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Composite Filament Winding Machine P09226 Detailed Design Review Christofer Brayton Shijo George Alex Sandy Tiago Santos Daniel Weimann
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Composite Filament Winding Machine P09226 Detailed Design Review Christofer Brayton Shijo George Alex Sandy Tiago Santos Daniel Weimann.

Dec 21, 2015

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Page 1: Composite Filament Winding Machine P09226 Detailed Design Review Christofer Brayton Shijo George Alex Sandy Tiago Santos Daniel Weimann.

Composite Filament Winding Machine P09226

Detailed Design Review

Christofer BraytonShijo George

Alex SandyTiago Santos

Daniel Weimann

Page 2: Composite Filament Winding Machine P09226 Detailed Design Review Christofer Brayton Shijo George Alex Sandy Tiago Santos Daniel Weimann.

Background

Why composite tubing?

High Strength Light WeightHigh creep and fatigue performanceChemical and corrosion resistance

Page 3: Composite Filament Winding Machine P09226 Detailed Design Review Christofer Brayton Shijo George Alex Sandy Tiago Santos Daniel Weimann.

Filament Winding

• The process by which a continuous strand of impregnated fibers is wound onto a mandrel with specific fibers’ orientation which is controlled by computer.

• Once resin has cured, mandrel is removed

Page 4: Composite Filament Winding Machine P09226 Detailed Design Review Christofer Brayton Shijo George Alex Sandy Tiago Santos Daniel Weimann.

RIT First Generation Filament Winding Machine

Capabilities

• Produce tubes of limited dimensions• Simple to operate• Maintain tension every time• Limited range of orientation angles• Able to be expanded upon

Primary Goals

• Learning Experience– New technology to RIT and students involved

– Create simple but bulletproof machine

Page 5: Composite Filament Winding Machine P09226 Detailed Design Review Christofer Brayton Shijo George Alex Sandy Tiago Santos Daniel Weimann.
Page 6: Composite Filament Winding Machine P09226 Detailed Design Review Christofer Brayton Shijo George Alex Sandy Tiago Santos Daniel Weimann.

Relative Speeds

• Relative Speeds control the angle at which fibers lay onto the mandrel

sc

c

m

NPV

V

Nr

2 θ is the fiber winding angle (°)

r is the radius of the mandrel Nm is the speed of the mandrel [RPM]Vc is linear velocity of the feed eyeP is the pitch of the rackNS is the pinion speed [RPM]

Page 7: Composite Filament Winding Machine P09226 Detailed Design Review Christofer Brayton Shijo George Alex Sandy Tiago Santos Daniel Weimann.

Relative SpeedsNm (rpm) 10 Nm (rpm) 20

Wind Angle Feed Eye Speed Pinion Speed Wind Angle Feed Eye Speed Pinion Speedtheta (deg) Vc (in/min) Vc (in/sec) Ns (rpm) theta (deg) Vc (in/min) Vc (in/sec) Ns (rpm)

5 360.0 6.0 540.0 5 720.0 12.0 1080.010 180.0 3.0 270.0 10 360.0 6.0 540.015 120.0 2.0 180.0 15 240.0 4.0 360.020 90.0 1.5 135.0 20 180.0 3.0 270.025 72.0 1.2 108.0 25 144.0 2.4 216.030 60.0 1.0 90.0 30 120.0 2.0 180.035 51.4 0.9 77.1 35 102.9 1.7 154.340 45.0 0.8 67.5 40 90.0 1.5 135.045 40.0 0.7 60.0 45 80.0 1.3 120.050 36.0 0.6 54.0 50 72.0 1.2 108.055 32.7 0.5 49.1 55 65.5 1.1 98.260 30.0 0.5 45.0 60 60.0 1.0 90.065 27.7 0.5 41.5 65 55.4 0.9 83.170 25.7 0.4 38.6 70 51.4 0.9 77.175 24.0 0.4 36.0 75 48.0 0.8 72.080 22.5 0.4 33.8 80 45.0 0.8 67.585 21.2 0.4 31.8 85 42.4 0.7 63.590 20.0 0.3 30.0 90 40.0 0.7 60.0

Nm (rpm) 30.00 Nm (rpm) 60.0

Wind Angle Feed Eye Speed Pinion Speed Wind Angle Feed Eye Speed Pinion Speedtheta (deg) Vc (in/min) Vc (in/sec) Ns (rpm) theta (deg) Vc (in/min) Vc (in/sec) Ns (rpm)

