Spooling is the most effective way for OEMs to conveniently package materials of exceptionally long length such as thread, film, wire and thermoplastics. Moog Animatics has been a long-time solution provider for winding and spooling applications, and recently developed new commands specifically for the winding industry. Contact us today for assistance with your motion control application or read more about our customer’s success in winding and spooling applications.
The integrity of a spool of any material is primarily based on the wind pattern and proper tension control used throughout the winding process. Typically, the spooling material is fed at a certain rate while a guide traverses the material back and forth corresponding to a desired pattern. The position accuracy of a traversing guide is best maintained when it's linked to the rotational velocity of the winding spool. Selection of proper traverse type for different materials is crucial, especially for profile materials that can’t twist or tolerate excessive stress.
Common Problems in Winding & Spooling
- Material tension control
- Setting proper dwell points
- Over-travel and under-travel (“dog-bone” spools)
- Inadequate or excess stress on the spooling material
- Tapered patterns with low friction material
- Tapered patterns wound onto cylindrical cores
The SmartMotor Solution offers
- Closed loop system control
- Reduced total cabling costs
- Write and test your program before the machine is built
- Easily add additional axes
- Auto-reversing electronic gearing
In addition, Moog Animatics’ newest firmware has the ability to define absolute or relative position control settings for
- Traverse points
- Spool widths
- Dwell points
Smartmotor Control Offer Gapless Material, Uncompromised Traverse End Points
OEMs can use the closed-loop PID (proportional, integral, derivative) control of their integrated motion control systems to set and maintain a critical tension level while taking advantage of new commands created specifically for winding and spooling applications.
Knowing the challenges of winding applications, we added the ability to dynamically phase adjust incoming master signals. This enables real-time offsets for variations in material width without sacrificing positioning accuracy at the traverse point, and allows for a complete, precise fill of material with no gaps or overlays.
Take a one-inch wide ribbon, for instance. With each turn of the spool, the ribbon must move one inch across the spool surface. But what happens if the ribbon varies in width throughout its total length? Previous industry solutions required dynamically changing the electronic gear ratio of the traversing motor or offsetting its traverse speed on the fly. By utilizing a sensor to feed back material width, the effective gear ratio can be dynamically compensated within the SmartMotor to ensure there are no gaps in the material wound onto the spool, and without compromising traverse endpoint locations.
Tapered Wind Patterns onto Cylindrical Cores
Tapered wind patterns prevent the material from getting hung up while unwinding when it can only be pulled from the spool in a direction parallel to the spool’s core. Tapered steel cores cost more than cylindrical cores and complicate the winding process due to material slip. If you do use a tapered core for winding low-friction material, the material tends to slip to the smallest end of the core regardless of the tension level.
The solution can be accomplished with an encoder to track angular position of the main spool, a screw-driven actuator to traverse the wire guide, and Moog Animatics Class 5 SmartMotors enhanced with the latest firmware. The Moog Animatics motion control system can be programmed to calculate the traverse speed by electronically gearing the spool encoder to the traverse axis.
Over- and Under-travel
Further Reading ...
Download Winding Industry Solution Brochure