RH16A Fiber Coil Winding Machine

 

Parameter	Specifications
Fiber Diameter Range (mm)	Φ0.1～Φ0.5
Winding Speed (r/min)	0-80
Maximum Tooling Diameter (mm)	250
Tension Control Range (g)	3-50
Tension Precision (g)	±0.5(20r/min)
Traverse Stroke (Coil Width) (mm)	200
Counting Accuracy (turns)	0.01
Displayable Parameters	Turns, Tension, Length, Layer Count, Spindle Direction, Traverse Direction, Coordinate, Speed, real-time display of wound length for current layer
Programmable Parameters	Fiber Diameter, Spindle Direction, Traverse Direction, Speed, Tension, Spool Diameter, Spool Width, etc.
Equipment Dimensions (mm)	L 1500 × W 1150 × H 1900

 

 

 

 

Before using the equipment, please carefully read the following safety section in order to ensure personal safety!!!!

 

WARNING

The power supply of this equipment is two-phase, three-wire 220V, pay attention to high voltage.

This equipment operates with rotating parts.

Failure to observe safe instructions may cause serious personal injury or property damage.

Only qualified personnel who thoroughly understand the following warnings, precautions and maintenance procedures should operate this equipment.

The key to safely using this equipment to produce qualified products lies in the proper mastery of the operation and maintenance process.

 

QUALIFIED PERSONNEL

Refers to people familiar with the operation and maintenance of this equipment and must have the following qualifications.

Trained and qualified in power supply, disconnection, cleaning, grounding, and marking of wiring and electrical equipment as required by safety regulations.

Trained in the proper maintenance and use of equipment as defined by safety regulations.

Trained in emergency care.

 

DANGER

Refers to death, serious injury or property damage that would have resulted if proper precautions had not been taken.

 

ATTENTION

Refers to the relevant parts of the product information and manuals that should be given high priority.

NOTES

Only qualified personnel familiar with this equipment and the information supplied with it are permitted to operate or service the equipment.

In the normal operation of the equipment, it is prohibited to touch the various production parts with your hands at will to prevent personal injury; to prevent damage to the machine.

Before performing intuitive overhaul and maintenance work, make sure that the AC power is disconnected; both the controller and the motor may carry dangerous voltages until the AC power is disconnected.

In the charged measurement, regardless of the circumstances are not allowed to touch the charged wiring; instrumentation measurement gear should be correct, to avoid incorrect gear and cause damage to the equipment phenomenon occurs.

Ensure that the equipment is well grounded and safe to operate.

After the equipment is energized, personnel without training, do not touch the various electrical components, terminals, etc., so as not to cause personal injury; such as the occurrence of line connection off phenomenon, please disconnect the power before processing.

When cleaning and maintaining the equipment, please turn off the power to carry out, do not operate with electricity, is strictly prohibited to clean with water.

Please strictly follow the equipment operation steps to ensure the production of qualified products; on maintenance of other notes, please contact us.

Requirements for Environment

In order to ensure the production of qualified products, and at the same time to extend the service life of the various components of the equipment, the user plant needs to have the following conditions:

Supply Voltage

Two-phase three-wire system 2×220V±10%, 50HZ±2% 3.5KW

Good grounding conditions must be provided (separate grounding device in accordance with international standards for personal protection and some degree of elimination of electromagnetic interference). With leakage and anti-static grounding.

Installation Environment

Temperature 20～25℃

Relative humidity 30 to 80% (no condensation)

Dust-free environment, cleanliness 100,000 grade

No corrosive or flammable gases

Well-ventilated premises, for hot air dissipation and personnel ventilation

No electromagnetic interference or harmful rays

Workshop illumination meets the requirements of precision instruments

The ground should be flat, bearing 500Kg / m2

Uses of Equipment and Features

RH16A multi-pole coil winding machine is the core equipment for making fiber coils of gyroscopes, and our company has the core technology of R&D and manufacturing. This winding machine can wind all kinds of symmetric or simple winding process of fiber coils, with easy operation, high precision automatic fiber laying, high precision automatic glue coating, high degree of automation, stable operation and so on.

 

Product Features

The whole machine adopts fully sealed welding structure. The bottom of the machine is equipped with universal Foma wheels, which is convenient for the movement of the equipment and also has shock absorption.

