P17221: FSAE Composite Tube Fabrication

Integrated System Build & Test with Customer Demo

Table of Contents

Team Vision for System Level Demo with Customer

'Goals for this phase'

When we had started out this phase we had planned to get the few known cleanup tasks including the electronics mounting and final fit and finish tasks (rough edges removed, parts fit better, missing features added) to get the machine capable to wind the first wet tube that would give us the best feedback as to how well the machine was meeting the engineering requirements. We had planned to have the first tube wound and cured for the customer demo and to have the machine ready to run another wet tube at the customer demo. The imagine poster would be at a presentable stage for the peer review process and the technical paper at a 75% complete level.

'What Got Completed'

The machine was quickly made ready with the new electronics mounted and final fit and finish completed. The more powerful cross feed motor was mounted and alleviated issues with stalling. Tailstock fitment and locking was improved and the mandrel was prepped for wet testing. Before we wound with the wet tube we decided to do some testing with the dry fiber. As we tested with the dry fiber we found that the machine was not as dialed in as we had thought. As we better familiarized ourselves with the parameters of the GRBL and CompisiCAD software, we were able to fine tune the performance of the machine and get it laying down the fiber much better. During this testing time were were also plagued with issues regarding the tensioning of the fiber and its delivery to the mandrel. The adjustable layout of the pegboard allowed us to try various configurations of pulley setups to alleviate small issues such as the fiber fraying, the fiber skipping off pulleys, wide variance in fiber tension, and tow width variation. These small issues resulted in us starting the wet winding testing much later than we had anticipated. After attempting to make the first wet tube we found that there were still issues to work out. There were issues with how long the part turn around zone needs to be to reduce slippage of the fibers and how much crossfeed travel the machine needs to make a part. We are fixing these issues by relocating the payout eye much closer to the mandrel as seen on many commercial machines and moving to a longer mandrel to allow for longer turn around zones. We were also hit with problems on the resin delivery and spilling resin out of the machine. New stock to machine revised resin bath components have been ordered. We are expecting to work out the rest of the known problems by the end of Week 12 and will be attempting to wind the next tube by Monday of Week 13 at the latest.

The compounding of many small issues have led to our schedule slipping a bit. However we feel that our plans to ironing out these problems will be effective and will result in us being able to finished tubes with less turn around time for adjustments than originally planned for. While we had planned to make 4 tubes (1 proof run, 3 test tubes) we may only be able to realistically deliver 3 tubes (1 proof run, 2 test tubes).

While we have not held a formal demo with the customer, there has been much buzz in the machine shop with our project. We hope that the enthusiasm of the Formula Team with our project will continue and expect our customer to get good use out of the machine.

The Imagine poster has been completed and handed in for peer review and the team is excited about the design. We are behind on the technical paper although each individual has been working on outlining what needs to be written about the development of their system. We expect to be able to complete most of the work on the paper during Week 12 as we are waiting on parts and materials for the next round of testing.

Photos from the first sets of testing (both wet and dry) can be found at the following link below. The photos document some of the problems that we have encountered along with the changes to the machine that have taken place including:

Here are some photos

'High precision 15 degree wrap angle ribbon test:'


'First wet wind test with 1/4 inch fiber at 45 degree wrap angle:'

Problems that can be seen in the video:


Test Results Summary

The current snap shot of our test plan results can be seen below:


DV = Design Value

TV = Threshold Value

IV = Ideal Value

MV = Measured Value

Green = Complete

Yellow = Preliminary testing indicates that this value is easily attainable, still needs to be formally tested

Red = Preliminary testing indicates that this will be hard to obtain, still needs to be formally tested

