Precision layer wound help

[lukin1977]

I am trying to modify a machine. The machine is a respooling machine for mig welding wire. Our machine wounds in random mode and I need to do it in precision layer mode. What are the key factors for acchieving a precision layer wound? Does anyone have experience with this kind of machines?

Unwinder: 24,6 kW DC motor
Winder: 10,1 kW DC motor + servomotor for thread guide (transverse movement of the wire guide)

 

[Compositepro]

Precision winding requires that the wire guide move over by one wire diameter for every revolution of the spool (fixed gear ratio). Flanged spools are required. Because of the flanges the wire guide cannot be very close to the surface of the spool. The wire will nest into the groove in the layer below. Defects in the wind pattern will affect layers above, so it is important to start the wind pattern perfectly at one edge.

 

[lukin1977]

Do we need different spool´s width sizes for different wire diameters?

 

[rhatcher]

We have a precision automatic winding machine that is used for winding field coils. It is also very useful and very fast at winding random wound coils. The random coils, while still 'random', are layed in an orderly fashion that theoretically reduces the 'randomness' of the turn-turn voltage.

A servo is used to position the wire guide so that each wire falls next to the previous one. Subsequent layers have the wires falling into the grooves of the previous layer.

Another servo is used on to turn the wire head. This is because the head must slow down at the transition when you switch directions at the edge of the coil.

For your purposes you do not need different spool sizes. The servo control calculates the number of steps (turns) of a specific wire diameter that can fit in a spool width and then steps back in the other direction when at the edge of the spool.

If you are using a servos then the only thing that is missing is the ability to adjust the servo to take steps equal to the wire diameter and the spool width.

Our machine uses a dedicated computer with a proprietary operating system and special I/O cards to interact with the servo controllers.

I cannot recall the manufacturer the machine at the moment but I can provide that information tomorrow if desired. I will warn you that it is very expensive.

 

[lukin1977]

Rhatcher

Yes. please send the information. It will be very helpful

by the way. Our servodrive is
brand: SOPREL
type: PWME 140x8/16

I tried many times to get the user manual. Anyone knows this equipment or have the user manual for it?

 

[rhatcher]

Sorry for the delay in responding. Our machinne is a Schleich WM 4000. The US distributor is:

http://www.eis-inc.com/products/electric-motor-repair-equipment/default.html