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Strong Electromagnet From An Old Transformer

by rocketman221 on September 3, 2011

Table of Contents

Strong Electromagnet From An Old Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Intro: Strong Electromagnet From An Old Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Step 1: Parts & Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Step 2: Disassemble The Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 3: Wind The Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Step 4: Put The Core Back In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Step 5: Using The Magnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

http://www.instructables.com/id/Strong-Electromagnet-From-An-Old-Transformer/
 Author:rocketman221 author's website
I enjoy building electronics & robots. I like building computers as well as writing programs & web sites. I like to build and launch rockets. I especially like to
play with high voltage power supplies (jacobs ladder, flybacks, neon transformers) and blowing stuff up with my 1 KJ capacitor bank.

Intro: Strong Electromagnet From An Old Transformer

This is a very strong electromagnet made out of an old transformer.
The materials used are recycled from transformers and motors.
This magnet can lift over 30lbs (14kg)

There will be a video soon.

Image Notes
1. The finished magnet.

Step 1: Parts & Tools

Parts:
1 Transformer
Enough magnet wire to fill the core.

Tools:
Box Knife
Pliers
Slotted Screwdriver
Small Hammer

Image Notes Image Notes

1. Transformer from an old wall wort. 1. The transformer that will be used.

http://www.instructables.com/id/Strong-Electromagnet-From-An-Old-Transformer/
 Image Notes
1. A roll of magnet wire. This is not the same wire I used on this magnet.

Step 2: Disassemble The Core

The transformer core is made of layers of "E" shaped & "I" shaped pieces which are held together with varnish.
To separate the layers use a box knife to break apart the first layer, then beat the piece out with a hammer and screwdriver. Once it breaks free it can be pulled out with
the pliers.
Once you get the first couple of layers out, put the transformer on a hard surface and hit all sides of the core with the hammer to help break the varnish loose. Then you
should be able to get the rest of the pieces out with the knife easily.

Image Notes
1. Separate the layers with the knife.

http://www.instructables.com/id/Strong-Electromagnet-From-An-Old-Transformer/
 Image Notes Image Notes
1. Tap out the first piece with a hammer and screwdriver. 1. Pull out the first piece.

Image Notes Image Notes

1. After beating with the hammer many of the "I" pieces fell out. 1. Half way done.

Image Notes Image Notes

1. All pieces removed. 1. The "E" Pieces will be used for the magnet.
2. The "I" pieces are not used.
3. The coil former.

http://www.instructables.com/id/Strong-Electromagnet-From-An-Old-Transformer/
 Image Notes Image Notes
1. The empty core. 1. The core has been prepared by cutting out the divider in the middle.
2. The hair wire on the primary wouldn't unwind in one piece, so I cut it off.

Step 3: Wind The Coil

I wound this coil by hand so I didn't get any pictures in the process.
I used wire that I collected from other transformers and motors.
So I ended up twisting together about 15 strands with a drill to make about 50ft (15m) of 20awg wire.

The coil form has a divider between the coils that needs to be cut out in order to wind one big coil.

This coil has 5 layers of wire in it.

The layers must all be wound in the same direction and should be wound as neatly as possible .

This coil will run at 5 volts. For a higher voltage use more turns of a thinner wire.

Step 4: Put The Core Back In

For this to work as an electromagnet we will only use the "E" core pieces.
To reassemble the core, the easiest way to put it back together is to put all but a few pieces in at once. Then put the rest in on at a time, and pound them in with a
hammer.
The core should stay in from friction alone, but you could use more varnish or super glue to hold them together.

http://www.instructables.com/id/Strong-Electromagnet-From-An-Old-Transformer/
 Image Notes
1. The finished magnet.

Step 5: Using The Magnet

These magnets work best when a piece of metal comes in contact with all 3 parts of the core.
I find them the most useful for lifting thick, flat pieces of metal. They have very little pull with sheet metal.
The core will heat up fairly quick and should only be used for intermittent use .

Image Notes Image Notes

1. Another magnet. This one runs at 2 volts from a super capacitor. 1. The finished magnet.

http://www.instructables.com/id/Strong-Electromagnet-From-An-Old-Transformer/
 Image Notes Image Notes
1. This one is slightly larger and is mounted to a bracket. This magnet lifts over 1. Even larger one to make in the future.
40lbs (18kg)

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