how this gives me huge amounts of information that is nowhere in your suggested googled searches.

Also:

Mainly for things that need a lot of power delivered. I used to make cross over networks for stereo systems before they became mainstream.
Also, antenna loading for high power transmission systems.
Wrapping electro-magnets.
Generally it is best to use pre-built, but when you get into high power stuff, often times it is cheaper to build your own.
The wire size will depend on how much current you are delivering.
You generally want to keep everything nice and neat because that makes the device more compact. It also increases the induction per unit volume. However, compact windings tend to get hotter.
Air-core inductors have uniform values across most current ranges. However, they can get quite large. Cored inductors have a higher inductance (all other things being equal) but suffer from magnetic saturation a lot sooner than air cores.
Typically, it is more efficient to wind them tight and close in layers.
You have to use magnet wire. It is coated with a varnish so the wires can be wound closer together.

This makes it clear that the practical applications where I would use it are the opposite of what I have in mind. I don't need high power delivered - I need lower power delivered.

I have done quite a few different coils, mostly for custom speaker passive x-overs and transformers. It's not hard if you have the setup already, you can use a drill and a threaded rod, the hardest part is to get all the materials, you need magnet wire, the former and poly tape.

Again detailed instructions on how people actually do this.

I'm gonna throw out some numbers out of my butt, because i don't know any of your requirements and you have a lot of variables like voltage, force, distance hold or pulse, but on 12v you could be between 1000 or 2000 turns on 32ga for something like a standard relay coil.

Useful answer to my question.

I find it interesting that the responses here have been about buying one or the machinery it takes to wind one yourself.
I'm going to approach this from a different angle: [...] you might be interested in winding your own coil. If this is the prototype stage, just find some magnet wire between 16-28 ga and put 50 wraps on your coil form (something that your armature can slide freely in but still dang close to the wire wraps). Test it out with your power source. Not enough power? Add more wraps. Too much power? Take some off. Wire gets too hot and melts? Go to a smaller size wire and add more wraps to compensate, or add a resistor inline. If the rest of your device works, NOW you can try to find a solenoid that is sized appropriately for your task.

Literally the opposite advice from everyone else.
And:

Forget the cost, you should definitely hand-wind it. When you are into building things, you should get the experience of building things. What you'll learn doing it will be worth much more than the price of a solenoid.

So I find your characterization of how I communicated my question in this thread, and the amount of other searches or looking elsewhere that I did, to be completely inappropriate.
@dave-in-nj I really welcome your feedback and advice, and I hope you'll appreciate that I took the time to address your concerns. I learned about the practicalities of what I'm doing.
This isn't something theoretical:
I am literally building the Arduino project I linked above. If the prototype works appropriately you can pledge a small amount on Indiegogo for one. I think, once this first project is completed and shipped, you will cut me more slack in asking certain practical questions around Arduino projects :smiley: :smiley:

Also please note that your rude reply completely shut down this thread. So, all of the information I quoted above is from elsewhere. Do you find it useful? I bet you do.

In fact I've since found out that you need thousands of turns of wire as thin as a hair to make a good solenoid

Not true in general.

A good solenoid is one that is designed for a specific purpose, and has the wire size, number of turns and magnetic path characteristics that are optimal for that purpose.

It is very common to hand-wind solenoids used as tuning elements in radio receivers and transmitters.

jremington:
Perhaps for some peculiar definition of "good", but in general, not true.

How confusing that you're disagreeing with that expert. Here's the context. I'd just written:

oh forget that. I had no idea. since I just needed a few grams of force, I figured it would be something that I hand wind I don't know, a few dozen turns or something. not that long. I misunderstood how much is involved.

