Filament winding machine

Types of filament winding machines

A filament winding machine is used to make filament-wound composite materials through the filament winding method. There are five common types of machines: a direct drive machine, a planetary drive machine, a double rotating machine, a three-dimensional machine, and an isoparametric drive machine.

• Direct drive filament winding machine

  The direct-drive filament winding machine uses an AC servo motor spindle to directly drive the rotating axis. The motor drives the workpiece to rotate during the winding process without any intermediate transmission mechanism. This can effectively reduce the transmission gap and improve the pre-tension accuracy control of the winding wire. Direct-drive machines offer fast response, high accuracy, and low inertia. They are suitable for winding products that require precise control of pre-tension and winding accuracy. They can meet the winding needs of composite materials with different shapes and specifications.

• Planetary drive filament winding machine

  The planetary drive filament winding machine uses a planetary gear box as the driving device. The winding axis and its speed are not the same due to the planetary gear's structure and principle of movement. This is another way to achieve the winding replica movement. The planetary gearbox has many advantages, such as a compact design, large transmission ratios, and high efficiency. They can meet the needs of different winding speeds and precision control. So, planetary-drive machines are ideal for making composite material products of various shapes and sizes.

• Double rotating filament winding machine

  This type of filament winding machine has two rotation systems: the mandrel's rotation and the wire's rotation. This allows for a wide variety of winding methods and winding patterns, which can meet the composite material workpiece with different shape requirements. Meanwhile, the double rotating machine has a high winding speed and efficiency. It can be used for mass production, as well as for large-scale filament winding workpieces, thus meeting the production needs of the filament winding process for different specifications and large quantities of workpieces.

• Isoparametric drive machine

  The isoparametric drive machine uses a special isoparametric gear transmission to change its speed. It has some advantages, such as a wide transmission ratio range and high reliability. This brings a good flexibility and adaptation to the filament winding process. The isoparametric driver can meet the winding requirements of composite materials with different shapes and sizes by adjusting the winding speed. It can also satisfy the technical needs of different filament winding processes for various kinds of materials and specifications.

• Three-dimensional machine

  The three-dimensional machine has a CNC control system that can precisely control the moving speed and moving path of the wire now. This allows for winding composite materials with complex shapes and three-dimensional structures. Moreover, the three-dimensional winding machine has a good flexibility and adaptability. It can meet the technical requirement of composite materials with different kinds and specifications. Thus, it can satisfy the winding precision and quality of composite materials with various kinds of materials and specifications.

Specifications and maintenance of filament winding machine

Specifications

• Winding Diameter: The filament winding machines have a winding diameter range of 0-165mm or 0-325mm. This means that the machine can wind materials onto a mandrel or spool with a diameter within this range, which is suitable for making small to medium-sized composite products such as pipes, rods, darts and other cylindrical objects.
• Winding Speed: The speed of the filament winding machine can reach 0-80r/min. The winding speed is an important parameter that affects the efficiency and quality of winding work. The speed can be adjusted to meet different winding requirements and production needs.
• Control System: The filament winding machine is equipped with a computer control system, which adopts a human-machine interface control method. The computer control system can realize digitization and automation on the machine, thus improving the accuracy and efficiency of winding operation.
• Power Supply: The power supply of the filament winding machine is 220V/50Hz, which provides the necessary power and working environment for the normal operation of the machine.

Maintenance

• Regular cleaning: It is important to keep the machine clean to remove dust, debris, and other contaminants. Use a soft brush or clean cloth to wipe the surface and parts of the machine, and use an appropriate liquid cleaning agent to clean the sticky dirt. Avoid using excessive water or liquid to prevent damage to electrical components.
• Lubrication and oiling: Lubricating and oiling the moving parts and transmission mechanism of the winding machine is necessary periodically. This reduces the machine's wear and tear over time and ensures smooth operation. Check the oil and lubricant regularly and them to the winding machine as necessary.
• Electrical Maintenance: Regular checks of the electrical components of the filament winding machine, including controllers, sensors, cables, etc., are essential. Inspect the wiring and connections to ensure they are secure, and clean, and replace the damaged or worn parts as needed.
• Adjust and tight: Periodically check the filament winding machines and adjusting the tightness of the fixed parts such as straps, pulleys, gears, etc. This guarantees the stability and accuracy of the winding operation.