Meet the requirements of quadrupole, octupole, and hexadecapole fiber coils;

Precise automatic fiber laying during winding, capable of optical fibers with outer diameters of 100um, 135um, 165um, and 250um;

Real-time display of winding length, number of turns, number of layers, position of fiber laying, direction of spindle rotation, direction of fiber laying, tension and other information;

English measurement and control software HMI;

With spindle synchronized rotation function, customizable speed;

Manual real-time adjustment of rotational speed, rotational speed can be customized in the range of 0-80r/min, fiber pitch can be adjusted in real time;

Manually control the increase or decrease of the speed.

Can stop at any time, and manual control, with fiber reversing;

With in-line automatic gluing function;

With winding video monitoring, it can monitor the fiber winding situation in real time, and it is equipped with LCD display. The lens can be adjusted in XYZ three-dimensional direction;

Safety protection to prevent personnel from wrong operation causing damage to the equipment or products, such as winding tension protection, left and right limits of the coil winding tooling, and so on.

 

Main Technical Indicators

No.	Item	Unit	Range
1	Fiber Length Supported	m	≤10000
2	Tension control range	g	3 to 50
3	Tension control accuracy	g	±0.5(20r/min)
4	Fiber Diameter Supported	mm	100-500
5	Turn Error	turn	≤0.01
6	Length Error		≤3 per cent
7	Spindle Radial Runout	mm	≤0.02
8	Spindle Axial Runout	mm	≤0.02
9	Fiber Laying Straightness	mm	≤0.01
10	Fiber Laying Repeatability	mm	±0.01
11	Winding speed	r/min	0 to 80
12	Fiber Laying Movement	mm	200
13	Winding Fiber Coil Outer Diameter	mm	20 to 250
14	Diameter of Spindle for Fixing Coil Skeleton	mm	φ15, φ10
15	Width of Pay-off Spool	mm	40 to 80
16	Spindle Rotary Diameter	mm	≥200
17	Spindle Center Height	mm	≥300

 

Equipment Composition and Working Principle

Equipment Composition

Fiber take-up device	1 set
Fiber laying device	1 set
Fiber pay-off device	1 set
Tension sensing device	1 set
Coil skeleton fixing spindle	1 set
Fiber guiding device	1 set
Automatic gluing device	1 set
Industrial control computer and display unit	1 set
HD camera and display unit	1 set
Standard fiber rewinding spool	2 pcs

 

Machine Structure

The external dimension of the equipment is 1550mm (L) x 1150 (W) x 1900mm (H); the bottom is installed with movable heavy-duty Footmaster wheels and equipped with a horizontal adjustment mechanism, which facilitates the movement of the equipment as well as horizontal positioning.

The spindle is the core component to ensure the main technical index of the coil winding machine. The spindle adopts high-precision spindle with rotary runout ≤0.02mm and is equipped with servo motor to drive the spindle to meet the requirements of speed and position.

The device profile is shown in the figure.

Figure 1: Product Picture

 

Figure 2: Product Form Factor II

 

Fiber take-up Device

Precision spindle

The spindle is mainly composed of spindle motor + original imported high-precision gear motor:

Figure 3: Precision spindle

 

Structure and working principle

This device is used in the fiber take-up of coil winding, and mainly completes the rotary function of fiber take-up. The device is powered by the main spindle motor, and the user can set the rotating speed and rotating direction of the motor on the operating panel. The motor rotation is transmitted to the main spindle through the high-precision imported gear motor and synchronous belt, and the main spindle drives the fiber coil to rotate at a uniform speed. In the coil winding process, the fiber coil is set on the skeleton fixed section and the fiber pay-off spool is set on the spool fixing section.

Skeleton Mounting Parts

The skeleton mounting parts are stepped and divided into a skeleton fixing section and a spool fixing section:

Figure 4: Skeleton mounting components

 

Fiber Take-Up Device

The fiber take-up device mainly consists of precision main spindle + skeleton mounting parts + skeleton fixing section:

Figure 5: Fiber take-up System

 

Precision Fiber Laying Device

Precision Fiber Laying Device mainly consists of fiber laying motor + high precision guide rail module:

Figure 6: Precision Fiber Laying

 

Structure and working principle

This device mainly completes the precision movement of fiber laying, using servo motors connected to highly speed reduction ratio gear motor, which will drive the working platform to move by the high precision rail. During fiber winding, according to the fiber take-up speed, fiber diameter, precisely calculating the movement of fiber laying, so that the movement of precision sliding rail will be the same as the speed of fiber laying, to achieve consistency, maintain balance, achieving precision fiber laying. Fiber pay-off device and tension sensor are fixed on the fiber laying system, they will stay relative static with the fiber laying system while working.

