Design and Fabrication of Fiber Optic Winding Machine

Project Title

Design and Fabrication of Fiber Optic Winding Machine

Project Area of Specialization Mechatronics EngineeringProject Summary

Different sizes and patterns of spools are required in many industries for different applications. Different spools of fiber optics can be used in Defense, solar industries, medical, etc.  Filament winding is the manufacturing technique to do continuous winding of fibers on rotating mandrel to maintain the specific pattern and uniformity of structure . The winding of fiber optic in different sizes and patterns is one of the difficult tasks and different sizes and pattern winding is required in many applications. We will transfer the fiber optic from one spool to another spool having desired pattern and length. As we know fiber optic is very sensitive and easily damaged so winding of fiber optic in different sizes and patterns is one of the critical and hard tasks. We must follow the approach very carefully to do the winding of fiber optics in such a way as to avoid loss, damage, and breaking. The available design for threads or yarns is not suitable for the fiber optic. We must make our mechanical design very precisely. We will design the control systems for the motor controls which are required for smooth motion. We will wind the fiber optic in different patterns precisely which will be used for further applications. Our goal is to design and fabricate a machine through which we can get the different winding patterns of fiber optics precisely. The system must be able to wind the fiber optic on different spool sizes with different winding speeds. The winding pattern must be consist of the minimal voids as much as possible. The winding of different patterns can be used for different industrial applications. Most of the winding machines consist of two axes of motion which are carriage travel and mandrel rotation. The final winded product can be used in the automotive industry for cutting steel for the building of cars, transmitting signals between different parts of vehicles at speed of light, traction control, and airbags safety. The optimized product can also use un medical applications like endoscopy used to make a bright light to avoid unnecessary incisions. It has a lot of  applications in militiary and aerospace components.

Project Objectives

To design and fabricate the fiber optic winding machine for different size and patterns of spools.

To do locally winding of fiber wire and not import from abroad.
The pitch of the winding will be variable.
The winding must contains the minimal voids.
To maintain the proper tension level to avoid the breakage and faulty in fiber optic
To maintain the proper different winding speeds to achieve the precise winding.

Project Implementation Method

To achieve the objective of our project, we will divide this project into mechanical and electronics part. We will design the structure for our system. We will design each and every system including motions of actuators mechanisms, spool holding mechanisms, pulleys etc. For the high strength fiber optic, and to avoid the breakage, we must have to design many pulley systems and the feeding mechanisms. Material will be selected accordingly to requirements. We may be used aluminium frame or may be we use the 3D printed parts. We will design and fabricate the universal spool holding system which will be able to hold the different types of spools We may be include the tension sensor, proximity sensors etc.

Electrical Circuitry is basically used to control all the mechanical parts. Electrical circuitry will used to communicate between differernt modules and sensors. Electrical circuitry will consist of many controllers, motor drivers, regulators, power supply, and voltage converterts etc. We will also design the graphical user interface to control the circuit. There will be communication between the circuitry and the graphical user interface. So we will use the graphical user interface to control the mechanical parts through electrical circuitry. We will set our parameters pitch, winding speed etc through user graphical interface. The below block diagram illustrates the general sketch of our system.

Benefits of the Project

This project will make avoid the import of fiber wires in different spools

pakistan will be able to produce different patterns and length of spools locally.

Technical Details of Final Deliverable

The final product will be consist of aluminum frame and three high precision stepper mortors. The motors we used in our product are imported stepper motors. Different pulley designed for precise winding. Different sensors attached for controlling and taking data for experimentation.

Final Deliverable of the Project Hardware SystemCore Industry TelecommunicationOther Industries IT , Others Core Technology RoboticsOther Technologies OthersSustainable Development Goals Decent Work and Economic Growth, Industry, Innovation and InfrastructureRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	71351
Load Cell Amplifier Module	Equipment	1	100	100
Proximity Sensor	Equipment	2	450	900
TFT Screen display(HMI)	Equipment	1	9530	9530
Spool	Equipment	5	2500	12500
Stepper Motor(Nema 23)	Equipment	3	1500	4500
Load Cell Sensor	Equipment	1	250	250
Stepper Motor Linear Actuator	Equipment	1	17071	17071
Pulley	Equipment	7	500	3500
Motor Driver (TB 6600)	Equipment	3	1150	3450
Arduino	Equipment	5	1100	5500
Power Supply (S-360-48)	Equipment	1	3500	3500
Aluminum Extrusion Profile 20x20	Equipment	1	8100	8100
Delivery Charges of Stepper motor	Miscellaneous	2	250	500
Delivery Charges of Aluminum Extrusion Profile	Miscellaneous	1	500	500
Delivery Charges of TFT Screen	Miscellaneous	1	250	250
Welding	Miscellaneous	1	400	400
Machine Operator charges	Miscellaneous	1	800	800