Beyond AWG

I have a d'Arsonval meter movement to repair. The voltage coil has a
number of breaks and will have to be rewound. After removing the old
coil, I measured the wire diameter. It appears to be copper, about 1.8
mil in diameter over the enamel insulation.

Thats down below the AWG chart I've got. 40 AWG is 3.14 mils. Anyone
have a link to a chart that goes down to 45 AWG? And does anyone have a
link to a supplier (with specs) of this size wire? Since I'm measuring
the diameter over enamel, it would be better to compare what I've got to
finished magnet wire specs.

I have a d'Arsonval meter movement to repair. The voltage coil has a
number of breaks and will have to be rewound. After removing the old
coil, I measured the wire diameter. It appears to be copper, about 1.8
mil in diameter over the enamel insulation.

Thats down below the AWG chart I've got. 40 AWG is 3.14 mils. Anyone
have a link to a chart that goes down to 45 AWG? And does anyone have a
link to a supplier (with specs) of this size wire? Since I'm measuring
the diameter over enamel, it would be better to compare what I've got to
finished magnet wire specs.

--
Paul Hovnanian mailto:Paul_at_Hovnanian.com
------------------------------------------------------------------
I bet the human brain is a kludge. -- Marvin Minsky

I have a d'Arsonval meter movement to repair. The voltage coil has a
number of breaks and will have to be rewound. After removing the old
coil, I measured the wire diameter. It appears to be copper, about 1.8
mil in diameter over the enamel insulation.

Thats down below the AWG chart I've got. 40 AWG is 3.14 mils. Anyone
have a link to a chart that goes down to 45 AWG? And does anyone have a
link to a supplier (with specs) of this size wire? Since I'm measuring
the diameter over enamel, it would be better to compare what I've got to
finished magnet wire specs.

I have a d'Arsonval meter movement to repair. The voltage coil has a
number of breaks and will have to be rewound. After removing the old
coil, I measured the wire diameter. It appears to be copper, about 1.8
mil in diameter over the enamel insulation.

Thats down below the AWG chart I've got. 40 AWG is 3.14 mils. Anyone
have a link to a chart that goes down to 45 AWG? And does anyone have a
link to a supplier (with specs) of this size wire? Since I'm measuring
the diameter over enamel, it would be better to compare what I've got to
finished magnet wire specs.

--
Paul Hovnanian mailto:Paul_at_Hovnanian.com
------------------------------------------------------------------
I bet the human brain is a kludge. -- Marvin Minsky

I have a d'Arsonval meter movement to repair. The voltage coil has a
number of breaks and will have to be rewound. After removing the old
coil, I measured the wire diameter. It appears to be copper, about 1.8
mil in diameter over the enamel insulation.

Thats down below the AWG chart I've got. 40 AWG is 3.14 mils. Anyone
have a link to a chart that goes down to 45 AWG? And does anyone have a
link to a supplier (with specs) of this size wire? Since I'm measuring
the diameter over enamel, it would be better to compare what I've got to
finished magnet wire specs.

In article <4C68B39E.1BDB6434_at_Hovnanian.com>,
"Paul Hovnanian P.E." <Paul_at_Hovnanian.com> wrote:

I have a d'Arsonval meter movement to repair. The voltage coil has a
number of breaks and will have to be rewound. After removing the old
coil, I measured the wire diameter. It appears to be copper, about 1.8
mil in diameter over the enamel insulation.

Thats down below the AWG chart I've got. 40 AWG is 3.14 mils. Anyone
have a link to a chart that goes down to 45 AWG? And does anyone have a
link to a supplier (with specs) of this size wire? Since I'm measuring
the diameter over enamel, it would be better to compare what I've got to
finished magnet wire specs.

This is where I buy magnet wire for guitar pickups and such, and they
have a good deal of reference data including diameters of bare copper
and insulated copper of various types. If you really want an accurate
measure of what you have, I recommend a good toolroom micrometer. I'm
not using "toolroom" carelessly, but to make a distinction between that
and a shop micrometer.

http://www.mwswire.com/

On Sun, 15 Aug 2010 20:42:22 -0700, "Paul Hovnanian P.E."
Paul_at_Hovnanian.com> wrote:

I have a d'Arsonval meter movement to repair. The voltage coil has a
number of breaks and will have to be rewound. After removing the old
coil, I measured the wire diameter. It appears to be copper, about 1.8
mil in diameter over the enamel insulation.

Thats down below the AWG chart I've got. 40 AWG is 3.14 mils. Anyone
have a link to a chart that goes down to 45 AWG? And does anyone have a
link to a supplier (with specs) of this size wire? Since I'm measuring
the diameter over enamel, it would be better to compare what I've got to
finished magnet wire specs.

http://www.mwswire.com

http://www.mwswire.com/pdf_files/mws_tech_book/copper_magnet_wire_data.pdf
They have insulated wire down to #55 AWG.

Hint: Use a microscope with a wire gauge reticle.

I'm impressed that you're still able to do such fine work. My
eyesight and manual dexterity are slowly disappearing as I get older.

I can see this stuff just fine with magnifying glasses. I just have trouble

The biggest problem is going to be counting 1800 turns! I can make a jig to
wind this on my bench lathe and incorporate a magnet/Hall sensor to advance
a counter.

