FILAMENT WINDING CONTROL
The ASI Automatic Filament Winding Control System (FWC) provides the means to control the position of a horizontal or vertical Carriage, in precise association with the position of an adjacent rotating Mandrel according to 3 programmable filament winding patterns.
Mylar – Hoop – Helical
FWC INTENDED PURPOSE
The FWC is intended for use by those pipe and tank filament winding companies who are searching for a control retrofit of an existing, outdated, control system on an existing filament machine or, for those who have the capability to manufacture their own filament winding machine but lack the necessary controls to create the basic 2X winding patterns.
HOW THE FWC CONTROL SYSTEM WORKS – IN GENERAL
Details of how to setup and run programs in the FWC are given in the following pages. Here is a general description of the control system works. There are four primary operating modes:
- Manual Operation, Mandrel and Carriage are moved with manual operators
- Mylar Program Operation, the Mylar program is running to lay down mylar on the surface of the Mandrel.
- Hoop Program Operation, the Hoop program is running to apply a continuously advancing filament band to the surface of the Mandrel
- Helix Program Operation, the Helix program is running to apply a precisely designed filament band pattern to the surface of the Mandrel.
All the information needed to run Mylar and Hoop programs are directly entered into the HMI and execution occurs only from these parameters.
The Helix program pattern is special in that there are requirements and limitations on what patterns can be correctly produced. A “correct” helical pattern will result in the last pass of a layer filling in exactly one bandwidth of filaments with all prior bands placed without overlap or gaps in the pattern. This takes a little predictive math to solve. The FWC utilizes an N-1 solution to generate this pattern using multiple integer based “targets” for its derivation. In its solution the FWC predicts the intersection of the “desired” helix pattern on the vessel diameter and calculates the distance to the nearest target. Adjustments to the helix angle (+/-0.5 deg.), dwell (up to 11 deg. max), are made in order to make the closest match to the desired path. These ranges are adjustable. Finally, the bandwidth is exactly calculated to eliminate overlap and gap in the pattern. The bandwidth is manually adjusted by the operator at machine setup.
To create a helix pattern the user enters the raw design criteria, circumference, helix angle, pattern length, dwell, transition distance. When “CALCULATE HELIX” is pressed the exact values of the pattern parameters for a perfect helical pattern are displayed. As changes to helix angle, dwell, bandwidth are made, it is up to the operator to determine if the solution is good. If not, changes to dwell, lead in/out, will result in a different pattern which may be more suitable. All software for helix program generation are included in the FWC controller. So, there is no worry of future conflicts with host PC operating system upgrades or need for other graphical interface software.
The lead-in and lead out for entry and exit to the helix pattern is based upon a 1/cos transition rate where the radius is defined as the transition distance. Other, more elegant relations can be used. This is suitable for most drives and surface speeds.
When a program is started, the carriage position is calculated and commanded every 1.3ms for smooth and accurate carriage positioning.
ROBOTIC CLIP ASSEMBLY CELLS
In automatic cycle the machine will start with the Fanuc Robot at the wait position, which is as close to the part nest as is practical. This particular machine handles two parts LH and RH.
- The clip transfer will be in the home position with a clip on the pin.
- Both clip drivers will be in the retracted position with a clip on the driver.
- The Bowl Feeder will be running in automatic mode.
- The conveyor will not be running.
- The robot or other part loading mechanism will have permission to enter and place a part on nest #1.
Part fixtures or part jigs, can accurately locate and hold a variety of different parts and material types. With these fixtures, the tooling setup time will decrease and processes will have an increased rate of reliability and production.
Automation Solutions, Inc. is capable of designing, constructing and integrating custom part fixtures. Weather you need a fixture for a new part or simply have an existing fixture that is outdated, ASI can provide a turnkey solution that meets your needs