 

Fiber Pay-off Device

The fiber pay-off device mainly consists of fiber pay-off motor + original imported high-precision gear motor:

Structure and working principle

This device mainly controls the precision movement of fiber pay-off, using servo motor connected to the high reduction ratio gear motor, which will drive the fiber pay-off spindle by a coupling. During fiber winding, according to the fiber take-up speed, tension, precisely calculating the movement of fiber pay-off, adjusting at any time, to ensure that the fiber will be winded by a stable tension onto the skeleton; equipped with a gimbal guide device, so that the fiber does not torsion at any angle, reduce additional stress because of torsion while winding.

Tension Sensing Device + Fiber Guiding Device

Tension sensing device mainly consists of tension sensor + fiber guiding wheel:

 

Structure and working principle

The tension sensing device + fiber guiding device are fixed on the precision rail of the fiber laying system.

Tension sensing device has a circular fiber guide wheel, fixed on a swing arm which can be rotated. There is a moving wheel that used to stabilize the tension. In the center of the swing arm, there is a tension sensor, timely feedback the position of the moving wheel to the PLC control system, the system in accordance with the received position of the moving wheel to adjust the speed of fiber pay-off.

When the fiber laying on the skeleton is not ideal, fiber appears to be stacked or loose, which needs to be retracted, the direction of the motor for fiber take-up, fiber pay-off and fiber laying can be controlled by the touch panel to reach an ideal situation.

In the winding process, if there is a need to replace the spool, according to Figure 9 Fiber guiding of fiber coil, directly put the corresponding spool on the fiber pay-off spindle, to achieve rapid spool change.

 

Gluing Device

The gluing device is mainly made of brush mounting hole and heater.

 

Structure and working principle

The gluing device is fixed on the fiber guiding device.

The glue box on the gluing device has a round hole, under normal circumstances, install the brush on the outlet of dispensing syringe, the syringe is installed in the round hole, the optical fiber goes through the center of the brush. Amount of glue can be controlled by adjusting syringe glue output. In addition, there is an electric heating device on the bottom, temperature of the glue can be controlled, to avoid the glue getting solid during long time use.

Precision Platform

Precision platform is mainly composed of marble platform as well as casting support frames:

Figure 11: Precision platform

 

Structure and working principle

This device mainly completes the task of supporting and adjusting the height of each part, using a combination of marble platforms and casting parts; marble platforms to ensure the flatness of the operation desktop, casting parts to ensure that the platform does not occur deformation during long time use.

 

Electronic Control System Program

The electric control system is an important part of the multi-pole fiber winding machine to realize the motion control and finally achieve the technical performance index. On the basis of the understanding of its technical performance indexes and the requirements for use, we put forward the technical scheme of the electric control system of the multi-pole fiber optic winding machine, which includes the following main contents:

The main components of the electronic control system;

Tension control system;

Precision fiber laying system;

Control system synthesis;

Security protection for system operation.

The program fully considered mature and advanced technology. The control system adopts position of the closed-loop digital composite control structure combined with the mainstream industrial control PC computer and Mitsubishi series PLC multi-axis motion axis control system. Friendly graphical human-machine interface provides flexible operation and display in the winding process; high-precision servo motor system with the position of the encoding reference signal of the optoelectronic incremental shaft encoder as a measurement of each axis of the movement of the feedback element; PLC axis motion controller and the control computer The PLC axis motion controller and control computer are configured with RS232 to communicate with the upper computer to realize control; the computer software is based on WINDOWS operating system with function expansion capability.

The control computer is the main part of the electronic control system, which accomplishes various control operations of the ring-winding machine, data input and output and the management functions of each functional template, as well as equipment fault monitoring and safety protection.

