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

Mechanical Designs 24” ” 12” Side view

Fiber winding Front View 37.5” X axis Y axis Z axis Front view

Fiber winding Isometric view

Mathematical Analysis Torque requirements M W 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 T Mandrel = (5252*HP)/rpm HP=1/3 rpm= 1750 motor rate T=1lb-ft In our case: W=10lb P=.125in e=.4 T=510 oz-in fiber Epoxy bath (T=2.66lb-ft) spool Running 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 encoder Power 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

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 materials Description Rutex servo motor drive Gecko drive Quantity 2 1 Price Shipping DB25 Relience servo motor (ebay) Metal 1.5X1.5X.5 angle Iron N/A $3/ft n/a Coupling Lovejoy Total $939.00

Flow chart of motor controller ISR feedback mcw mccw count Dec ctr. Incr. ctr. end ISR off Dec ctr. Incr. ctr. end ? ? Program system overview PC step/ dir

Tasks List in weeks Research testing G-code Feasibility Test motor controller Design Design Test mandrel Mechanical design Web site design Demo Existing technology Program HC08 Power supply Determine speed and winding pattern demonstration Making last minute changes and writing web site Selecting motor/ drawing whole chassis using Master5CNC Complete drawing and design chassis

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