Somebody replied quoting me:

a few dozen turns
A good solenoid will have 1000+ turns, of wire as thin as a hair.

i.e. they quoted me writing 'a few dozen turns' and disagreed with me. This person seems to be an expert, writing (in other threads, these are combined quotes)

"On clear wire like that, the rib is nearly invisible. Only way to find it is with your fingernail, and even then you might have to compare the 2 several times" and "Single coil operates all poles. 3 pole would be for 3 phase. 2 pole would be for 240V. A 3 pole will work fine for 240V, by just not using 1 pole" and "Nope. Here is a diagram for a variety of motors using the same type of 3 pole switch. 3 phase motor is on lower left, notice that the top pole doesn't actually do anything." and "n adapter cable is safe. A check of all screws being tight in the existing house wiring is a really good idea. The thing not to do is change out the 30A breaker to a 40 or 50 if it trips too often." and "Can also be used on a single phase motor if the proper wires are accessible." and "Rheostat" is the wrong term for a motor speed controller. A picture, or part# of the control that stopped working would help us."

You will agree that this person certainly sounds like an expert in his field. The same is true of your posts, where you've written (again, combined quotes):

"How are you powering the sensor, in the battery circuit? It requires 5V. Please post a wiring diagram (photo of a hand drawn sketch, not Fritzing)." and " 'can I use voltage 5v from resistor divider 1:5 to get it from unstable 27v DC supply (+-10%) for Arduino' Absolutely not. Use a DC-DC converter instead, like this one. It takes considerable skill in electronics to make a useful DC-AC inverter." and "You need to know the input impedance of the PLC input. If it acts as a dead short (unlikely), you can use a 250 ohm resistor to convert 1.0 - 5.0 V to 4-20 mA. Connect the grounds together."

I think it's fair to say that you two are both experts and that you two have disagreed here pretty fundamentally.

Anyway if you want to give me very specific advice: I am moving a SMALL SPRING a SMALL AMOUNT using a SMALL AMOUNT OF FORCE. If you think I should bother to try wrapping a few dozen turns of thin-gauge wire to do it, I'll investigate, if not I won't. (I was clear on my application in that other forum - I had written: "The application woiuld be just moving a small spring, not much force is needed... I would just like to move a pawl out of the way in a pawl-and-ratchet solution. This is just the prototype stage.".)

If you're correct and a few dozen turns are enough, the thing that I thought I would have liked is that I can just do it myself buying just magnetic wire. In light of the other responses I've received I won't bother to experiment like that unless you suggest it. To put some numbers on it, let's say I want between 50 and 500 grams of force. (0.49 N - 4.9 N). I'm sorry I'm only able to ballpark it within an order of magnitude. I can reduce the required force by making sure the pawl doesn't catch, or may even be lubricated.

Say, I hope you'll put your vote of support behind this suggestion (by replying there saying you would like that subforum) since we're now, again, talking about newtons and force, to the expressed annoyance of some people in this general Project Feasibility sub-forum. There is a General electronics section for the circuitry side ("Resistors, capacitors, breadboards, soldering, etc") and we should have a "General kinematics, dynamics, and statics for Arduino projects" for the physical side. It's not a perfect fit here to talk about my pawl and ratchet needs, the amount of force I'd need, the type of solenoid etc. Literally several people have expressed that they don't want to see this type of mechanical aspect of arduino projects discussed in this sub-forum, that it's too mechanical. So I hope you'll support a sub-forum where we can discuss it if you're interested. If you would reply here with your support it would help! :slight_smile:

How confusing that you're disagreeing with that expert.

That person was thinking of a particular application.

Also please note that your rude reply completely shut down this thread. So, all of the information I quoted above is from elsewhere. Do you find it useful? I bet you do. [./quote]

no, I find this a complete waste of time and board space.

in your previous threads, it is clear that you have not spent any time trying to find answers for your self, but rather post here and ask others to do your research for you.

if you find me rude, then how rude is it to not bother to do your end, learn about a thing, than once you find a stumbling block, ask for help.

as for your topics, this is an Arduino site. there are lots of electronics-101 sites and mechanical sites.

in the length of time it took to read my last post, you could have would your own coil as the experts suggested. did you even try ?

dave-in-nj:
in the length of time it took to read my last post, you could have would your own coil as the experts suggested.

yes of course. For the record the answer to the question posted in the title of this thread is "NO". (In my case) It is not worth it for a beginner to hand-wind a small solenoid (which are exceedingly cheap and, also, can easily be salvaged). They can be had for a dollar.

Thanks for your help, everyone.

This thread is solved.