5 1080.0 18.0 1620.0 5 2160.0 36.0 3240.010 540.0 9.0 810.0 10 1080.0 18.0 1620.015 360.0 6.0 540.0 15 720.0 12.0 1080.020 270.0 4.5 405.0 20 540.0 9.0 810.025 216.0 3.6 324.0 25 432.0 7.2 648.030 180.0 3.0 270.0 30 360.0 6.0 540.035 154.3 2.6 231.4 35 308.6 5.1 462.940 135.0 2.3 202.5 40 270.0 4.5 405.045 120.0 2.0 180.0 45 240.0 4.0 360.050 108.0 1.8 162.0 50 216.0 3.6 324.055 98.2 1.6 147.3 55 196.4 3.3 294.560 90.0 1.5 135.0 60 180.0 3.0 270.065 83.1 1.4 124.6 65 166.2 2.8 249.270 77.1 1.3 115.7 70 154.3 2.6 231.475 72.0 1.2 108.0 75 144.0 2.4 216.080 67.5 1.1 101.3 80 135.0 2.3 202.585 63.5 1.1 95.3 85 127.1 2.1 190.690 60.0 1.0 90.0 90 120.0 2.0 180.0

Page 8: Composite Filament Winding Machine P09226 Detailed Design Review Christofer Brayton Shijo George Alex Sandy Tiago Santos Daniel Weimann.

Motors - Mandrel

rFmgF

Τ is the torque applied [N-m]F is the force applied [N]r is the radius on which the force is applied [m]m is the mass of applied load [kg]g is the acceleration of gravity [9.81 m/s2]

ozin 2093.1055.11395.70

Page 9: Composite Filament Winding Machine P09226 Detailed Design Review Christofer Brayton Shijo George Alex Sandy Tiago Santos Daniel Weimann.

Motors – Feed Eye

)cos(sin

22

mFF

i

FD

i

DF

A

L

TL is the torque appliedF is the force appliedD is the diameter of the pinionη is the efficiency of the gear train (assumed to be .9)i is the Gear Ratio of the rack and pinion (1.5 in/rev)

ozinTL 3505.505.1567.335.1

Page 10: Composite Filament Winding Machine P09226 Detailed Design Review Christofer Brayton Shijo George Alex Sandy Tiago Santos Daniel Weimann.

Motor Selection

Page 11: Composite Filament Winding Machine P09226 Detailed Design Review Christofer Brayton Shijo George Alex Sandy Tiago Santos Daniel Weimann.

Controls

Page 12: Composite Filament Winding Machine P09226 Detailed Design Review Christofer Brayton Shijo George Alex Sandy Tiago Santos Daniel Weimann.

Controls

V15VDC

V212-24Vdc

V33.3Vdc

V43.3Vdc

V53.3Vdc

R1

1k

R2

1k

R3

1k

SW1

SW MAG-SPST

SW2

SW4

SW MAG-SPST

SW5

SW MAG-SPST

0

0

Direction

ON/OFF

Input 2

IGND

A (-)

B (+)

INDEX

CHA

+5V

CHB

VIN

Output 1

Hard -

Hard +

Input 1

GND

GND

23MDSI SERIES

SW6

SW7

SW8

SW9

SW10

Feed Eye

RS-485 IN

Computer / User Interface

D1

LEDD2

LEDD3

LED

V65VDC

V712-24Vdc

SW3

0

A (-)

B (+)

Input 2

IGND

Hard +

Direction

ON/OFF

VIN

Output 1

Hard -

+5V

CHB

GND

INDEX

CHA

GND23MDSI SERIES

Input 1SW11

SW12

SW13

SW14

SW15

Mandrel

RS-485 IN

00

Page 13: Composite Filament Winding Machine P09226 Detailed Design Review Christofer Brayton Shijo George Alex Sandy Tiago Santos Daniel Weimann.

Motor BOMSystem Item Manufacturer/

Vendor

Part No. Qty Unit Price Total Price

Motors/Controls mod/Smart Crome Switch Moddersmart TSW-M-CHR 3 4.25 12.75

Motors/Controls Green LED Moddersmart LED-10-G 10 0.25 2.50

Motors/Controls Red LED Moddersmart LED-10-R 10 0.25 2.50

Motors/Controls Yellow LED Moddersmart LED-10-A 10 0.25 2.50

Motors/Controls Limit Switch Grainger 4B803 1 66.45 66.45

Motors/Controls Power Supply Anaheim Automation PSAM24V1.2A-5V3.5A

1

Motors/Controls Power Supply Grainger 5JW03 1 104.85 104.85

Motors/Controls Integrated Stepper Motor Anaheim Automation 23MDSI 2 196.25 196.25

Motors/Controls Stepper Motor (Feed Eye) Anaheim Automation 17Y201S-LW4 1 160 160

Motors/Controls Stepper Motor (Mandrel) Anaheim Automation 17Y402S-LW4 1 210 210

Motors/Controls Bipolar Microstep Driver Anaheim Automation MBC25081 2

Motors/Controls Programmable Controller Anaheim Automation PCL601 or PCL501

2