Fiber winding machine is a device used to orderly wind continuously produced fiber materials (such as synthetic fibers, glass fibers, carbon fibers, natural fibers, etc.) through a mechanical transmission system. Its core function is to transform loose fiber bundles into regularly formed roll bodies, which are convenient for subsequent processing, transportation, and storage. According to different process requirements, fiber winding machines can be divided into the following categories:

-By driving mode: mechanical (gear/belt transmission), servo motor driven;

-According to the winding form: parallel winding machine, cross winding machine;

-According to the degree of automation: manual operation type, semi-automatic type, fully automatic intelligent type;

-According to applicable materials: universal type (suitable for multiple fibers), specialized type (such as carbon fiber specific rewinder).

Application fields of fiber winding machine

Fiber winding machines are widely used in the following scenarios:

-Textile industry: finished winding of synthetic fibers such as polyester, nylon, and acrylic;

-Composite material manufacturing: winding of carbon fiber and glass fiber prepreg;

-Production of non-woven fabrics: coiling of melt blown non-woven fabrics and hydroentangled non-woven fabrics;

-Special material processing: precision winding of aramid fibers and ultra-high molecular weight polyethylene fibers.

The core value of fiber winding machine

-Improve production efficiency: achieve continuous production and reduce manual intervention;

-Ensuring product quality: By precisely controlling tension and winding angle, fiber damage is avoided;

-Reduce labor intensity: replace traditional manual winding and reduce labor costs;

-Optimize warehouse logistics: Standardized roll packaging forms facilitate stacking and transportation.

Structure composition and working principle of fiber winding machine

Main mechanical structure analysis

Unwinding unit

-Function: Carrying raw material drums and releasing fibers;

-Key components: inflation shaft, magnetic powder brake, correction device;

-Technical parameters: Maximum load-bearing capacity of 500kg, unwinding speed range of 0-500m/min.

Traction and tension control system

-Traction roller set: composed of rubber rollers and steel rollers, with a surface roughness Ra ≤ 0.8 μ m, ensuring smooth fiber transmission;

-Tension sensor: using strain gauge sensors with an accuracy of ± 1%;

-Closed loop control logic: Real time adjustment of the output torque of the magnetic powder clutch through PID algorithm to maintain the set tension value.

Winding actuator

-Core clamping device: Pneumatic expansion head, suitable for paper or plastic tubes with an inner diameter of Φ 76-152mm;

-Reciprocating guide wire mechanism: The groove cylinder speed can reach 3000rpm, and the stroke error is ≤± 0.1mm;

-Wire grating ruler: resolution of 0.01mm, coupled with servo motor to achieve precise displacement control.

Human Computer Interaction Interface

-Touch screen specifications: 10 inch color touch screen, supporting multi language switching;

-Parameter setting module: can store 20 sets of process formulas, including tension curves, winding speed gradients, and other data;

-Alarm diagnosis system: Real time display of fault codes (E-01 to E-20) to guide quick troubleshooting.

Electrical Control System Architecture

-Main control PLC: Siemens S7-1200 series, integrated PROFINET communication protocol;

-Drive unit: Yaskawa ∑ -7 servo drive, response frequency 2kHz;

-Safety protection: The emergency stop button is connected in series with the control circuit, in accordance with IEC 60204-1 standard;

-Data acquisition port: equipped with RS485/Modbus interface, supporting MES system docking.

Operation specifications and debugging points of fiber winding machine

Preparation before startup

Environmental Requirements

-Temperature and humidity conditions: temperature 18-28 ℃, relative humidity ≤ 65% RH;

-Cleanliness level: workshop suspended particle concentration ≤ 352000pcs/m ³ (ISO Class 8 standard);

-Ground bearing capacity: concrete foundation thickness ≥ 15cm, bearing capacity ≥ 800kg/m ².

Raw material preparation

-Core pre-treatment: Use dry and clean paper tubes with an outer diameter deviation of ≤± 0.2mm;

-Adhesive tape pasting specification: Wrap double-sided tape evenly along the end face of the paper tube, with a width of 15mm, and leave no gaps at the overlap;

-Belt connection method: Hot melt adhesive is used for bonding, with a peel strength of ≥ 8N/cm.

Principles for Setting Key Parameters

Design of winding speed gradient

-Low speed range (0-30%): The starting speed is set to 30% of the rated value to prevent initial layer slip;

-Acceleration stage (30-70%): increase to the working speed according to a linear law;

-Constant speed range (70-90%): Maintain stability until approaching full roll;

-Deceleration section (90-100%): Reduce speed in advance to minimize impact vibration.

Adjustment of directional sensitivity

-Distance between photoelectric switches: Two pairs of detection devices are spaced 5mm apart to ensure timely triggering of steering commands;

-Reversing delay time: set to 0.1-0.3 seconds to avoid edge collapse caused by inertia;

-Reverse acceleration: controlled within ± 0.5g to reduce mechanical impact.

Key monitoring points during the trial operation phase

-Inspection system: The first 5 rolls of continuous production must be fully inspected, and the following indicators should be recorded:

-Winding hardness (Shore A type): 65 ± 3 degrees;

-End face flatness: runout ≤ 0.5mm;

-Weight consistency: Single roll difference ≤ ± 0.3%.

-Abnormal sound recognition: using a stethoscope to detect abnormal bearing noise (high-frequency whistling) and poor gear meshing (periodic clicking sound);

-Temperature inspection route: Measure the temperature of the motor casing, gearbox body, and inverter cooling fins every half hour, and do not exceed the ambient temperature+40 ℃.

Maintenance system for fiber winding machine

Seasonal special maintenance

Summer high temperature protection measures

-Cooling system upgrade: Install a water cooling circulation device on the basis of the original air cooling, and control the inlet and outlet water temperature difference within 5 ℃;

-Dust prevention renovation of electrical cabinet: adding nano coating waterproof breathable film, with protection level raised to IP54;

-Lubricating oil viscosity adjustment: Use ISO VG46 high-temperature chain oil with a flash point not lower than 200 ℃.

Winter low temperature start-up plan

-Preheating program activation: Before starting up, start the heating drum surface of the heat tracing belt to above 15 ℃;

-Low temperature lubrication management: Add an appropriate amount of MoS ₂ solid lubricant to improve boundary lubrication conditions;

-Material brittleness prevention: Suspend the use of aged fiber raw materials stored for more than one year.

Protection measures during long-term idle period

-Anti rust treatment: spray WD-40 anti rust spray to protect the exposed metal surface;

-Electrical moisture-proof maintenance: power on once a month and run continuously for 2 hours to remove moisture;

-Mechanical locking device: fix moving parts with wedges to prevent accidental sliding and damage;

-Archive record management: Establish an "Equipment Idle Ledger", indicating the sealing date, responsible person, and restart precautions.