Continuous filament winding machine

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CFW Machine

A continuous filament winding machine (CFW Machine / CW Machine) is a machine for laying filament windings continuously over a cylindrical steel band. The steel band is carried on a forward moving mandrel which is able to collapse and return to the beginning of the travel. The steel band is released after the mandrel collapses and is continuously fed back to the start of the travel where it is again wound on to the mandrel.

Filament winding is a fabrication technique mainly used for manufacturing open (cylinders) or closed end structures. This process involves winding filaments under tension over a rotating mandrel. The mandrel rotates around the spindle while a delivery eye on a carriage traverses horizontally in line with the axis of the rotating mandrel, laying down fibers in the desired pattern or angle. The most common filaments are glass or carbon and are impregnated in a bath with resin as they are wound onto the mandrel. Once the mandrel is completely covered to the desired thickness, the resin is cured. Depending on the resin system and its cure characteristics, often the rotating mandrel is placed in an oven or placed under radiant heaters until the part is cured. Once the resin has cured, the mandrel is removed or extracted, leaving the hollow final product. For some products such as gas bottles, the 'mandrel' is a permanent part of the finished product forming a liner to prevent gas leakage or as a barrier to protect the composite from the fluid to be stored.

Mandrel

A mandrel is one of the following:

This machine is mainly used to manufacture fibre-reinforced plastic (FRP) pipes and couplings, especially glass-reinforced plastic (GRP) pipes. They are used for the manufacture of large diameter pipes and there is a minimum diameter below which the technique becomes unrealistic. Machines are available for diameters from 0.25 to 4.0 m (9.8 to 157.5 in).

Fibre-reinforced plastic (FRP) is a composite material made of a polymer matrix reinforced with fibres. The fibres are usually glass, carbon, aramid, or basalt. Rarely, other fibres such as paper, wood, or asbestos have been used. The polymer is usually an epoxy, vinylester, or polyester thermosetting plastic, though phenol formaldehyde resins are still in use.

A raw material storage and mixing areas for resins, catalysts, etc. is needed to feed the machine. This will usually involve heating of the chemical mix. The raw material is fed on a continuous steel band. The steel band moves forward a distance equal to its width for each turn. The mandrel does not move forward and there is no collapsable mandrel in the process. The process of Continuous filament winding is also known as the Drostholm Process. In addition to the continuous advancing band, many alternative methods of filament winding also exist.

While the process is innovative in many ways, the work performed on the machines proved to carry HS&E risks caused by fumes, emissions, fire risks and mechanical pinch points.


History

The first winding machine for production of GRP-pipes was invented in 1965 - 1967 by Danish and Norwegian engineers: Peder Ulrik Poulsen, Tage Debess and Agnar Gilbu in cooperation between two companies, the Norwegian Vera Fabrikker (later, Flowtite Technology AS) and the Danish Drostholm Ltd. The Danish engineers mainly focused on the invention of the winding machine, whereas the Norwegian ones were responsible for the development of the process enabling this machine to produce GRP pipes and tanks. [1] [2]

Flowtite Technology

Flowtite Technology AS is a Norwegian technology company, owned by Amiantit Group. It develops GRP pipe manufacturing technology and designs tailor-made manufacturing equipment under the brand name Flowtite. Its predecessor, Vera Fabrikker, was the first company in the world to utilize a continuous filament winding machine for production of glassfibre-reinforced plastic pipes and to invent the corresponding manufacturing process, commonly known as continuous filament winding process or Drostholm process.

Peder Ulrik Poulsen invented the rotating mandrel with an endless steel band (strip) in 1967, which made the continuous filament winding process possible. The corresponding patent application was filed in August 1968, and the patent granted in 1969. [3] At the time, Poulsen worked with Drostholm Ltd., the company that acquired all the rights to utilize his inventions. That is where the continuous winding process derives its “Drostholm Process” name from. The first winder was built in Copenhagen, Denmark in 1968 and shipped to Vera Fabrikker in Sandefjord, Norway for the production of GRP-pipes.

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References

International Standard Book Number Unique numeric book identifier

The International Standard Book Number (ISBN) is a numeric commercial book identifier which is intended to be unique. Publishers purchase ISBNs from an affiliate of the International ISBN Agency.

  1. Gilbu A., Method for producing tubes of reinforced setting plastic material, US3770541 A, 06.11.1973, Retrieved from http://www.google.is/patents/US3770541
  2. Black, Sandra. “Designing for high pressure: Large-diameter underground pipe” Composites Technology 5.31.2012 http://www.compositesworld.com/articles/making-continuous-composite-pipes (accessed on 04.02.2016)
  3. P.U., Poulsen Peder. "Driven mandrel rotatable about its longitudinal axis for continuous production of tubing in running lengths, preferably glass fibre reinforced plastic tubing." U.S. Patent No. 3,464,879. 2 Sep. 1969