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straightening copper wire
By blueyonder, Section Mechanical Posted on Sat Mar 1st, 2008 at 12:01:39 AM MST
it works

just like to say a big thank you to OZTULES.
from him i got the idea to make my own wire straightener.
i already had the bits i just needed a bit motivation.
so when i saw the pics oztules posted on recycling copper wire post.
i got to work. yes it was simple to make .yet works so well.
i think wooden wheels from a kids toy would also work.
the bearings i had already had. nylon on them .
methinks they come from sum type door runner. but cant remember whare i got them.
only mod i made was a small groove .before i made the groove the wire kept slipping off.
in the pic its got a 14 gauge wire on it.
also tried a 20gauge . all came out perfect for winding coils.
but had i saw a thing like this on ebay i might have paid out a bit of cash for it.
it was also a great feeling after i saw how good it worked.
made from junk . for straightening junk.
i bet my coils will be much neater in future
so menny helpful folk on here who pass on there good ideas.
might also be useful to redo any coils or windings that went wrong.

straightening copper wire | 8 comments (8 topical, 0 editorial)

Re: straightening copper wire (3.00 / 0) (#1)
by fcfcfc on Fri Feb 29th, 2008 at 05:11:38 PM MST
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Hi: Pretty good....

Re: straightening copper wire (3.00 / 0) (#2)
by Ungrounded Lightning Rod on Fri Feb 29th, 2008 at 07:26:30 PM MST
(User Info)

Nice. Simple, cheap, and effective.

I've straightened wire before by chucking one end in a vise, the other in a power drill, leaning back, and spinning away. But that stress-hardens it a bit and can change its gauge. This looks like it will leave the wire in much better condition.

But I'll still make twisted pair with the drill and vise. B-)

Re: straightening copper wire (3.00 / 0) (#3)
by vawtman (vawtman(at)charter(dot)net) on Sat Mar 1st, 2008 at 09:52:11 AM MST
(User Info)

Ya Yonder,Oz is a crafty fellow, kind of reminds me of the Professor from Gilligans Island.
Not has pretty though :>)

Re: straightening copper wire (3.00 / 0) (#4)
by coldspot on Sun Mar 2nd, 2008 at 10:20:41 AM MST
(User Info)

Very NICE work-
From the picture, on the right side it looks
like the varnish is cracking and falling off?
I've used clear fingernail polish and
spray can clear to re-coat this on my recycling
of wire. What are you doing???

Re: straightening copper wire (3.00 / 0) (#5)
by bob golding (photoman290 at yahoo dot com) on Sun Mar 2nd, 2008 at 10:50:42 AM MST
(User Info)

i doubt the enamel is cracking off unless it has got very hot. its tough stuff. unless it is very old lacquer covered wire. if you go into a motor rewind shop and see what they do to wire you will know what i mean. if it is wire from an old transformer or something the varnish it was dipped in, to hold the windings together to prevent noise, might come off,but not the enamel. good idea by the way.

cheers
bob golding

[ Parent ]

Re: straightening copper wire (3.00 / 0) (#6)
by dinges on Sun Mar 2nd, 2008 at 12:53:34 PM MST
(User Info)

I have noticed when taking apart one particular motor that pulling wires loose from eachother (they were varnished to eachother) took the insulation of the wires and left one of the wires with bare copper.

Apparently, the baked/dipped varnish adhered better to the wire lacquer than the lacquer adhered to the copper itself...

This was another confirmation of my plan to never ever bother with re-used copper wire. Others seem to get good results though. But apart from living on a (nearly-) deserted island (Hi Oz ;) ) I think it'd be much wiser to spend a few $$ and buy new wire.

At least, it's what I do.

Would be a shame after having spent dozens of hours building a generator having to arrive at the conclusion that it doesn't work because the wire insulation failed.

Also notice that the back-and-forth bending of the copper wire stress hardens it. It becomes harder and more brittle and may break when bent a few more times again. And become more susceptible for fatigue.

Anyone who knows me know I'm a scrounger, but sometimes one needs to use the best quality materials available. In the case of generators, that would be copper wire, magnets and epoxy. One could compromise a bit on the other parts, I suppose.

Peter.

[ Parent ]

Re: straightening copper wire (3.00 / 0) (#8)
by wdyasq on Mon Mar 3rd, 2008 at 05:07:19 AM MST
(User Info)

Used bearings ....

Adventure is just bad planning." -- Roald Amundsen
[ Parent ]

Re: straightening copper wire (3.00 / 0) (#7)
by blueyonder (windwoodgood at yahoo dot co dot uk) on Sun Mar 2nd, 2008 at 04:23:11 PM MST
(User Info)

well sum good comments. at first i was afraid i might strip or tear the enamel off the wire.
but after a while i started to just try and get the enamel off.
so i would understand how much it took to remove.
so bob your right its very tough stuff that enamel.
so considering the wire hasent been overheated in the past . and looks good
then i dont see a problem.
but after i wind a coil i test it every way i can.
it was great when i made the rotor as i could test with rotor in lath and watch the ac out.
but now rotor is fitted to the gen i can only test with a meter .
i am not going to be building gens all my life but would love to have a scope.
i find if i had a spare rotor i could test things such as coils.
but having neos tied up on a steel plate would be a luxury.
so will wait till i build my next rotor .
in the pic i can see the lighter colour bit it dos look like a bit missing.
but that was a bit test wire i was using when playing with and setting the rollers.

as yet i havent tried to repair enamel damage.
there was a coil i wound that had a wee bit missing.
but as the wires it was laid up to were good i done nuthing.
once the coils are potted only bad over heating will make the coils lose there insulation .
as this is all a learning curve for me. its good i dont need worry about what i do with expensive new wire.
and peter yes i found a motor that was the same as you talk about.
it was a pain to try unwind. it to was pulling off the enamel.
but as it was a fast spinning type thing. then that's why it had varnish on it i suppose .
looks like transformers are better. or the field coils on the stator .
but the fact i found one thing pulling off the enamel. dident stop me in my tracks .
my motto is .IF AT FIRST YOU DONT SUCCEED THEN TRY AND TRY AGAIN.
i don't intend to build a wind gen with copper wire that's no good .
far from it . i hope the wire i am using will be better than the cheap chinese
stuff that is being imported from Asia.
nothing against the chinese as i do love there magnets.
i think there trying to figure out what quality control means .
yes sum wire is junk but that can be put in my scrap box.
my wife has that nail varnish stuff .
maybe i can bye her half a gallon for her birthday.
who knows.
its a ill wind that dos no good

straightening copper wire | 8 comments (8 topical, 0 editorial)

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