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


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for use by those pipe and tank filament winding companies who are searching for a control retrofit of an existing, outdated, control system on an existing filament machine or, for those who have the capability to manufacture their own filament winding machine but lack the necessary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.


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.


Our Robotic Clip Assembly Cells offer a reliable solution for accurately integrating both metal and plastic clips into your injection molded parts.  These cells come designed in a variety of different configurations and are all built specific to fulfill our customers’ needs.
How it works…

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/JIGs

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

Leak & Pressure Test Connectors

 ASI has designed leak and pressure test connectors for a broad range of manufacturing industries.

ASI Leak & Pressure Test Connector for automotive heat exchangers.

The pictured quick connector engages the black plastic component simulating the mating component in the vehicle.

Automation Solutions Inc. uses advanced engineering to build secure trustworthy connectors for diverse pneumatic lines, compressed air lines, fluid lines such as gas, water, oil, etc. ASI connectors are ideal for a wide range of threaded profiles, tubes, bores, swages, barbs, hoses and many more.

A custom designed ASI Leak & Pressure Test Connector ensures advanced quality control.

Benefits of incorporating ASI Leak & Pressure Test Connectors

  • Cost Savings
  • Simplifies Repetitive Testing Procedures
  • Increases Productivity
  • Reduces Operation Times
  • Immediately Secures Pressure-Tight Connections
  • Fast and Simple Connect/Disconnect
  • Protects Operator from Repetitive Strain Injury (RSI)

Here at ASI our Engineers undergo rigorous training to be able to solve the most complex test applications. Our engineers use sophisticated design tools and wide-ranging resources to accurately develop custom connectors. We ensure that our test connectors meet and exceed expectations; we accomplish this by working directly with our customers throughout the entire process. If your process involves any type of leak and/or pressure test application, ASI can be of service to you.

ASI has the capability to design a wide variety of testing connections.