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Filament Winding Machine P09226

Filament Winding Machine P09226. Budget Presentation. P09226. Goals: Build Composite Filament Winding Machine Produce composite tubing Test product, compare with analytical data Benefits: Support Formula and Baja teams with composite implementation

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Filament Winding Machine P09226

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  1. Filament Winding Machine P09226 Budget Presentation

  2. P09226 Goals: • Build Composite Filament Winding Machine • Produce composite tubing • Test product, compare with analytical data Benefits: • Support Formula and Baja teams with composite implementation • Use as lab equipment for Composites course • Learning tool for students

  3. System Design

  4. Raw Materials • Fibers $40-$400 - Fiberglass $1/lb vs. Kevlar $10-15/lb - Soller Composites - Suggested amount of 40-45 lbs. - Less fraying than carbon fiber - Need masks, gloves • Resins $350-$400 - Fiber determines resin - Fiberglast/Mertons/US Composites - 5 gallon drum - Includes pump costs • Hardener $100-$125 - Time/Temp/Resin determines hardener - Cheaper hardeners tend to yield faster pot lives (restrains design)

  5. Creel • Single Spool • Minimal raw material cost • Extremely long production time • Multiple Spool $50-$75 • Decreases production time (Crucial due to resin pot life) • Requires additional design and raw materials • Angle and hardware for stand • McMaster Carr • Delivery Combs/rings • Waiting on pricing • Multiple Tensioners • Varies with type

  6. Resin Bath • Drum Type Resin Bath $200 - Chemically Resistant Bin $15-$25 - 3-4 Idler Rollers (Urethane) $15 each - Rubber “Drum” $50 - Doctor Blade $5-$10 - McMaster Carr - Benchmarked at McClean Anderson $4,014 • Fiber Dip Type Resin Bath $150 - Chemically Resistant Bin $15-$25 - 5-6 Idler Rollers (Urethane) $15 each - McMaster Carr - Benchmarked at McClean Anderson $3,917

  7. Sensors • Proximity Sensor $1.99 - per unit per order of 1000+ units - Freescale MC33794 - Industrial, Automotive Applications - Non-contact proximity sensor for control of feed-eye travel 2. Hall Effect Sensor $2.40 - per unit per order of 1000+ units - Analog Devices - Detect rotation of mandrel 3. Overstock distributor in Rochester

  8. Temperature Measurement • Thermocouple Probe $5 - $25 • Sears • Monitor resin temperature • Thermocouple Sensor $100-$250 • Monitor resin temperature • Thermometer $5-$25 • Monitor resin temperature

  9. Ventilation • Duct $100 • Drill Spot • To vent vapors from resin • Fans $6-$18 • Radioshack • Ventilation Fan $150-$300 • Specific to need, but much higher cost • Insulation $10

  10. Maintain Tension • Variable Spring Rate $50 - Rotary Tensioner - Up to 30lbs, adjustable by angle - Need pulley - Fenner Drives RT1000 series - One attachment point • Rubber Bushing $45 - Dependent on spool size, ½”, ¾”, 1” OD - 3 @ approx $15 ea - McMaster Carr - Less Control • Torturous Path $140 - Multiple Rollers - 4 @ approx $35 ea - Osbourne Int. 1” dia. - Can reduce cost by being used with bath - Multiple attachment points

  11. Tension Measurement 1. Strain Gage - Roller(s) w/ strain gage - Continuous loop feedback - Waiting on pricing 2. Load Cell - Roller(s) w/ load cell - Continuous loop feedback - Waiting on pricing • Small Force Gage $200 - Jonard - MSC

  12. Mandrel Material 1. Aquacore - $ - Soluble w/water - Some available already 2. Metal - $15 - Difficult to remove 3. Plastic - $10 - Chemical bonding considerations

  13. Motors • AC Motors $78-$250 • DC Motors • Brushed $230 • Brushless $170-$700 • Stepper $16-$500

  14. Final Est. Budget Raw Mat'l: $500-$600 Creel: $75 Temp Control: $25-$100 Resin Bath: $150-$200 Tensioner: $100-$150 Ventilation: $250-$350 Motor Assy: 2x $500-$700 Mandrel: $10-$15 (Aquacore?) Controller/Control Panel: $150-$200 (Total Range) x (Contingency) = Final Est. Budget $2260 - $3090 x 30% = $3000 - $4020

  15. References Tensioner www.fennerdrives.com www.tensionmeters.com www.jonard.com www.mcmaster.com Mandrel www.acrtucson.com Motors www.inverterdrive.com www.germes-online.com www.orientalmotor.com www.societyofrobots.com Creel www.mcmaster.com Raw Materials • www.sollercomposites.com • www.fiberglast.com • www.mertons.com • www.uscomposites.com • www.mcmaster.com Resin Bath • www.mcleananderson.com Sensors • www.freescale.com • www.analog.com Ventilation • www.drillspot.com • www.radioshack.com Temperature Measurement • www.sears.com • http://us.st12.yimg.com/us.st.yimg.com/I/yhst-19701683355538_2030_667414 

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