MATERIAL

CADWIND
Process simulation system for filament winding

User manual

MATERIAL

Copyright 2007:
MATERIAL S. A.
Lozenberg 23
B - 1932 Zaventem/Brussels
Belgium
Tel.: 32/2/715.94.94
Fax.: 32/2/715.94.90
E-Mail: [email protected]

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Contents

1 Getting started ....................................................................................................................... 4

2 General hints ......................................................................................................................... 5
3 The working principle of CADWIND ...................................................................................... 7
4 Generating the mandrel models ............................................................................................ 13
4.1 The mandrel generator............................................................................................. 13
4.2 Generating the mandrel models by yourself ............................................................ 15
5 View ....................................................................................................................................... 26
6 Winding.................................................................................................................................. 27
6.1 Calculation methods and winding parameters ......................................................... 27
6.2 The material parameters .......................................................................................... 37
6.3 Display of the results ................................................................................................ 37
6.4 Options ..................................................................................................................... 38
7 Postprocessing ...................................................................................................................... 39
7.1 Calculation of the control data.................................................................................. 39
7.2 The control data formats .......................................................................................... 43
7.3 Running the part program ........................................................................................ 44
7.4 Graphical display of the machine motion ................................................................. 44
7.5 The open postprocessor .......................................................................................... 44
8 Machine ................................................................................................................................. 46
8.1 Characteristics of the winding machine ................................................................... 46
8.2 Characteristics of the control.................................................................................... 50
9 Print / Plot .............................................................................................................................. 54
9.1 Print .......................................................................................................................... 54
10 The editor ............................................................................................................................ 55
11 Function summary ............................................................................................................... 56

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1 Getting started

Installation
Copy all the files from the disk with your specific serial# into a new directory. All parameter files
generated with a previous version of CADWIND are compatible.
On some Windows 95/98/NT systems the drivers for the hardlock on the parallel printer port have
to be updated. This is done automatically by the DOS program HLDINST.EXE which you find on
the Installation Driver Utility Disk. To run the program proceed as follows:
1. copy the program HLDINST.EXE to your hard disk
2. go in MS-DOS mode
3. go to the directory that contains HLDINST.EXE
4. run HLDINST.EXE by typing: HLDINST -INSTALL
The drivers are now installed for your specific Windows version. Return to Windows by typing EXIT
at the DOS prompt. Now you should be able to run CADWIND on your system.
Requirements
CADWIND requires the following:

IINTEL PENTIUM processor or better

WINDOWS 95/98/NT
at least 8 MB RAM
at least 5 MB of free hard disk space

Versions and modules

Please check which CADWIND version and which modules you are using. Some program functions
can only be executed with the appropriate module.
Hotline
Should you encounter difficulties or have any questions, please call us:
32 / 2 / 715 94 94
Fax.: 32 / 2 / 715 94 90
E-Mail: [email protected]
We recommend for support on a special problem to save the mandrel file (name.mdr) and all
winding, postprocessing and machine parameters under FILE / SAVE PROJECT as CWP-file.
Than you can send these files by E-Mail to MATERIAL and we can reproduce the problem and give
advice.

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2 General hints
The user interface of CADWIND NG corresponds to the common WINDOWS standard. As a
WINDOWS user you will be familier with the handling of the application windows and most of the
short-key combinations of the editor.
The menu bar
All program functions can be reached via the menu bar on the upper edge of the screen. The
functions can be selected as follows:
Menu items with three points (...) opens a dialogue window for entering parameters. Menu items
with arrows (->) opens a sub menu. All other menu items executes the function.
The graphics display

fig. 2.1: graphics window

The graphics window contains a toolbar with selection boxes and buttons. They allow to change
views and they allow to switch on/off several graphics features according to fig. 2.1.
To magnify an area of the graphics display the mouse can be used to select a zoom window. Klick
the mouse button and drag from the top left corner to the bottom right corner. To return to the initial
zoom factor drag the mouse from the bottom right to the top left.

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Dialogue windows
All parameters are entered via uniform dialogue windows. They contain four different elements:

input fields
radio buttons to choose one out of several options
check boxes to switch on/off options
function buttons to execute directly a function

These elements can be reached as follows:

by using TAB or SHIFT-TAB
by pressing ALT and the highlighted character
by clicking with the mouse
The parameters in a dialogue window can be confirmed by pressing the OK button. You can cancel
with ESC or by pressing the CANCEL button.

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3 The working principle of CADWIND
An example shall give a general view of the working principle of CADWIND. It shows the
winding of a pressure vessel. The procedure is:
1. creating the model of the mandrel
2. calculating the winding
3. generating the part program
Starting
1. If you havent started the program yet, do it now.
Creating the mandrel model
1. Choose the menu FILE / CREATE MANDREL / CIRCULAR CROSS-SECTION....
2. Enter the parameters shown in fig. 2.1. (the input elements can be reached by TAB or SHIFTTAB or by clicking with the mouse):

fig. 2.1: dialogue window for mandrel geometries with circular cross-section
Remark:
CADWIND lite and CADWIND vessel assumes that the front and back pole caps are equal.
Therefore there is only one input field for the pole cap selection.
3. Confirm the values with the OK button.
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The dialogue window for the input of the mandrel file name will appear.
4. Enter VES.MDR as file name and confirm with the OK button.
Immediately after closing the last dialogue window, the model will be calculated, displayed and
saved as VES.MDR.
Winding
1. Choose WINDING / SELECTION from the menu, select helical winding and confirm the
dialogue with the OK button (see fig. 3.1).
number of rovings: 3
roving width: 4 mm
TEX-value: 800
fibre volume content: 60 %
fibre density: 1.77 g/cm3
resin density: 1.20 g/cm3

fig. 3.1: Material parameters

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2. Choose WINDING / HELICAL from the menu, enter the following parameters
and confirm with the OK button (fig. 3.2):
winding angle: 22
starting frame: 20
pattern number: 3/2
degree of coverage: 100 %
number of layers: 1
close winding pattern: change entire path
dwell front: 0
dwell back: 0

fig. 3.2: helical winding parameters

3. Click on "Start winding".
You will see that the program calculates the winding pattern according to the entered winding and
material parameters by iterating the first fibre path. After the first path is found, the complete
laminate
will be adjusted to it. Finally, the different fibre elements will be sorted to a continuous
fibre track.
Eventually, the build-up of the laminate is shown as it will be produced on the filament
winding
machine (fig. 3.3).

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fig. 3.3: laminate display

4. under WINDING / SAVE the winding parameters can be saved.

