Fiber Winding CNC

By Somnang Rom

Background

• The main focus of this project is to design and create a small-scale fiber winding machine to produce composite structures

• It will serve as a educational tool in which the materials science classes can explore the fundamental of how composite materials are made.

• Existing fiber winding processing systems requires continuous fibers. The winding pitch on the mandrel maybe be controlled to achieve desired patterns.

Solutions

• The Fiber Winding CNC Machine will use existing CNC software to control the motors speed and winding patterns.

• The system will process cylindrical shape and the working area are approximately 30” x 12” x 12”

System Overview

Top view

Motor controller

G-code

AC power

1

23

4

5

6

7

8

9

10

11

12

13

14

Mechanical Designs

24”

12.125”

12”

Side view

Fiber winding Front View

37.5”

X axis

Y axis

Z axis

Front view

Fiber winding Isometric view

Mathematical AnalysisTorque requirements

MW

Torque of lead crew:

Torque=(2.55*W)/P*e (Oz-in)

Where: •W=weight in lbs•P= screw pitch•e=efficiency for lead screw .4

M

TMandrel= (5252*HP)/rpm

HP=1/3rpm= 1750 motor rate T=1lb-ft

In our case:•W=10lb•P=.125in•e=.4

T=510 oz-in

fiberEpoxy bath

(T=2.66lb-ft)

spoolRunning at 350 rpm for the mandrel which is1/5 of the motor rating

Mandrel:

Electrical

---Custom power supply design: Hand drawn in the composition booklet

--DB 25 breakout cable schematic are not available.

----Manufacture design US digital encoderPower supply: Red wire 5v, and black are ground

---Manufacture design servo motor controller. : Schematic are not available

X axis

Y axis

Chassis GND

Electrical system overview

Chassis GND

Input data

Input data

Software

Master 5 CNC

Typical PM servo motor Controller Overview

step

dir pc count

Encoder

H Bridge D/A

P

I

D

motor

Servo motor controller

feedback

DB25 breakout cable

Bill Of materialsDescriptionRutex servo motor drive

Gecko drive

Quantity2

1

Price296.00

119.00

Shipping17.00

12.00

DB25

Relience servo motor (ebay)

1

3

20.00

444.00

10.00

21.00

Metal1.5X1.5X.5 angle

IronN/A $3/ft n/a

Coupling

Lovejoy 2 20.00

Total

$939.00

Flow chart of motor controller

ISRfeedback

mcwmccw

count

Dec ctr.Incr. ctr.

end

ISRoff

Dec ctr.Incr. ctr.

end

??

Program system overview PC step/ dir

                 

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                                            

 testing G-code                                            

Feasibility Test                                            

                                             

motor controller Design                                            

                                             

Design                                            

                                             

Test mandrel                                            

                                             

Mechanical                                            

 design                                            

Web site design

Demo                                            

Existing technologyExisting technology

Program HC08Program HC08

Power supplyPower supply

Determine speed and winding pattern Determine speed and winding pattern

demonstration demonstrationMaking last minute changes and writing web site Making last minute changes and writing web site

Selecting motor/ drawing whole chassis

using Master5CNC

Complete drawing and design chassis

Question?