Maintain Tension

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					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
  – Use as lab equipment for Composites course
  – Learning tool for students
System Design
                                 Raw Materials
1. 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

2. Resins $350-$400
   - Fiber determines resin
   - Fiberglast/Mertons/US Composites
   - 5 gallon drum
   - Includes pump costs

3. Hardener $100-$125
   - Time/Temp/Resin determines hardener
   - Cheaper hardeners tend to yield faster
   pot lives (restrains design)
                                      Creel
1. Single Spool
  -    Minimal raw material cost
  -    Extremely long production time

2. Multiple Spool $50-$75
  -     Decreases production time
        (Crucial due to resin pot life)
  -     Requires additional design and raw materials
      a.     Angle and hardware for stand
            -      McMaster Carr
      b.     Delivery Combs/rings
            -      Waiting on pricing
      c.     Multiple Tensioners
            -      Varies with type
                                Resin Bath
1. 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

2. 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
                                         Sensors
1. 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
      Temperature Measurement
1. Thermocouple Probe $5 - $25
  -   Sears
  -   Monitor resin temperature


1. Thermocouple Sensor $100-$250
  -   Monitor resin temperature



2. Thermometer $5-$25
  -   Monitor resin temperature
                             Ventilation
1. Duct $100
   -   Drill Spot
   -   To vent vapors from resin

2. Fans $6-$18
   -   Radioshack

3. Ventilation Fan $150-$300
   -   Specific to need, but much higher cost


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


3. Small Force Gage $200
   - Jonard
   - MSC
                              Mandrel Material
1. Aquacore - $
   - Soluble w/water
   - Some available already




2. Metal - $15
   - Difficult to remove




3. Plastic - $10
   - Chemical bonding considerations
                         Motors
1. AC Motors $78-$250


2. DC Motors
   a. Brushed $230

   b. Brushless $170-$700

   c. Stepper $16-$500
                     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
                                          References
Raw Materials                                        Tensioner
•     www.sollercomposites.com                       •     www.fennerdrives.com
•     www.fiberglast.com                             •     www.tensionmeters.com
•     www.mertons.com                                •     www.jonard.com
•     www.uscomposites.com                           •     www.mcmaster.com
•     www.mcmaster.com                               Mandrel
Resin Bath                                           •     www.acrtucson.com
•     www.mcleananderson.com                         Motors
Sensors                                              •     www.inverterdrive.com
•     www.freescale.com                              •     www.germes-online.com
•     www.analog.com                                 •     www.orientalmotor.com
Ventilation                                          •     www.societyofrobots.com
•     www.drillspot.com                              Creel
•     www.radioshack.com                             •     www.mcmaster.com
Temperature Measurement
•   www.sears.com
•   http://us.st12.yimg.com/us.st.yimg.com/I/yhst-
    19701683355538_2030_667414

				
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