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Generating the control data for the winding machine (only with module 3)
1. Choose POSTPROCESSING / PARAMETERS from the menu, enter the following parameters
and confirm with the OK button (fig. 3.4):

Fig 3.4: postprocessing parameters

calculation mode: enveloping contour
min. distance: 20 mm
control data optimization: min. production time
filter value: 5 mm
Axes to calculate: Cross carriage, Pay-out rotation
save: in CCDF-format
2. Press F4 to generate the control data for the winding machine.
The control data will be generated according to the parameters in the menu POSTPROCESSING
and the machine characteristics in the menu MACHINE. You can look at the control data by using
the editor:
3. Choose TOOLS /EDITOR , enter VES.DAT as file name and confirm with the OK button.
4. Leave the editor
You can also display the displacement-time, velocity-time and acceleration-time diagrams of the
machine motion:
5. Press F8 to display the diagrams (fig. 3.5).

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Fig 3.5: displacement-time and velocity-time diagrams

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4 Generating the mandrel models
4.1 The mandrel generator
CADWINDs mandrel generator allows you to automatically create the mandrel models (menu item
MANDREL / CREATE). You already worked with it in the preceding example.
Geometries and parameters
The basic geometries with their parameters are:
circular cross-section
You have to enter the diameter and the length.
rectangular cross-section (only with module 1A or 1)
You have to enter the lengths A and B of both edges, the edge radius and the mandrel length.
elliptical cross-section (only with module 1A or 1)
You have to enter the lengths A and B of both axis and the mandrel lengths.
elbows (only with module 1)
In addition to the above mentioned parameters the characteristics of the elbow have to be
defined. You have to enter the opening angle, the inside radius, the transposition between the
rotation axis and the axis through the centre of the middle frame, as well as the lengths of the
linear sections (fig. 4.1).

L1

L2

Fig. 4.1: Elbow parameters

: opening angle
R: inside radius
D: transposition rotation axis / central axis
L1, L2: linear sections

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cone (not with CADWIND lite or CADWIND vessel)
You have to enter the diameters A and B at the front and back end of the cone, as well as the
length.
T-parts (only with module T)
T-parts are described by three main segments A, B and C (fig. 4.2). You have to enter the
lengths
and diameters of the segments. Diameter A is always equal to diameter C.
Furthermore you have
to enter the inside radius and the transposition between the rotation
axis and the central axis. You
have also to choose the position of the T-part: the rotation
axis can be parallel to the horizontal
central axis (in the dialogue: position = horizontal) or
parallel to the vertical central axis (in the
dialogue: position = horizontal).
Apart from the above described parameters the geometries of the front and back pole cap have to
be entered (not for T-parts).
Remark:
CADWIND lite and CADWIND vessel assumes that the front and back pole caps are equal.
Therefore there is only one input field for the pole cap selection.
After the input window for the basic geometry the dialogues for the pole caps follow. Finally, you
have to enter the name for the mandrel file.
You can load stored mandrel models with MANDREL / LOAD any time.

LB

LA

Fig 4.2:

LC

T-part parameters
LA, LB, LC: lengths of the segments A, B, and C
A, C: diameters of the segments A, B, and C
H: horizontal central axis
V: vertical central axis
R: inside radius
D: transposition rotation axis / central axis

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4.2 Generating the mandrel models by yourself
You can create mandrel geometries, which cant be calculated with the mandrel generator, yourself
and load them with MANDREL / LOAD. There are three different formats: the mandrel contour
format for axisymmetric mandrels, the mandrel surface format for any mandrel geometries and the
T format for T-parts.
Mandrel description
To describe the mandrels a coordinate system has to be defined. In this system, the Y-axis must be
identical with the rotation axis and its positive orientation must be from the chuck to the tailstock.
The geometry of the mandrel is then split up into characteristic cross-sectional frames (fig. 4.2
right).
When using the mandrel contour format it is sufficient to specify the Y-coordinates and the
diameters of the cross-sectional frames.
For the description in the mandrel surface format the frames have to be approximated by polygons
(Fig. 4.2 left). The X,Y,Z-coordinates of the corner points of the polygons are finally stored in the
mandrel file. You have to consider the following when choosing the polygon points:
Edges (e. g. on rectangular cross-sections) have to be rounded by radiuses.
On non-axisymmetric frames all polygon points must be distributed equally, i. e. the distances
between two neighbouring points must be constant.
The gradients of corresponding polygon lines must be (approximately) equal. Otherwise it is
possible that the mandrel model structure is twisted (fig. 4.3). If the gradients are not equal then
the mandrel surface is not appropriate for the winding algorithm.
The coordinates and the diameters are in millimetres or in inches. The mandrel files are ASCII text
files and can be created with the CADWIND editor or any other appropriate text editor.

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Z

16
15

1 2

3
4

28
34

TB

TF
Fig. 4.2: Mandrel description
left: numbering of the polygon points (16 points per frame)
right: divided into frames (34 frames)
TF: front turning zone (frame 1 to 6)
TB: back turning zone (frame 28 to 34)

b
d

Fig. 4.3: Twisted mandrel model structure

left: gradient a gradient b => twisted structure
right: gradient c = gradient d => no twisting

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The mandrel contour format
The mandrel contour format is used for axisymmetric mandrels only. It has the following structure:

Line
CADWIND CONTOUR DATA FILE
MM
PINS FRONT: NO
PINS BACK: NO
28
24
7
22
-50.00
30.00
-41.67
68.69
-33.33
82.17
-25.00
90.62
...
850.00
30.00

Explanation
identification
values in millimetres
no pins at the front
no pins at the back
number of frames
number of points per frame
front turning zone ends at frame 7
back turning zone begins at frame 22
Y-coordinate / diameter of the 1. frame
Y-coordinate / diameter of the 2. frame
Y-coordinate / diameter of the 3. frame
Y-coordinate / diameter of the 4. frame
Y-coordinate / diameter of the 28. frame

Besides the Y-coordinates and the diameters of the frames you have to indicate the unit (MM or
IN), if there are pins in the turning zones, the number of frames (valid range: 4 ... 60), the number of
points per frame (valid range: 12 ... 84) and the turning zones.
Remark:
If no unit is indicated the program assumes the values in millimetres.
Remark:
CADWIND lite and CADWIND vessel can only read cylinders and vessel geometries with elliptical
pole caps.
Display of the mandrel (not with CADWIND lite or CADWIND vessel)
The example above represents an axisymmetric mandrel with different diameters. You can find it
on the CADWIND diskette under the name MEX1.MDR. You can look at it with the following steps
(fig. 4.5):
1. Choose MANDREL / LOAD from the menu.
The dialogue window for the mandrel file name appears.
2. Enter MEX1.MDR as file name and confirm with the OK button.
The mandrel file will be loaded.
3. Press F2 to display the mandrel model.
The mandrel model will be calculated and displayed.
4. Return to the text screen with F10 .

