Composite Filament Winding Machine: P09226 Shijo George Christofer Brayton Alex Sandy Tiago Santos Daniel Weimann Project Manager Electrical Engineer Chief Engineer Mechanical Engineer  Sponsored by RIT Mechanical Engineering Department

Project Description A machine to produce composite tubing (i.e. fiberglass, carbon fiber) Market: RIT ME Department Key high level customer needs / engineering specs: o Robust o Quality Control o Ease of use Simple but effective machine that produces limited products Minimize raw materials (resin, fiber) Maintain fiber tension throughout process Fiber volume fraction > 50% Operation procedure simple Easily disassembled for cleanup

Concept Description Creel to hold and tension fiber Resin bath to impregnate fibers Mandrel to wind fibers on Control system for accurate winding Separate Motors to drive spindle and carriage

System Architecture

Technical Risk Assessment Effective Impregnation System Description Fully impregnate fibers, but not soak Ensure quality of product Maintain constant temperature Mitigation Trial & Error Method with mock-up Resistance Heater or Hot plate to heat resin Monitoring System using thermocouples & sensors feedback Controllability of Motors Description Micro-controller compatibility Precise positioning of fibers Ease of use (set & forget) Expandable & Cost Efficient Mitigation Consulting with professors & technicians from suppliers Mock up with any available motors in Department Testing on Anaheim Automation motors

Current State of Design Sponsor obtained with fixed budget of $2,000 Design meets customer needs Design of machine elements completed, driving system & controls selected and unnecessary parts removed Part’s raw materials in house, machinery BOM prepared Design meets engineering specifications for full system and subsystems Project expenses within budget: So far ~ $ 1,000 allocated Behind one week in programming for system’s control Design of spindle’s motor bed still in process Mitigation: -Team effort in catching up with programming control routines -Team is working over the break

MSD 1 Project Schedule Milestones Mar. 20 th (Week 2) – Impregnation, Tension Test complete Apr. 3 rd (Week 4) – Motors and Controls Test complete Apr. 17 th (Week 6) – Complete Machine Build May 1 st (Week 8) – First Composite Part produced (post- debugging) May 8 th (Week 9) – Composite Part test complete (tentative)