Fiber Winding CNC ELM 4702 Project II

1
Fiber Winding CNCELM 4702 Project II

• By Somnang Rom

2
Background

• What is Fiber Winding?
• Manufacturing method
• Thin fibers ( ex. Nylon, fiber glass carbon
  fiber) are wound on a shaped mandrel
• Epoxy resin is applied during (or after) the
  winding operation allow to dry
• Creates a very light weight, corrosion resistant
  continuous structures.

3
Background (cont.)

• Typical Applications
• Helicopter blade and other airplane parts
• Power poles
• Ski poles, canoe paddles,hockey sticks

4
Problem Statement

• Goal is to design and create a small-scale fiber
  winding machine to produce composite structures.
• Produce at least two different patterns.
• Fit on the desktop
• At least two axis
• produces parts minimum 28X 12X 12

5
Solution

• My design includes
• commercially available Master5 CNC will be used
  to enter G-codes.
• 3 Rutex servo motor controllers to drive primary
  motors
• Solid base, 37X 24
• One spool of fiber, nylon
• User operates the system from a Laptop or PC

Ideal design
Reliance servo motor
Reliance servo motor
mandrel
mandrel
1.5x1/8x24 angle iron
Click on the picture
Reliance servo motor
Pitman dc motor
Pitman dc motor
6
System Overview
Gcode
Motor controller
125AC
7
Mechanical Drawing of FWCNC
mandrel
mandrel axis
Z axis
12.125
Y axis
37.5
8
Mechanical Designs
12
24
Side view
9
Mechanical Designs
The inertia of the PVC plastics cylinder
Non hollow mandrel radius (r) to zero
mandrel
M
L
(oz-in-sec2)
J.700Pi 15 (54-4.8754)/7682.585 oz-in-sec2
The inertia of the lead screw
W
M
L
(oz-in-sec2)
Densities of lead screw (oz/in3)
Common Densities(oz/in3) GE plastics
PVC---.700 Steel----------4.54
Length of lead screw
Diameter of lead screw
Inertia
J(4.54pi 15 .6254)/12352 .00264 oz-in-sec2
Mmotor
10
Mechanical Formulas

• 1/3 HP
• HP (Torque x rpm)/52501/3HP
  (.00175lb.900rpm)/5250
• Torque(1/3)(5250)/900rpm.00175lb.ft

11
Mechanical Designs
The inertia of the PVC plastics cylinder
Non hollow mandrel radius (r) to zero
mandrel
M
L
(oz-in-sec2)
J.700Pi 15 (54-4.8754)/7682.585 oz-in-sec2
The inertia of the lead screw
W
M
L
(oz-in-sec2)
Densities of lead screw (oz/in3)
Common Densities(oz/in3) GE plastics
PVC---.700 Steel----------4.54
Length of lead screw
Diameter of lead screw
Inertia
J(4.54pi 15 .6254)/12352 .00264 oz-in-sec2
Mmotor
12
Mechanical Designs
The inertia of the PVC plastics cylinder
Non hollow mandrel radius (r) to zero
mandrel
M
L
(oz-in-sec2)
J.700Pi 15 (54-4.8754)/7682.585 oz-in-sec2
The inertia of the lead screw
W
M
L
(oz-in-sec2)
Densities of lead screw (oz/in3)
Common Densities(oz/in3) GE plastics
PVC---.700 Steel----------4.54
Length of lead screw
Diameter of lead screw
Inertia
J(4.54pi 15 .6254)/12352 .00264 oz-in-sec2
Mmotor
13
State Diagram for Winding Logic
start
Delay 2sec.
V 120inches/ min. Amandrel rotation
if
no
V120 inches/min
yes
no
If Y15 inches, A120 rotations
yes
off
14
Computer Numerical control (Gcode)
G0 y0 move at max. N2 g4 p2 delay for
2 seconds N5 g1 y0 starting point N10 g1 y15
a 20 f120 count 15 at 20 rotations N20 y0
N30 y15 a30 f120 N40 y0 N50y16 a 400
f120 N60 y0
15
Winding Patterned
Rotational ratio

• The space of the
• hop winding will be determine
• the mandrel rotation

Feeder in/sec
Hop winding

• Helical winding pattern will depend on feeder
  speed. If the feeder Increase and the mandrel
  rotation must decreasing

Helical winding
Typical fiber winding patterns
16
Electrical Overview
PC parallel port
Pin number
step
Servo motor control
4
M1
Y axis
5
dir
6 step
Servo motor control
M2
A axis rotational axis
7 dir
M3
16 0 or 1 signal
Spindle motor circuit
17
Power supply overview
24Vout
Manufacture Motor power supply
-
Circuits board
Transformer
5 V _at_3A
125V
_
36V _at_ 10A
18
Spindle motor control
4V
500
42 V
_
1.2K
1.2K
2N7000 mosfet
These circuit are use to control the spindle
motor. I designed the circuit but at the end I
found out that my design does not required motor
spindle control circuit.
19
Rutex servo motor controllers
Step Dir input
Y axis
42 V _
Step Dir input
A axis
42 V _
20
Fiber Winding CNC schedule
Fall
                 
Tasks List in weeks 10 11 12 13 14 15 1 2 3 4 6 7 8 9 10 11 12 13 14 15
                                             
Research                                            
 Learning how to use software                                            
Feasibility Test                                            
                                             
Writing Gcode                                            
                                             
Electrical                                            
                                             
Test mandrel                                            
                                             
motors                                            
Mechanical drawing                                            
Web site design
Demo                                            
Spring

• Budget

Existing technology
using Master5CNC
Wooden model for feasibility test
Program writing g Code for winding patterns
Power supply
Determine speed and winding pattern
Reliance/ pitman motor / drawing whole chassis
Resin bath chassis design
web site
demonstration
21
Summary

• Pre-impregnate fiber with resins
• The next part I will create a resin bath
• There are a huge market for fiber winding CNC
  because
• Fiber winding create a light composite structure.

22
Acknowledge

• Dr. John Kidder
• David Jeremy
• Rogers Howes
• Professor St. Denis

23
Questions