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The mandrel surface format (only with module 1A or 1)
With the mandrel surface format you can describe axisymmetric and non-axisymmetric mandrels. It
has the following structure:

Line
CADWIND SURFACE DATA FILE
MM
AXISYM: NO
PINS FRONT: NO
PINS BACK: NO
8
48
2
7
0.00
0.00
0.00
0.00
1200.00
0.00
25.00
0.00
-0.50
25.00
0.00
-0.40
...
17.82
0.00
-17.82
25.00
100.00
-0.50
25.00
100.00
-0.40
...
17.82
100.00
-17.82
...
25.00
1200.00
-0.50
25.00
1200.00
-0.40
...
17.82
1200.00
-17.82

Explanation
identification
values in millimetres
mandrel non-axisymmetric
no pins at the front
no pins at the back
number of frames
number of points per frame
front turning zone ends at frame 2
back turning zone begins at frame 7
X, Y, Z - coordinates of the start point
X, Y, Z - coordinates of the end point
X, Y, Z - coordinates of the 1. point of the 1. frame
X, Y, Z - coordinates of the 2. point of the 1. frame
X, Y, Z - coordinates of the 48. point of the 1. frame
X, Y, Z - coordinates of the 1. point of the 2. frame
X, Y, Z - coordinates of the 2. point of the 2. frame
X, Y, Z - coordinates of the 48. point of the 2. frame
X, Y, Z - coordinates of the 1. point of the 8. frame
X, Y, Z - coordinates of the 2. point of the 8. frame
X, Y, Z - coordinates of the 48. point of the 8. frame

Besides the X,Y,Z-coordinates surface points you have to indicate the unit (MM or IN), if the
mandrel
is axisymmetric or not, if there are pins in the turning zones, the number of frames
(valid range: 4 ...
60), the number of points per frame (valid range: 12 ... 84) and the turning
zones. Furthermore, you
have to define a start point and an end point. These are in general the
centres of the first and last
frame.
Remark:
If no unit is indicated the program assumes the values in millimetres.
Remark:
With module 1A only tubes with rectangular and elliptical cross-section can be read via the
mandrel
surface format.
Display of the mandrel
You can find the example above on the CADWIND diskette under the name MEX2.MDR. You can
look at it with the following steps (fig. 4.6):
1. Choose MANDREL / LOAD from the menu.
The dialogue window for the mandrel file name appears.

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Fig. 4.5: axisymmetric mandrel with different diameters

Fig 4.6: transition circular cross-section / rectangular cross-section

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2. Enter MEX3.MDR as file name and confirm with the OK button.
The mandrel file will be loaded.
3. Press F2 to display the mandrel model.
The mandrel model will be calculated and displayed.
CAD (DXF) Interface
The mandrel generator has to be limited to standard geometries and to create CADWIND MDRfiles yourself for complex geometries can become very awkward. Hence the two CAD-interfaces
"DXF->contour..." and "DXF->surface..." can help you to create "CADWIND CONTOUR DATA
FILE" and "CADWIND SURFACE DATA FILE" easier.
DXF->contour...
This option is used to create axis-symmetric mandrel geometries with a CADWIND CONTOUR
DATA FILE. In fig. 4.7 and 4.8 an example of a CAD-contour is shown and the corresponding 3D
CADWIND mandrel model.

fig. 4.7: Example of a CAD-contour

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fig. 4.8: CADWIND 3D mandrel model calculated from CAD- (DXF-) data with calculated winding
pattern
You need to be aware of the following rules for the use of the "DXF->contour..." interface:

The CAD-drawing is two dimensional and represents only the contour of an axis-symmetric
mandrel
the CAD-data must be in DXF-format (AutoCAD-standard)
the CAD drawing must only contain straight lines and arcs. Splines, Bezier lines, polylines, ...
must not be used and need to be approximated if necessary with straight lines and arcs
the x-axis of your CAD co-ordinate system corresponds to the Y-axis (rotation axis) of the 3D
CADWIND mandrel model
the origin of the CAD co-ordinate system corresponds to the origin of the mandrel co-ordinate
system in the 3D CADWIND mandrel model
the distance from the CAD-X-axis to the contour represents the radius of the mandrel's crosssection
the ending point of a straight line and an arc of the CAD-contour must be identical with the
starting point of the following straight line or arc; this can be realized easily by using the "snap
to object" feature of most CAD-systems
if imperial units (Inch) is used in CAD-drawings the "CADWIND CONTOUR DATA FILE" has to
be changed from MM to INC in it's header

DXF->surface... (only with Modul 1)

To generate non-axis-symmetric mandrel models with the help of the "DXF->surface..." interface
you need to be aware of several restrictions when creating the required 3D-CAD-model.
For non-axis-symmetric geometries resp. for the "CADWIND SURFACE DATA FILE" format every
point of a frame has to be defined. The 3D-CAD-model must contain all the frames and points of
the mandrel model. Hence the frames are polygones which have to be composed of straight lines.

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These "frame polygones" can be put in different layers as 2-dimensional CAD-drawings and these
2D polygones can later be converted to 3D and can be positioned on the Y-axis of the CAD coordinate system (Y-axis corresponds to the rotation axis of the CADWIND mandrel model).
At first you should decide how many points per frame are required to approximate the mandrel
geometry with sufficient precision, because
all frames must contain the same number of points
and as mentioned on page 15
Edges (e. g. on rectangular cross-sections) have to be rounded by radiuses.
On non-axisymmetric frames all polygon points must be distributed equally, i. e. the distances
between two neighbouring points must be constant.
The gradients of corresponding polygon lines must be (approximately) equal. Otherwise it is
possible that the mandrel model structure is twisted (fig. 4.4). If the gradients are not equal then
the mandrel surface is not appropriate for the winding algorithm.
The last mentioned condition can be achieved with the help of a CAD-system.
fig. 4.9 shows an example of a 2D frame polygone which is approximated with a defined number of
straight lines to the original mandrel cross-section. Around the polygone you see the straight lines
isolated which are used to build the frame polygone. All these lines have a fixed gradient resp. a
fixed series of different gradients.
e.g. line 1 with a gradient of 0
line 2 with a gradient of 20
line 3 with a gradient of 40
etc.

