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

2. Background Why composite tubing? High Strength Light Weight High creep and fatigue performance Chemical and corrosion resistance

3. 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

4. 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

6. Relative Speeds Relative Speeds control the angle at which fibers lay onto the mandrel θ is the fiber winding angle (°) r is the radius of the mandrel N m is the speed of the mandrel [RPM] V c is linear velocity of the feed eye P is the pitch of the rack N S is the pinion speed [RPM]

7. Relative Speeds Nm (rpm)10Nm (rpm)20 Wind Angle Feed Eye Speed Pinion SpeedWind Angle Feed Eye Speed Pinion Speed theta (deg)Vc (in/min)Vc (in/sec)Ns (rpm)theta (deg)Vc (in/min)Vc (in/sec)Ns (rpm) 5360.06.0540.05720.012.01080.0 10180.03.0270.010360.06.0540.0 15120.02.0180.015240.04.0360.0 2090.01.5135.020180.03.0270.0 2572.01.2108.025144.02.4216.0 3060.01.090.030120.02.0180.0 3551.40.977.135102.91.7154.3 4045.00.867.54090.01.5135.0 4540.00.760.04580.01.3120.0 5036.00.654.05072.01.2108.0 5532.70.549.15565.51.198.2 6030.00.545.06060.01.090.0 6527.70.541.56555.40.983.1 7025.70.438.67051.40.977.1 7524.00.436.07548.00.872.0 8022.50.433.88045.00.867.5 8521.20.431.88542.40.763.5 9020.00.330.09040.00.760.0 Nm (rpm)30.00Nm (rpm)60.0 Wind Angle Feed Eye Speed Pinion SpeedWind Angle Feed Eye Speed Pinion Speed theta (deg)Vc (in/min)Vc (in/sec)Ns (rpm)theta (deg)Vc (in/min)Vc (in/sec)Ns (rpm) 51080.018.01620.052160.036.03240.0 10540.09.0810.0101080.018.01620.0 15360.06.0540.015720.012.01080.0 20270.04.5405.020540.09.0810.0 25216.03.6324.025432.07.2648.0 30180.03.0270.030360.06.0540.0 35154.32.6231.435308.65.1462.9 40135.02.3202.540270.04.5405.0 45120.02.0180.045240.04.0360.0 50108.01.8162.050216.03.6324.0 5598.21.6147.355196.43.3294.5 6090.01.5135.060180.03.0270.0 6583.11.4124.665166.22.8249.2 7077.11.3115.770154.32.6231.4 7572.01.2108.075144.02.4216.0 8067.51.1101.380135.02.3202.5 8563.51.195.385127.12.1190.6 9060.01.090.090120.02.0180.0

8. Motors - Mandrel 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/s 2 ]

9. Motors – Feed Eye T L is the torque applied F is the force applied D is the diameter of the pinion η 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)

10. Motor Selection

11. Controls

12. V1 5VDC V2 12-24Vdc V3 3.3Vdc V4 3.3Vdc V5 3.3Vdc 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 23MDSI SERIES SW6 SW7 SW8 SW9 SW10 Feed Eye RS-485 IN Computer / User Interface D1 LED D2 LED D3 LED V6 5VDC V7 12-24Vdc SW3 0 A (-) B (+) Input 2 IGND Hard + Direction ON/OFF VIN Output 1 Hard - +5V CHB GND INDEX CHA GND 23MDSI SERIES Input 1 SW11 SW12 SW13 SW14 SW15 Mandrel RS-485 IN 0 0

13. Motor BOM SystemItemManufacturer/ Vendor Part No.QtyUnit PriceTotal Price Motors/Controlsmod/Smart Crome SwitchModdersmartTSW-M-CHR34.2512.75 Motors/ControlsGreen LEDModdersmartLED-10-G100.252.50 Motors/ControlsRed LEDModdersmartLED-10-R100.252.50 Motors/ControlsYellow LEDModdersmartLED-10-A100.252.50 Motors/ControlsLimit SwitchGrainger4B803166.45 Motors/ControlsPower SupplyAnaheim AutomationPSAM24V1.2A- 5V3.5A 1 Motors/ControlsPower SupplyGrainger5JW031104.85 Motors/ControlsIntegrated Stepper MotorAnaheim Automation23MDSI2196.25 Motors/ControlsStepper Motor (Feed Eye)Anaheim Automation17Y201S-LW41160 Motors/ControlsStepper Motor (Mandrel)Anaheim Automation17Y402S-LW41210 Motors/ControlsBipolar Microstep DriverAnaheim AutomationMBC250812 Motors/ControlsProgrammable ControllerAnaheim AutomationPCL601 or PCL501 2