Applications of Filament Winding Machines

The filament winding machine performs various applications in different industries. It is mainly used to make composite parts that have a high strength-to-weight ratio. Some industries that use the filament winding machine are the aerospace, sports equipment, automotive, and oil and gas industries.

• The filament winding machine makes aerospace parts like rocket nozzles, satellite arms, and fuselage parts. These parts are light yet strong enough to survive in space and harsh environments. The machine winds strong and light materials like carbon or glass fiber around molds, creating complex shapes.
• In the sports and fitness industry, the filament winding machine produces various products, such as tennis rackets, bicycle frames, and fishing rods. These products are made of composites that are very light.
• Automotive manufacturers use filament winding machines to produce automotive parts like car driveshafts, pressure vessels, and automotive structural components. The automotive parts made with this machine are light and strong. Some automotive parts also have better impact and chemical resistance compared with those made with other methods.
• The filament winding machine creates pressure vessels and pipes in the oil and gas industry. Filament-wound corrosion-resistant pipes are used in offshore oil extraction, chemical plants, and water treatment facilities. In offshore oil extraction, the oil and gas industry uses the filament winding machine to make low permeability fiber epoxy vessels. These epoxy vessels prevent hydrocarbons from permeating.

How to choose filament winding machine

Choosing a filament winding machine for sale is an easy, straightforward process when one knows the factors to consider. The first step in choosing a suitable filament winding machine is assessing the kind of materials that will be used in the future. The machine that is going to be chosen will usually be compatible with specific composite materials and will have its own set of feed systems, darts, and tension controls.

Another important step in choosing a filament winding machine is determining the available budget for the purchase. Winding machines come in different prices and budgets, so it is essential to look for a vendor or supplier that is within the set budget. Despite what budget one is looking at, it doesn’t hurt to prioritize the quality and reliability of the machine in question.

As winding machines also come in different types, both automatic and semi-automatic, it is important to define the desired level of automation one is comfortable with. Semi-automatic machines require manual setup and loading of the workpiece, while automatic winding machines offer more efficient production, streamlined … and integrated filament feeding and winding control systems.

The size and weight of the filament winding machine to be chosen should be appropriate and should be able to handle the capacity and dimensions of workpieces. The winding area in the chosen machine should also accommodate the maximum diameters of the cylinders.

Finally, the compatibility of the winding machine to be chosen with other production line elements and auxiliary systems, such as the preform transportation systems and fiber feeding systems, should be prioritized. Seamless integration helps enhance productivity.

Filament Winding Machine FAQ

Q1: Are filament winding machines obsolete in the industry?

A1: No. Filament winding machines are still relevant and widely used in various industries. The machine has been upgraded to suit modern industry demands in aerospace, automotive, sports goods, and many other applications.

Q2: What are some recent trends in filament winding machines?

A2: Some recent trends include automated filament winding machines, flexible production systems, hybrid machines, and integration with CAD/CAM technology.

Q3: What are some challenges faced when using a filament winding machine?

A3: Some challenges include achieving uniform fiber distribution, dealing with complex shapes, maintaining materials compatibility, and the need for skilled operators.

Q4: What are the recent advancements in filament winding technology?

A4: Recent advancements include automated winding patterns, robotic filament winding machines, integration with CAD/CAM technology, and hybrid manufacturing techniques.

Q5: What are the benefits of using a filament winding machine for composite material production?

A5: The filament winding machine offers precise control over fiber orientation, uniform distribution of reinforcing fibers, efficient production of complex shapes, and high-strength lightweight composite materials.