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90

80
60

40
0
fig. 4.9:

20

2D-CAD-drawing of a single frame (inside)

range of straight lines with defined angles which are used to approximate the original
frame (outside)

In order to get a reasonable CADWIND 3D-model these lines with the fixed gradients have to be
used for every frame of the mandrel model.
From frame to frame only the length of the corresponding lines can change.
The chosen series of lines can then be used as tangents to the original mandrel cross-section
contour. The so called "trim"-feature which most existing CAD-systems use allows to maintain your
series of line gradients and helps to adjust the length of the lines, in order to build the polygone. At
the same time it guarantees that the ending point of one line is identical to the the starting point of
the following line.
In fig. 4.10 an example of 4 3D frame polygones is shown in a 3D CAD drawing. The shown frames
fulfil all the mentioned requirements for the use of the DXF-interface.
In fig. 4.11 the corresponding CADWIND mandrel model is shown which was created with the help
of the CADWIND DXF-interface.

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fig. 4.10: 3D CAD display of frames for CADWIND mandrel model

fig. 4.11: CADWIND mandrel model corresponding to fig. 4.10

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The T format
The T format allows you to describe T-parts. Because of the specific shape of the T-parts no points
of the contour or surface are stored. Instead the characteristical values as they are used by the
mandrel generator (see 4.1 T-parts) are stored.

Line
CADWIND T DATA FILE
MM
100.00
100.00
100.00
50.00
50.00
10.00
0.00
POSITION: HORIZONTAL

Explanation
identification
values in millimetres
length A
length B
length C
diameter A
diameter C
inside radius
transposition rotation axis / central axis
position relative to the rotation axis

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5 View
The loaded mandrel can be shown in a new display window with the command DRAW. As
described in chapter 2 regarding the graphic display window the view can be changed by using the
tool buttons on top window tool bar. Respectively the mouse can be used to zoom in or out.
With VIEW / RESULTS the laminate results window can be opened. After the pattern calculation is
finished the corresponding laminate values will appear in this window. In section 6.3 you will find
and example which explains the Laminate results window in detail.
With submenue item SHOW ONLY LAST PATTERN the view status for the display of several
different and combined layers for one mandrel can be switched off.

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6 Winding
6.1 Calculation methods and winding parameters
The winding pattern is calculated according to the mandrel shape, the given winding parameters,
the number of rovings and the roving width. You can choose between different calculation
methods, which can be selected via WINDING / SELECTION. The winding parameters for the
chosen calculation method can be entered via the corresponding item in the menu WINDING. You
can start the calculation with WINDING / START WINDING or F3.
Circumferential winding
In circumferential winding the winding angle approaches 90. In general (with a degree of coverage
of 100%) the carriage advances one full band width (band width = number of rovings roving width)
every full mandrel rotation. Circumferential winding is only possible on the cylindrical parts of a
mandrel.
degree of coverage
Fig. 6.1 should help to explain the correlation between bandwidth b, degree of covering and
distance from band to band Z (= carriagemovement per mandrel rotation).

fig. 6.1: degree of covering >100% on a cylindrical mandrel

As already mentioned above a degree of coverage of 100% means that the fibres are placed
without overlapping and gaps. By entering a higher value you will receive an overlapping
(example: 200% corresponds to an overlapping of one half band width). By entering a smaller
value you will create gaps (example: 50% corresponds to a gap of one band width).
Corresponding to fig. 6.1 the distanc e from to band Z resp. the carriage movement per mandrel
rotation can be calculated with the following equation:

Z =

b
100%
degr. of . cov.[%]

Dwell
by entering a Dwell value a mandrel rotation without any motion of the carriage at the end of the
turning zone can be obtained.
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In fig. 6.2 an example is shown of a parameter window for circumferential windings.

fig. 6.2: parameter table for cicumferential winding

The first row represents the starting point of the cirecumferential winding at position Y1 = 0 mm
which is the origin of the mandrel co-ordinate system. The positions are always related to the
mandrel co-ordinate system and not necessarily to the first frame of the mandrel model. But
first at position 1 there will be wound a 360 dwell. Then follows the circumferential winding from
position 1 to position 2 with a degree of coverage of 110%.
The second row represents the end position Y2 = 500 mm of the "first circumferential layer". At this
position a dwell of 360 will be wound as well which is followed by the circumferential winding from
position 2 to position 3 with a degree of coverage of also 110%.
etc.
The tool buttons can be used to add or insert new rows to the table or to delete them.
The calculation of the circumferential winding can be started directly from the parameter window.
The graphical display of the winding path was dropped in order to realise the simpler calculation
algorithm and the simplified handling.
Helical winding
With helical winding you can wind geodesically on cylinders and vessels with equal pole openings.
The winding path is calculated according to the condition of Clairaut (r sin = constant) with
consideration for the starting point and the starting winding angle.
starting angle
The calculation starts with this winding angle. It is entered in degrees and is related to the
rotation
axis. The winding angle in the subsequent parts of the winding path results
from the condition of
Clairaut.
starting frame
This parameter defines the frame where the winding will begin. You can see the numbering of
the frames in the mandrel display.
pattern number
The pattern number characterizes the winding pattern. It can be positive or negative. If you enter
a
positive value the new starting point of a cycle is left of the previous one, if you enter a negative
value it is right of the previous one. Beside the pattern number you can enter the skip index.
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Both values must be separated by a slash "/". Figure 6.1 shows the meaning of the pattern
number and the skip index on different examples. You can see the starting frame of the mandrel.
The numbers represent the sequence of the starting points of the cycles.
If the desired pattern cannot be achieved under the given conditions, CADWIND calculates a table
with recommendations for the pattern number. Besides the pattern numbers, the corresponding
number of cycles and degree of coverage are displayed. You can choose a pattern number and try
it for the next calculation or one of the pattern numbers can be clicked directly in the
recommendation window. The winding simulation can also be started with F3. It is not guaranteed
that a recommended pattern can be calculated. The patterns at the top of the table are the most
likely to be achieved.
In fig. 6.4 a "master path" (corresponds to the first winding cycle) is shown which is the first thing to
be calculated for the pattern determination. It's calculation starts at the starting frame and ends at
the same frame. The pattern point represents the pattern number 1/1 for this example. Obviously it
can't be hit by the master path with the given parameter combination. Thus the winding parameters
need to be changed in order to hit a pattern point and to start the calculation for all winding cycles
resp. for the entire pattern and to display the pattern.

fig. 6.4: example for pattern selection for a vessel geometry

degree of coverage / number of cycles
Depending on the chosen option in WINDING / OPTIONS you can enter the desired number
of cycles (number of back and forths of the carriage) or the desired degree of coverage (see 6.4).
The degree of coverage determines the fibre distribution around the mandrel. 100 % means that
at the frame with the biggest circumference the fibres are placed without overlapping and gaps.
By entering a higher value you will receive an overlapping (example: 200% corresponds to an
overlapping of one half band width). By entering a smaller value you will receive gaps (example:
50% corresponds to a gap of one band width).