[snip]

I also disposed of my dead cars several years ago as I needed
the parking spaces.

On Mon, 16 Aug 2010 10:19:26 -0700, "Paul Hovnanian P.E."
paul_at_hovnanian.com> wrote:

The biggest problem is going to be counting 1800 turns! I can make a jig to
wind this on my bench lathe and incorporate a magnet/Hall sensor to advance
a counter.

Magnetic is rotation speed sensitive. If you go too slow, it won't
register a pulse.

I suggest optical with an LED emitter/detector
pair. Debounce the output with a one-shot. Send the output pulses to
an HP universal counter. Count pulses. Good luck.

You might also make some kind of friction clutch arrangement intended
to keep the tension under the breaking strength of the #45 AWG wire.
This way, the lathe can spin merrily while you control the wire feed
with your fingers. (Hint: wear gloves). If rigidly attach the spool
to the lathe, it's gonna break.

When I moved to my house in the woods 35 years ago, I bought a chain
saw. I then dropped and split about 1 cord of firewood. The next
year, I hired someone to deliver firewood, and have lived happily ever
after. I also disposed of my dead cars several years ago as I needed
the parking spaces.

On Mon, 16 Aug 2010 11:07:05 -0700, Jeff Liebermann <jeffl_at_cruzio.com> wrote:

On Mon, 16 Aug 2010 10:19:26 -0700, "Paul Hovnanian P.E."
paul_at_hovnanian.com> wrote:

The biggest problem is going to be counting 1800 turns! I can make a jig to
wind this on my bench lathe and incorporate a magnet/Hall sensor to advance
a counter.

Magnetic is rotation speed sensitive. If you go too slow, it won't
register a pulse.

Hall effect shouldn't be? I agree a pickup coil would be speed
sensitive.

I suggest optical with an LED emitter/detector
pair. Debounce the output with a one-shot. Send the output pulses to
an HP universal counter. Count pulses. Good luck.

Optical might count flouro lights or something extra too? Whatever's
handy...

Grant wrote:

On Mon, 16 Aug 2010 11:07:05 -0700, Jeff Liebermann <jeffl_at_cruzio.com> wrote:

On Mon, 16 Aug 2010 10:19:26 -0700, "Paul Hovnanian P.E."
paul_at_hovnanian.com> wrote:

The biggest problem is going to be counting 1800 turns! I can make a jig to
wind this on my bench lathe and incorporate a magnet/Hall sensor to advance
a counter.

Magnetic is rotation speed sensitive. If you go too slow, it won't
register a pulse.

Hall effect shouldn't be? I agree a pickup coil would be speed
sensitive.

I suggest optical with an LED emitter/detector
pair. Debounce the output with a one-shot. Send the output pulses to
an HP universal counter. Count pulses. Good luck.

Optical might count flouro lights or something extra too? Whatever's
handy...

I'm not going to be running the chuck very fast (good way to break fine
wire). At these speeds, a reed switch will work.

I have a 30 year old car with a reed switch speedo sensor. It works just
fine.

Smitty Two wrote:

In article <4C68B39E.1BDB6434_at_Hovnanian.com>,
"Paul Hovnanian P.E." <Paul_at_Hovnanian.com> wrote:

I have a d'Arsonval meter movement to repair. The voltage coil has a
number of breaks and will have to be rewound. After removing the old
coil, I measured the wire diameter. It appears to be copper, about 1.8
mil in diameter over the enamel insulation.

Thats down below the AWG chart I've got. 40 AWG is 3.14 mils. Anyone
have a link to a chart that goes down to 45 AWG? And does anyone have a
link to a supplier (with specs) of this size wire? Since I'm measuring
the diameter over enamel, it would be better to compare what I've got to
finished magnet wire specs.

This is where I buy magnet wire for guitar pickups and such, and they
have a good deal of reference data including diameters of bare copper
and insulated copper of various types. If you really want an accurate
measure of what you have, I recommend a good toolroom micrometer. I'm
not using "toolroom" carelessly, but to make a distinction between that
and a shop micrometer.

http://www.mwswire.com/

Thanks (to everyone) for the links and info. What I've got appears to be
AWG
45. As Grant suggested, its possible to use a slightly different wire size
than the original. As long as several parameters remain close to the
original. The voltage winding is self supporting (not wound on a form) and
swings in free space. All I've got to do is keep the ampere turns and coil
area close to the original. I can tweak the accuracy by trimming a couple
of series resistors (part of the original design) once its fixed.

The biggest problem is going to be counting 1800 turns! I can make a jig
to
wind this on my bench lathe and incorporate a magnet/Hall sensor to
advance
a counter.

--
Paul Hovnanian paul_at_hovnanian.com
----------------------------------------------------------------------
Have gnu, will travel.

"Paul Hovnanian P.E." <paul_at_hovnanian.com> wrote in message
news:Uv2dna7xQLZ_7_TRnZ2dnUVZ_iydnZ2d_at_posted.isomediainc...

The biggest problem is going to be counting 1800 turns! I can make a jig
to
wind this on my bench lathe and incorporate a magnet/Hall sensor to
advance
a counter.