Mitsubishi PLC is the core of each axis motion control, through the drive unit with each axis, motion mechanism, axis angle measurement and feedback unit constitutes a position closed-loop system, to achieve the coordinated motion control of each axis, and provide cycle measurement circuit for speed calibration measurement and provide fixed-angle synchronized pulse output. The control computer also accomplishes various human-machine interface management functions of the equipment, such as user data input, equipment real-time data output and motion trajectory curve display.

High-Definition Camera and Display Unit

The display unit is divided into two parts, the first part is the camera display unit, the second part is the human-computer interaction interface, displaying the machine's operating functions and parameters, besides, the convenient operation buttons can also operate the coil winding machine:

 

Industrial Control System

Industrial control system consists of industrial control machine + PLC control system + server, the human-machine interface control system is installed in the industrial control machine, together with PLC controller, making the entire industrial control system, complete each motion of the equipment.

The HMI control system interface is as follows:

Figure 14: Industrial control system control interface

 

Equipment Operation

Preparation

Open the air switch (lower left corner) of the main power, press the power button on the touch panel, at this time the machine is powered on, the machine enters the working state.

Check if there is abnormal alarm on the operation interface

Examine each part of the machine for any abnormalities that may affect the normal operation of the machine;

Inspect all parts of the machine for abnormalities that affect safety.

Running Operation

Configuration

Figure 15: Parameter setting interface

 

Item	Description
Fiber diameter	Setting the currently used fiber diameter
Coil inner diameter	Setting the coil inner diameter of the currently used skeleton
Skeleton width	Setting the coil inner width of the currently used skeleton
Fiber take-up speed	Setting the basic speed of fiber take-up axis
Fiber laying speed	Setting the basic speed of fiber laying speed
Fiber pay-off speed	Setting the basic speed of the fiber pay-off axis
Total coils	Recording the total coils that have been winded
Total length	Recording the total length
Total layers	Recording the total layers
Total turns	Recording the total turns
Start-up turns of glue injection	Glue will be injected every certain turn
Camera left/right move	Click to move the position of the camera
Equipment lighting	Click to turn on/off the light in the machine

The parameters of coil winding (e.g. fiber ring skeleton width, skeleton diameter, fiber diameter) are set through this interface as follows:

Enter the HMI - Parameter/Data button to set up.

Control

The operation of this equipment is mainly on the human-machine interface, and the location of each operation key is shown in the following figure:

Figure 16: Control Interface

 

Item	Description
Menu	Operation monitoring interface (power-on interface)
Tension display	Current encoder tension display of fiber
Spool A data	Record the data generated when spool A is running.
Spool B data	Record the data generated when spool B is running.
Current rate	Current winding spindle speed (r/min)
Current location of fiber laying	Current position of the fiber laying spindle
Left fiber laying Position	This means the Position calculated by the system based on the current width of the skeleton
Right fiber laying position	This is the button for setting the starting position of the fiber laying
New layer	Finish winding the current layer. Click the Wind New Layer button. The current length and number of turns are cleared, and the current layer increases by 1.
New coil	The current coil is finished. Click new coil. All data of spool A and B are cleared and counting starts again.
Clear tension	Clear the current encoder coordinate value
Glue injection trigger	Glue injection signal– setting the parameters of glue injection
Servo enable	This means the servo is enabled
Emergency stop	This means emergency stop.
Tension overload	This means the tension is overloaded.
Return to origin	This is the button for Fiber laying axis goes returns to origin when the machine is stopped or in manual mode. Doesn't work in automatic mode.
Left alignment	This means the left alignment function starts
Right alignment	This means the right alignment function starts
Continuous mode	This is the button for three axes work together
Separate mode	This is the button for three axes work separately
Left alignment startup	This is the button for starting three axes working together
Right alignment startup	This is the button for starting three axes working separately
Forward rotate	This means the winding axis is rotating forward
Backward rotate	This means the winding is rotating backward
Spool A	This the button for executing program of spool A, and recording spool A data
Spool B	This the button for executing program of spool B, and recording spool B data
Fiber laying leftward	This is the button for laying fiber leftward
Fiber laying rightward	This is the button for laying fiber rightward
Menu	Access to the main operator interface button
Parameters/data	This is the button for entering the parameter setting/data logging interface
I/o monitoring	Access to PIC input/output I/O

 

Tension control

 

Control Panel

No.1 is to adjust the speed of the winding spindle

No.2 is to change the rotating direction: forward or backward

No.3 is to change the direction of fiber laying: leftward or rightward

No.4 is to slightly change the direction of fiber laying: leftward or rightward

No.5 is to start the machine

No.6 is to stop the machine

 

Fault Alarm and Remove

Fault Alarm

When the machine is running automatically or manually, a warning message appears on the operation monitor, which indicates that the machine is in a fault alarm state and puts the machine in a suspended state, while the interface usually displays a fault message.