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By entering the number of cycles you can fix the number of back and forths of the carriage. The
degree of coverage results from the calculated winding pattern.
number of layers
This parameter represents the number of desired layers.

-5/1

5/2
2

5/1

-5/2
5

Fig. 6.1: Sequence of the cycle starting points for the

pattern number / skip index 5/1, -5/1, 5/2, -5/2
W: fibre transposition

30

MATERIAL
close winding pattern
To achieve the desired winding pattern, it may be necessary to change the winding path and thus
to deviate from the geodesic line. With the button you can chose when and where such a
deviation is allowed: not at all, all over the mandrel or only in the turning zones (the turning zones
are defined in the mandrel file, see 4.2).
Unlike the non-geodesic calculation, there is no verification of the slippage limits. This means
that during the winding the fibres might slip. Therefore it is advisable to try first to achieve the
winding pattern without changing the winding path.
dwell front / dwell back
see circumferential winding
Polar winding
With polar winding you can wind vessels with equal or unequal pole openings with the
characteristic length 2 diameter. The winding path is calculated as a direct line between the two
pole openings (fig. 6.2). The winding angle results from the following equation:
tan =

with

R1 + R 2
L

= winding angle
R1, R2 = radiuses of the pole openings
L = length of the vessel

Polar winding is in principle non-geodesic. There is no verification of the slippage limits.

pattern number
In polar winding only two pattern numbers are possible: +1 and -1. Apart from that the pattern
number has the same meaning as in helical winding.
degree of coverage / number of cycles
see helical winding
number of layers
see helical winding
dwell front / dwell back
see helical winding

R2

R1
W

L
Fig. 6.2: polar winding on a vessel
W: winding path as direct line between the pole openings
: resulting winding angle
R1, R2: radiuses of the pole openings
31

MATERIAL
L: length

D: diameter

Non-geodesic winding (not with CADWIND lite)

The non-geodesic calculation offers you the widest range of winding possibilities. You can use it for
all mandrel geometries (except T-parts). It allows you to define the laminate structure for each
mandrel section. The winding path is calculated according to the desired winding angle under
consideration for the slippage limits (see friction factor).
winding angle
This parameter represents the desired winding angle in degrees. The winding angle is related to
the axial reference line. This is the line through the centroid of area for all frames, which on
axisymmetric mandrels is the rotation axis.
If the dialogue window for the winding parameters is open, you can toggle with with the tool button
"VAR/CONST" between constant and variable winding angle. This gives you the possibility to enter
varied values for the

32

MATERIAL
different mandrel segments. For instance, a drive shaft can be wound with a winding angle of
45 in the middle and 30 at the ends. The tool button "SET" opens a dialogue for setting one
value for several mandrel segments.
friction factor
This factor represents the friction between the fibre and the mandrel surface. This friction permits
a deviation from the geodesic line. According to the friction factor, CADWIND calculates the
maximum deviation (before the fibre begins to slip) and then optimizes the fibre lay up according
to the given winding angle and the pattern required. If the factor zero is entered, the geodesic
fibre path will be calculated. You can use the following table as guide line values:
[ Surface
metal
plastic
dry laminate
impregnated laminate
prepreg-laminate

dry fibre
0.18
0.20
0.22
-

wet fibre
0.15
0.17
0.14
-

prepreg
0.35
0.32
0.37

If the dialogue window for the winding parameters is open, you can toggle with the tool button
"VAR/CONST"between constant and variable friction factor. This gives you the possibility to enter
varied values for the different mandrel segments. The tool button "SET"opens a dialogue for
setting one value for several mandrel segments.
pattern number
see helical winding
degree of coverage / number of cycles
see helical winding
number of layers
see helical winding
turning zone front / back
With these parameters you can redefine the pole cap sections of the mandrel. You have to enter
the frame number where the front turning zone ends and the frame number where the back
turning zone begins. After loading the mandrel file these values are preset with the
corresponding values in the mandrel file. You can see the numbering of the frames in the mandrel
display.
starting frame / starting position
With these parameters you can define the starting point of the winding calculation. The position is
entered in degrees and represents the starting point on the starting frame (fig. 6.3). The position
is only important for combinations on non-axisymmetric mandrels. You can see the numbering
of the frames in the mandrel display.
dwell front / dwell back
see helical winding
Combination (only with module 2)
To wind two different layers (e. g. helical and circumferential) without machine stops, a transition
between the layers has to be calculated. After the transition is found and its part program calculated
you can wind the complete laminate. First run the part program of the first layer. At the ending
position of the first layer you can begin with part program of the transition. At the end of the
transition you start with the part program of the second layer. Depending on the syntax of your
machine controller you can combine the part programs e. g. by using subprograms.
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MATERIAL
starting angle
This parameter represents the winding angle, with which the transition shall start. It has to
correspond to the winding angle of the first layer.
starting frame / starting position
With these parameters you can define the starting point of the transition. The starting point has to
correspond to the ending frame of the first layer.
So enter as starting frame the ending frame of the first layer. If the first layer is a circumferential
laminate, the ending frame has been defined in the circumferential winding parameter dialogue. If
the first layer is another laminate, the ending frame of this layer is its starting frame. Since the
starting and ending point of closed laminates are the same, then the starting and ending frame
are the same.

