Mechanical System of Tattoo Machines: Learn to Maximize Efficiency

[youfourian]

Hi, I'm new to the site. I posted this question in another thread to no avail, so I'll try starting over with a new one of my own. I am doing research on tattoo machine mechanics and this came up in Google. It is very interesting, so here I am. I don't have a lot of technical knowledge regarding any of the systems at work here, but I do have a general idea based on what I have been reading. Tattoo machines have a lot going on when in operation. They have an electrical system, a magnetic system created by the electrical system, and a mechanical system that is operated by the magnetic system. I am fairly intuitive and can learn almost anything. I am fascinated with these machines and want to be able to build my own. I have done a few rebuilds and have run into some issues that I need some technical assistance with. I have a few different questions, but I'll try to work them out one at a time so I don't get any more confused.
The basic function of the machine is to place tattoo ink into the dermis of a person's skin. Different people have different skin and the required needle configurations differ as well which require different amounts of force to accomplish this. The machine must generate enough force to drive the needle configuration into where it needs to be. Also different skin types require different amounts of force and different depths of needle travel. The taper of the needle tips are also a factor. For example a single, long taper needle does not require much force to go into thin skin. On the other hand it takes much more force to drive 13 short taper needles into tough skin.
The electromagnets of the machine use electricity to create "pull" on the steel armature of the machine. The needle configuration is attached to this armature so as to move with it. The distance of travel, or stroke, is determined by; the bottom gap (space between the armature and the magnet surface) and the amount of front spring compression. A rear spring attached to the base frame of the machine applies force to the front spring and is used to counteract the magnetic pull. At rest, the front spring is compressed against the electrical contact completing an electrical circuit used to power the magnets. When you step on the foot switch and apply voltage to the circuit, the magnets pull the armature toward them releasing the front spring compression until the circuit is broken as the front spring leaves the contact point. This begins the "open" part of the oscillation. The armature continues to the magnet surface form inertia until it hits. The rear spring then takes over and returns the armature to the contact point, ending open contact time and beginning the "closed" part of the oscillation. The front spring compresses against the contact point from inertia and then the magnets pull it down again for the next oscillation. This happens many times per second, most machines run between 100 and 150 hertz. The balance between open and closed contact time results in the machine's duty cycle, which is critical for a well running machine. This duty cycle is a relationship between bottom gap, contact point gap, and front spring compression, which also equal the stroke of the needle. The weight of the armature, the stiffness of the rear spring, the needle configuration, and skin type are all factors in how much pull is required.
My first question is how to maximize the efficiency of the voltage used to power the magnets. Standard magnets are made by taking 1" or 1-1/4" lengths of 5/16" or 3/8" diameter 1018 low carbon steel rod, insulating it with a thin layer, putting ends on it to form a spool and winding 24 or 26 gauge magnet wire around it, 8 - 12 layers thick. I am currently planning on making my own coils and am hoping to get some insight into how to maximize the efficiency of the voltage in the coil. What effect the diameter and length of the steel and the gauge and length of wire have on how the electricity is used to create the magnetic pull?
I realize that this may be menial to some of you, but any comments on this are greatly appreciated. I have been digging for this type of info all over the web, but am having a hard time finding exactly what I need.

 

[eljose79]

Hello and welcome to the site! It's great to see someone so passionate about tattoo machine mechanics and wanting to learn more about it. I'll do my best to answer your questions and provide some insight into maximizing the efficiency of the voltage used to power the magnets in the machine.

Firstly, the efficiency of the voltage used to power the magnets is dependent on a few factors such as the diameter and length of the steel, the gauge and length of wire, and the number of layers of wire in the coil. These factors affect the strength of the magnetic field produced by the coil, which in turn affects the force of the needle movement.

The diameter and length of the steel used in the coil can affect the strength of the magnetic field. Generally, a smaller diameter steel will create a stronger magnetic field, but will also require more layers of wire to achieve the desired strength. The length of the steel also plays a role in the strength of the magnetic field, with longer steel creating a stronger field.

The gauge and length of wire used in the coil also impact the strength of the magnetic field. A thicker gauge wire will produce a stronger field, but will also require more layers to achieve the desired strength. The length of wire used also affects the strength of the field, with longer wire creating a stronger field.

In terms of maximizing the efficiency of the voltage, it's important to find a balance between the strength of the magnetic field and the amount of voltage used. Too much voltage can cause the magnets to overheat and potentially damage the machine, while too little voltage may not produce enough force for the needle to penetrate the skin effectively.

One way to maximize the efficiency of the voltage is to experiment with different combinations of steel diameter, length, wire gauge, and wire length to find the optimal setup for your specific machine and needle configuration. You may also want to consider using higher quality magnets or using a different type of steel that is known for its magnetic properties.

I hope this helps guide you in your research and experimentation. Good luck with building your own coils and feel free to ask any further questions you may have. Happy tattooing!

 

[charng]

I find your interest in tattoo machine mechanics and your desire to build your own machine very intriguing. This is a complex system that involves multiple components and their interactions to achieve the desired result of placing tattoo ink into the skin. Your understanding of the electrical, magnetic, and mechanical systems involved is impressive and shows your dedication to your research.

To answer your first question about maximizing the efficiency of the voltage used to power the magnets, it is important to understand the concept of energy conversion. When electricity flows through the coil, it creates a magnetic field that pulls the armature towards the magnets. This conversion of electrical energy into magnetic energy is not 100% efficient, meaning that some of the energy is lost as heat or other forms. To maximize efficiency, the design of the coil and its components is crucial.

The diameter and length of the steel rod used for the core of the coil will affect the strength of the magnetic field produced. A longer and thicker rod will have a stronger magnetic field, but it will also require more energy to create that field. The gauge and length of the wire used to wrap around the core will also impact the efficiency of the coil. Thicker wire will have less resistance and therefore require less voltage to produce the same amount of magnetic pull, but it will also take up more space and add weight to the coil. A longer length of wire will also increase the resistance and require more voltage.

In order to maximize efficiency, it is important to find the right balance between all of these factors. A coil that is too large or too small may not produce enough magnetic pull or may require too much voltage, resulting in wasted energy. It may be helpful to experiment with different combinations of core diameter and length, wire gauge and length, and number of layers to find the optimal design for your specific machine and its intended use.

I hope this information helps in your research and pursuit of building your own tattoo machine. Best of luck in your endeavors.