Alarm Status Remove

According to the fault information on the operation interface or through observation to determine the fault, after the fault is solved, the alarm is removed, the machine restores the original operating state.

Emergency Stop

When an emergency situation requires an immediate stop, press the red Emergency Stop button immediately.
At this time, the machine stops immediately and all operations do not work, there will be no warning in the operation monitoring. After troubleshooting, rotate

 

the Emergency Stop button so that it pops out, and press the reset button before the problem is solved.

 

Operation Precautions

Please keep the operator away from the equipment body when the equipment is running to avoid personal injury;

Do not operate the machine at high speeds (speeds of 300m/min and above) for optical fibers with diameters smaller than 170um (including 170um). This is because small diameter optical fibers are easily damaged at high speeds. It is recommended to control the speed within 200m/min.

Do not turn off the power while the machine is in normal operation as this may cause significant damage to the machine;

Please check each wearable and fragile part of the machine regularly;

Please perform timely maintenance on all moving parts, such as line guide bearings, guide wheel small bearings and other parts;

Please draw a warning line range where the machine is to be used to avoid injury to personnel caused by fiber breakage during high-speed operation;

 

Periodic Maintenance Schedule

Type	Frequency	Content
Daily	Everyday	Check operating temperature, humidity, dust, foreign matter, etc.
		Check abnormal vibration and noise
		Check power supply voltage
		Check whether there is a strange odor
		Check the cleanliness of the front of the servo drive, connectors
		Check the wires
		Check connection parts with equipment and deviation of core feet
		Check there is no foreign objects embedded in the load section
		Check guide wheels are clean, smooth and burr-free, and stable
		Check the tension control system is flexible and no stuttering
		Use clean and dry dust-free gauze to wipe the surface plane of the machine, the surface of the slide table, the skeleton fixed parts, guide fiber wheel and other small parts need to use tweezers to clip the alcohol cotton cleaning
Periodically	Weekly	Skeleton fixing parts rails, sleeves are lubricated with sewing machine oil.
	Monthly	Tightening of fiber pay-off bearing screws
		Tightening of fiber take-up bearing screws
		Tightening of line guide fixing screws
		Guide wheel bearing positioning in the same plane
		Lubrication of each working bearing
	Yearly	Whether the wiring of the drive is loose or not
		Check for loose connection plugs between servo motor and drive
		Whether the grounding wire of each device is secure
		Rotating bearing inspection

 

Common Failures and Handling Methods

No.	fault	cause	Treatment	note
1	No power after the equipment mains plugged in	No power to the mains plugs socket; Air switch Q1 in the electrical cabinet is not closed; The power button on the operation panel is not pressed;	Turn on power to the main power outlet; Close the Q1 air switch in the electrical cabinet; Press the power button on the operation panel;	be careful of electrocution
2	The equipment has power, the servo drive display panel of fiber laying, fiber pay-off, fiber take up, etc. has no display	Servo drive air switch Q1 to Q7 is not closed for fiber laying, fiber pay-off and fiber take-up.	Close air switches Q1 to Q7 in the electrical cabinet.	be careful of electrocution
3	PLC module not working	PLC module is not powered up PLC mode is "STOP".	Close air switch Q9 Switch the PLC mode to "RUN"	be careful of electrocution
4	The left and right "OFF/ON" buttons do not light up.	The tension is too high or too low, or the upper/lower tension protection limit is set too low.	Manually adjust the tension so that the tension is within the upper/lower limit of the tension protection value or set the protection value higher.	be careful of electrocution
5	Alarm box prompts "left limit or right limit" alarm indicator lights up	Line guide reaches limit position, automatic machine protection	An emergency stop button needs to be pressed to reset the guide rail by manually turning the guide rail screw when a guide rail left/right limit alarm occurs. Keep the row of wire base away from the left/right limit protection switch.	Power must be turned off