16
15

1 2

Fig. 6.3: definition of the starting point on the starting frame

P: starting point
: starting point value in degrees

34

MATERIAL
At the starting position enter the ending position of the first layer. The ending position is
displayed after the laminate calculation with all other laminate values (see 6.3). For axisymmetric
mandrels the starting position is not needed.
ending angle
This parameter represents the winding angle, with which the transition shall end. It has to
correspond to the winding angle of the second layer.
ending frame
The ending frame of the transition has to correspond to the starting frame of the second layer.
friction factor
To achieve the transition between the winding angle of the first layer and the winding angle of the
second layer, it may be necessary to deviate from the geodesic path. This means that the friction
between fibre and mandrel has to be taken into consideration. For a detailed description of the
friction factor see the parameters for the non-geodesic winding.
Winding of T-parts (only with module T)
For T-parts there is only a limited range of useful winding patterns. According to the geometry
CADWIND automatically calculates several optimized winding paths. The so called "CADWIND T
SEQUENCE FILE" - see example in the following table - contains the different patterns which can be
combined any way you like.
line
CADWIND T SEQUENCE FILE
1
longo 0 100
cricr 0 100
trian 0 100
hoop1 0
100
hoop2 0
100
hoop3 0
100

explanation
Identification as CADWIND-T-file
number of layers
0-winding around branch B (100% degr. of coverage)
criss-cross pattern (100% degr. of coverage)
cross pattern (100% degr. of coverage)
circumferential winding branch A (100% degr. of coverage)
circumferential winding branch B (100% degr. of coverage)
circumferential winding branch C (100% degr. of
coverage)

In fig. 6.7 an example is shown for a winding pattern combination on a T-part which is used to
explain how the TSQ-files are used.

35

MATERIAL

fig. 6.7: example of a T pattern for the following TSQ-file

CADWIND T SEQUENCE FILE
1
Trian
0
100
Hoop1
3
0
Hoop2
0
200
Hoop3
0
100
A TSQ-file contains a list of combined winding patterns which will be calculated (see example
above). These patterns can be assigned to a number of "cycles" (first value) e.g.
Hoop1

with 3 cycles, resp. 3 rotations on branch A of the T-part or

the degree of coverage (second value) can be assigned to a pattern e.g.
Trian

100

with a degree of coverage of 100%.

Remark:
You have to decide which of the two parameters "number of cycles" or "degree of coverage" you
want to set. Thus one of these two values must be set ZERO.
36

MATERIAL
6.2 The material parameters
You can enter the material parameters via WINDING / MATERIAL PARAMETERS:

number of rovings
roving width
TEX value
fibre volume content / fibre mass content
fibre density
resin density

Depending on the chosen option in WINDING / OPTIONS you can enter the fibre volume
content or the fibre mass content (see 6.4).
The TEX value, the fibre volume content / fibre mass content and the densities are only used to
calculate the resulting laminate weight and thickness. They have no influence on the calculation of
the winding pattern or the control data.

6.3 Display of the results

Display of the resulting laminate values
The resulting laminate values are displayed in the "Calculation results window", which can be
opened under VIEW / RESULTS after their calculation (fig. 6.8). They can differ from the entered
values. For the winding angle, the degree of coverage and the laminate thickness maximum and
minimum values are calculated related to the midle section in between the turning zones. The
winding lengths represents the width of the laminate in the front turning zone, in the middle and in
the back turning zone. Depending on the calculation method some values might make no sense
and are not displayed.

fig. 6.8: display of laminate values

37

MATERIAL
The colour scale
The colour scale allows you to look at different laminate values in the display of the winding pattern:
winding angle deviation (only with non-geodesic calculation)
The colour scale indicates the absolute deviation from the desired winding angle in degrees.
geodesic behaviour (only with non-geodesic calculation)
The colour scale indicates if the fibre is placed more on the geodesic path or more on the
slipping limit.
fibre bridging (only with non-geodesic calculation)
Fibres can lift over the core of a convex-concave mandrel surface area. With the colour scale
you can see the factor of safety against fibre bridging. If the factor is zero the fibre lifts from the
mandrel surface.
laminate thickness (not with combinations)
The colour scale indicates the laminate thickness in the different mandrel surface areas. You can
define the range of the colour scale for the laminate thickness by entering the minimum and
maximum value.

6.4 Options
You have the following options to adapt the winding calculation to your needs (WINDING /
OPTIONS):
pattern display for axisymmetric parts
This check box can be used to avoid the protracted pattern display for a high number of cycles.
This has no influence on the calculation of the winding path. However, the resulting degree of
coverage and laminate thickness can not be determined when the display is switched off.
save laminate values for axisymmetric parts
If this option is activated, the laminate values are saved on disk during the calculation of the fibre
path. The current file name is shown and can be changed with the FILE NAME button.
The CADWIND laminate data file has the following structure:
Line
CADWIND LAMINATE DATA FILE
MM
-150.391
230.308
24.994
-149.980
235.366
18.636
-149.665
237.598
16.903
-140.990
299.064
16.712
...
-155.380
168.957
24.196

0.145
0.140
0.133
0.105

Explanation
identification
values in millimetres
record of the 1. roving element
record of the 2. roving element
record of the 3. roving element
record of the 4. roving element

0.196

record of the last roving element

A record contains the Y-mandrel-coordinate, the mandrel diameter, the fibre orientation and the
laminate thickness.
save winding path (only with module OP)

38

MATERIAL
If this option is activated, the winding path is saved on disk during its calculation. The current file
name is shown and can be changed with the FILE NAME button. For a description of the
winding path file see 7.5.

6.5 Mandrel up-date

Depending on the calculated thickness of the layer, the mandrel contour can be updated (WINDING
/ UPDATE MANDREL F6). The previous contour can be restored using WINDING / RESET. The new
mandrel can be stored as CADWIND CONTOUR DATA FILE using WINDING / SAVE UPDATE.
It is understood that the mandrel update takes only the last layer into account. This function is valid
for axisymmetric mandrel geometries only.

39

MATERIAL
7 Postprocessing
7.1 Calculation of the control data
The postprocessor calculates the control data according to the generated fibre path. In doing so the
characteristic machine parameters in menu MACHINE and the postprocessing parameters in menu
POSTPROCESSING are taken into consideration.
Postprocessing parameters

fig. 7.1: dialog window for postprocessing parameters

The postprocessing parameters are:
calculation mode
You can choose four different modes to calculate the control data. When using constant free fibre
length the distance between the point where the fibre contacts the mandrel, and the feed-eye
will be kept constant. If you choose an enveloping cylinder or contour, the program will generate
a
surface, which surrounds the mandrel and on which all feed-eye positions will be situated. The
difference between open enveloping cylinder, closed enveloping cylinder and enveloping
contour are illustrated in fig. 7.1. As you can see the cross carriage is not needed if the calculation
uses an open enveloping cylinder.
free fibre length
This value specifies the constant free fibre length if this mode is chosen.
minimal distance

40

MATERIAL
This value specifies the distance between the largest mandrel eccentric and the enveloping
cylinder or contour (fig. 7.1).
control data optimization (only with module 3)
With this you can control the time scaling. If you choose minimal production time the control data
is calculated so that the machine will move as fast as possible. The slowest axis is then moving
with maximum speed. The other options keep the fibre pay-out speed or the mandrel speed
constant. You also have the possibility to switch off the time scaling. In this case there will be no
time scale in the CCDF-format and no feed commands in the part program.
pay-out speed
This value is only taken into consideration when the control data is calculated with constant payout speed. If you enter a value which cannot be achieved the fibre pay-out speed will be set to
the maximum possible value.
filter value
To obtain a smoother machine travel and to reduce the part program size you can eliminate very
small machine movements using the filter. The filter value represents the minimal distance
between two feed-eye positions. Distances which are smaller will be eliminated by the filter.
positioning length
The positioning length represents the horizontal transposition of the mandrel in the chuck. See
also MACHINE / REFERENCE POINT.
save
You can choose if you want to save the control data in absolute values in CCDF-format as ASCII
file (see 7.2) or directly as part program (part program only with module 3). The current file name
is shown and can be changed with the FILE NAME button.