ER# Engr. Req. Unit DV TV IV MV Notes Test
1 Operator Safety Operator does not need to interact with moving machine Yes Yes Yes Yes Requirement has been met. Motion control is accomplished remotely. The machine can be safely and immediately paused and shut down at the user interface. n/a
2 Part Size Capacity Inches (DxL) 6"x30" 3"x24" 6"x30" ??? Our original part capacity projections did not include the large turn around areas that we have now determined that we need. Part length may be affected but with the revised payout eye location, drive shafts of sufficient length will be able to be manufactured. n/a
3 Power Draw Requirements W 1000 20A at 110V = 2.2k 10A at 110V = 1.1k 517 The max value that is even possible because of fuses in the supplies is <1kW. ER03
4 Max Wrapping Angle Degrees 10 45 5 45 The crossfeed motor has no difficulty providing the torque required to wrap at this angle. See Problem Tracking for the latest information. D02
5 Wrapping Angle Precision Degrees 1 5 1 ??? Requires a completed tube for test. D02
6 Filament Tension lbs 0-10 Adjustable 0-2 ??? We have deferred testing this requirement until we have resolved all issues with the tensioning system as the addition of new pulleys and wiper systems will affect the final output tension. n/a
7 Step Required for Operator to Run Integer 10 15 1 ??? We are still actively working to reduce the required steps for setting up the machine and running it as we are testing the machine. # of Steps will be evaluated after final revision of user manual.
8 Total Machine Cost Dollars 1500 2000 1000 1075.03 This value is the actual value spent. While are well under budget, we have had delays with ordering through our customer due to budgeting priority for the Formula SAE vehicles . Better forecasting with the customer may have resulted in a tighter budget constraint in MSDI Costing
9 Max Tow Width Supported Inches 0.5 0.125 0.5 0.5 The tensioning system has been using tow up to 3/8in with no problems. We expect that the machine would function similarly with 1/2 in tow n/a
10 Max Spindle Speed RPM 100 50 150 471.2 We tested this ER and found the motor stalled at a much higher speed than the ER. GUI and GRBL limits set to ER and well below actual motor limit. n/a
11 Max Spindle Acceleration rad/s^2 120 80 120 34.9 We tested this ER and found that we have not required a higher setting and experience smoother motor operation with a lower limit. GUI and GRBL limits set to value shown. Value is set in GRBL
12 Spindle Speed Precision RPM 0.5 1 0.5 ??? This is very accurate. We just need to document it. This still needs to be formally tested.
13 Spindle Position Precision Deg/1k Rev 2 5 2 <3 after 1000 revolutions Further accuracy can be obtained through microstepping if necessary, but the current value is deemed sufficient for now. This still needs to be formally documented.
14 Max Feed Speed Inches/Minute 100 10 100 ??? We tested this ER and found that we easily met it without the motor stalling. GUI and GRBL limits set to ER and well below actual motor limit. This still needs to be formally documented.
15 Crossfeed Speed Precision Inches/Minute 0.2 0.5 0.1 ??? We tested this ER and found that we easily met it without the motor stalling. GUI and GRBL limits set to ER and well below actual motor limit. This still needs to be formally documented.
16 Machine Has Resin Bath Y/N Y Y Y Y After testing we may have found that we should have better planned out the specifications for the resin bath. The resin bath has required changes to make it wider and deeper along with a revised dip roller setup. Lack of published data made it hard to forecast these issues. n/a
17 Spool Capacity lbs 10 5 10 >10 The machine was loaded with the max spool weight and had no issues. n/a

At this point we have tested the machine to a point that we feel that it can achieve the accuracy and precision that we need it to. A large portion of work for has been making adjustments to the machine parameters both physical and software side to get it tuned in to wrap an acceptable tube. The large amount of testing with the machine as allowed us to gain intimate understanding of how each of these parameters affect the machine.

Risk and Problem Tracking

Items highlighted in gray are solve and no longer under consideration. Green represents having recently been resolved. Orange indicates the process portion of an active problem that has been completed. Red indicates the remainder of the problem process flow which still needs completion.

Problem Tracking Pg 1

Problem Tracking Pg 1

Problem Tracking Pg 2

Problem Tracking Pg 2

The following shows some progression to the process of trying different tensioning system layouts. While testing with the dry fiber we found that fiber tended to skip of the dip rollers and could cause the machine to stall. Our first attempt at a solution was a quick rearrangement of the setup to a single grooved roller with supporting infeed and out feed rollers to keep the fiber from slipping sideways which greatly alleviated the problem and allowed us to continue on to the wet winding testing.

ceter|Starting configuration showing how the fiber falls off of the resin bath roller

ceter|Starting configuration showing how the fiber falls off of the resin bath roller

First step towards a solution after a groove was cut into the roller

First step towards a solution after a groove was cut into the roller

Despite the success of the grooved roller, it was deemed necessary to create a new resin bath due to problems 9 & 10 in the problem tracking document. A replacement with a larger roller has been modeled for manufacturing. Materials expected to be in Mid week 12 to manufacture bath componenets.

The revised placement of the payout eye can also be seen here. This was deemed to be the quickest to implement solution as it can be completed using in stock materials and will require only a 1/2 day of manufacturing time to complete. Manufacturing to be completed week 12.

Tensioning revisions showing larger resin bath, dip roller and payout eye

Tensioning revisions showing larger resin bath, dip roller and payout eye

After watching the delivery of resin to the fiber we found that at times the fiber became over saturated during the run. We came up with a couple quick to implement concepts that could be made of materials we have on hand. We chose concept 3 as the path to resolve this problem as we feel that it will be the quickest to implement will still providing good squeegee action without much risk of damaging the fiber. We expect to have this change implemented by the end of week 12.

Resin Delivery revision concept 1

Resin Delivery revision concept 1

Resin Delivery revision concept 2

Resin Delivery revision concept 2

Resin Delivery revision concept 3

Resin Delivery revision concept 3

Imagine RIT Poster Progress

Our current design for the poster can be seen below:

Imagine RIT Poster First Cut

Imagine RIT Poster First Cut

Budget Update

Currently we have spent 1075.03 on the project including the materials to build machine, the necessary materials to test with and additional materials needed to make revisions to the machine. Our customer has asked us to be frugal in our spending to reduce impact on them.
Current Budget

Current Budget

Live purchasing BOM can be found here

Plans for next phase

Gannt Chart

Gannt Chart

3 Week Plans

Daniel's 3-Week Plan

Ryan's 3-Week Plan

Patrick's 3-Week Plan

Jon's 3-Week Plan

Andrew's 3-Week Plan

Matt's 3-Week Plan

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