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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 Weight High creep and fatigue performance Chemical and corrosion resistance. - PowerPoint PPT Presentation
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Composite Filament Winding Machine P09226
Detailed Design Review
Christofer BraytonShijo George
Alex SandyTiago Santos
Daniel Weimann
Background
Why composite tubing?
High Strength Light WeightHigh creep and fatigue performanceChemical and corrosion resistance
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
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
Relative Speeds
• Relative Speeds control the angle at which fibers lay onto the mandrel
sc
c
m
NPVVNr
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]
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
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
Motors – Feed Eye
)cos(sin22
mFFi
FDiDF
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
Motor Selection
Controls
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
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