41

MATERIAL
a
b

a
b

Fig 7.2:

enveloping contour, closed and open enveloping cylinder

a: minimal distance
b: minimal distance + 0.5 pay-out eye width

42

MATERIAL
Remark:
If the part programs are calculated in the user defined format using subprograms only the main
program will be stored under the preset file name. For the naming of the subprograms see 8.2
(Format / {SUBPROG}, {ENDSUBPROG}).
If the part programs are calculated in the TCS84-format for Baer winding machines only the
header
file will be stored under the preset file name. The "stamm" and "prog" files are stored
under the
file names STAMM and PROG with the added program number, which has
been entered in
POSTPROCESSING / PARAMETER / PART PROGRAM
Source (only with module OP)
With this dialogue window you can chose if the calculation of the control data uses the actual
winding path or a saved winding path from the hard disk (see 6.4 save winding path and 7.5).
Axes
You can define the axes which shall be considered by the calculation.
Part program
If the control data is calculated as part program the following parameters might be needed:
program number
This value represents the number of the part program.
gear
If the part program is generated in the TCS84 format for the Baer winding machines this value
specifies the used gear. By entering this parameter the velocities and resolutions in the menu
Machine are not adapted automatically. They have to be entered always for the current gear.
spindle
If the part program is generated in the TCS84 format for the Baer winding machines this value
specifies the used spindle.
Display of the resulting postprocessing values
The resulting postprocessing values are displayed in the lower information window on the text
screen after their calculation. The fibre pay-out speed is only displayed if the control data has been
calculated with constant pay-out speed option. The pay-out speed can differ from the entered
value. The program size is only displayed if the control data is calculated as part program.

43

MATERIAL
7.2 The control data formats
Depending on what you have entered in POSTPROCESSING / PARAMETER the control data is
calculated in the machine independent CCDF-format or directly as part program.
The CCDF-format (CADWIND Control Data File)
The CCDF-format contains the positions of the machines axes in absolute values refered to in the
coordinate system of the mandrel model. It has the following structure:

Line
CADWIND CONTROL DATA FILE
MM
AXISYM: YES
REFERENCE POINT
180.00
200.00
130.00
LAYER UNIT
66
1
69.33
132.19
105.00
2
96.73
156.20
96.91
...
17
252.06
132.19
105.00

180.00

0.00

0.00

251.71
250.29

0.00
0.00

0.00
0.00

5.0000
5.0505

Explanation
identification
values in millimetres
mandrel axisymmetric
next line program start point
program start point
begin of the positions
repetitions
1. position
2. position

251.71

0.00

0.00

5.8081

17. position

The values of the program start point have the following meaning: position of mandrel rotation,
carriage, cross carriage, pay-out rotation, vertical axis, yaw axis. The values in a position data
record have the following meaning: running number, position of mandrel rotation, carriage, cross
carriage,
pay-out rotation, vertical axis, yaw axis and running time. The positions of the
translational axes are refering to the mandrel coordinate system and are absolute in millimetres or
inches. The values of the rotation axes are absolute in degree. For the zero position and the
orientation of the rotation
axes see 7.1 MACHINE / REFERENCE POINT. The time scale is in
seconds.
For axisymmetric mandrels only the first cycle of a layer is stored. The number of repetitions
represents the number of cycles multiplied with the number of layers, which has been
entered in the menu WINDING. For non-axisymmetric mandrels the complete layer is stored. The
number of repetitions represents the number of layers.
If you switched off the optimization in POSTPROCESSING / PARAMETERS no time scale will be
written.
The part program formats (only with module 3)
In MACHINE / FORMAT / SELECTION you can choose between the following:
definition file
You can define the structure of the part program yourself in a definition file. Chapter 8 gives
an exact description.
Baer TCS84
The part program is directly generated in the format for Baer winding machines with TCS84
controller. For details see the Baer manuals.

44

MATERIAL
7.3 Running the part program
If the part program is calculated you can transfer it to the machine controller. For details please see
the manuals of the winding machine or the controller.
After the transfer you can start the program. Run to the first point of the winding and stop the
program. Attach the fibre tangential to the mandrel at the position of the starting frame (see
WINDING / WINDING PARAMETERS).
You can now run the complete program.

7.4 Graphical display of the machine motion (only with module 3)

The machine movement according to the CADWIND Control Data File (CCDF) can be displayed in
three independent X-Y-diagrams by using the command POSTPROCESSING / DISPLAY. You can
control the three displays with the dialogue windows POSTPROCESSING / DISPLAY 1 to DISPLAY 3:
X co-ordinate
For the X-axis you can choose the time, the block number or the displacement of a machine axis.
Y co-ordinate
For the Y-axis you can choose the displacement, velocity or the acceleration of one, several or all
machine axis.
Min / Max
The values in the diagrams are shown as percentage of their maximums. To look closer at a
certain
part of the diagram you can set the minimum and maximum percentage for the X- and
Y-axis.
File name
The name of the actual CADWIND Control Data File is shown. It can be changed with the FILE
NAME button.
On / Off
With this button you can activate or deactivate the corresponding diagram.

7.5 The open postprocessor (only with module OP)

The extension "open postprocessor" offers you additional interfaces in connection with the winding
path calculation and the postprocessing. This gives you an even better range of manufacturing
possibilities.
The winding path file
With the menu item WINDING / OPTIONS / SAVE WINDING PATH you can store the winding
path
as ASCII file on the hard disk during its calculation (see 6.4). Furthermore the postprocessor
can
read such a stored winding path and convert it into a part program (see 7.1 source). This allows
you to edit and change a winding path and then to calculate the corresponding control data for the
machine.
45

MATERIAL
The winding path file has the following structure:

Line
CADWIND WINDING PATH FILE
MM
AXISYM: YES
PINS FRONT: NO
PINS BACK: NO
VECTORS: YES
100.0
-80.0
680.0
LAYER UNIT
1
45
17
98.29
12.94
96.59
25.88
...
-76.86
61.16

0.0
52.35

1552.91
1552.91

204.44
204.44

0.0
0.0

Explanation
identification
values in millimetres
mandrel axisymmetric
no pins at the front
no pins at the back
winding path with vectors
radius of the largest mandrel
eccentric
minimal mandrel Z-coordinate
maximal mandrel Z-coordinate
begin of the positions
number of layers
number of cycles
winding path skip index (*)
1. point of the winding path
2. point of the winding path

-13.89

-276.36

212.06

-71.15

last point of the winding path

(*) winding path skip index = round

number of cycles

pattern number skip index

In the position data records the first three values are the X-, Y-, Z-coordinates of the winding path
points related to mandrel coordinate system. The other three values represents the norm vectors of
the mandrel surface at these points.
The norm vectors are only needed for the calculation of the vertical axis and the yaw axis.
CADWIND
generates the winding path file automatically with the vectors. If you want to change
the winding
path file and you do not need a calculation for the vertical axis or the yaw axis, you
can leave out the
vectors for simplification. To do this enter VECTORS: NO in line 6.
Converting a CCDF into a part program
You can convert a CCDF (CADWIND control data file) into a part program via POSTPROCESSING /
CCDF -> PART PROGRAM. This allows you to edit a CCDF created by the processor (e. g. to enter
manually additional motions) and to run it after the conversion into a part program. The advantage of
the CCDF is that you can work with absolute values related to the mandrel coordinate system.
Unlike the part program these can be clearly surveyed and are easy manageable.
The conversion is carried out according to the parameters of MACHINE / FORMAT (see 7.2 part
program format and 8.2 format).

46

MATERIAL
8 Machine
8.1 Characteristics of the winding machine
Via the menu item MACHINE the characteristic parameters of the winding machine are entered.
Reference point
To calculate the part program, the coordinate system of the machine has to be transformed into the
coordinate system of the mandrel model. Therefore, drive your machine in the reference point (zero
position) and measure the characteristic parameters (fig. 8.1).
yaw pivot point
R

FE

+
X

Ref

Y Ref
Z M

X M
Y Pos

Fig 8.1: reference point, positioning length

FE: feed eye in the reference point (zero position) of the machine
XM, YM, ZM: mandrel coordinate system
XRef: reference point cross carriage (always > 0)
YRef: reference point carriage (here > 0)
YPos: positioning length
distance between chuck and origin of the mandrel coordinate system (always > 0)
R: yaw radius
All these parameters except the carriage axis are constant on one specific machine and have to be
measured only once. However, in the direction of the carriage different clamping and different
mandrels result in different parameters. To facilitate this handling the transformation value has
been divided. The reference specification for the carriage is refered to as an easy accessible, fixed
machine point, e. g. the chuck (YRef). Like the other reference parameters this value is constant. If
you change the clamping or the mandrel only the positioning length (YPos) - the distance between
the origin of the mandrel coordinate system and the chosen fixed machine point - must be
measured. The positioning length as variable parameter is entered in POSTPROCESSING /
PARAMETER.
For the cross carriage and the vertical axis you simply have to enter the distance between feed-eye
and rotation axis.
CADWIND defines the zero position of the pay-out rotation horizontal with the rovings supported
from below. The zero position of the yaw axis is defined so that the feed eye is perpendicular to the
mandrel rotation axis. If in the reference point your machine is positioned differently, you have to
enter the angle differences.

47

MATERIAL
Regarding the mandrel rotation axis you have to clamp the mandrel so that in the zero position the
Z- axis of the mandrel coordinate system points vertically upwards. If you want to clamp the mandrel
differently, you have to add or subtract the corresponding angle. CADWIND defines the cross
carriage feeding horizontally. If this is not the case on your machine, the feeding angle has to be
considered as well. For axisymmetric parts the alignment of the mandrel is not necessary.
The positive orientation of the axes is defined as follows:
carriage: from the chuck to the tailstock
cross carriage: towards the mandrel rotation axis
vertical axis: upwards
all rotation axes: counterclockwise
Dimensions
Here you have to enter the maximum travel ranges of the axes, the pay-out eye width, the
eccentricity of the fibre guide (distance pay-out rotation axis / fibre) and the yaw axis radius (see
fig. 8.2 and 8.3).
The following two examples illustrate the term "eccentricity of the fiber guide".

Fig. 8.2:

ecc
en
tric
i

feed-eye
pivot axis

ty

Figure 8.2 shows the example of an active pay-out eye with eccentricity (on 4 to 6 axes machines).
CADWIND calculates the position of the pay-out eye rotation so that the roving is always in the
furthest point of the shown ring. The distance between the pay-out eye rotation axis and the
roving's contact point represents the eccentricity which has to be entered in machine parameter
dialog.

active pay-out eye with eccentricity

Figure 8.3 shows a ring shaped passive pay-out eye (on 2 axes machines). Because of the fiber
forces the roving slides on ring's inside radius. Therefore the inside radius of the ring represents
the eccentricity which has to be entered in machine parameter dialog.
To consider the effect of the eccentricity on the movement of the carriage you have to activate the
calculation of the pay-out eye in POSTPROCESSING/PARAMETER. However for a 2 axes
machine we have to eliminate the positions of the pay-out eye in the part program. You can do this
by entering a resolution of zero INC/360 for the pay-out eye in the machine parameter dialog.
48

MATERIAL
roving contact point

Ri

Ri = eccentricity

s
spindle axi

Fig. 8.3:

ring as passive pay-out eye

Figure 8.4 shows the case that the pay-out eye rotation axis is not on the same height than the
mandrel rotation axis.

Fig. 8.4:

vertical offset of the pay-out rotation axis to the mandrel rotation axis

Velocities
Here you have to enter the maximum velocities of the axes. If you want to slow down an axis you
can enter a lower value.
Accelerations
49

MATERIAL
Here you have to enter the maximum admissible changes of velocity between two control data
records. By reducing these values you can achieve a smoother running machine.
In particular for applications with big mandreldiameters and high moment of inertia for example we
would recommend a low acceleration value for the spindle axis.
Resolutions
Here the incremental resolutions of the axes are fixed.
The positive orientation of the axes is defined as follows:
carriage: from the chuck to the tailstock
cross carriage: towards the mandrel rotation axis
vertical axis: upwards
all rotation axes: counterclockwise
If an axis of your machine should be orientated differently, you can change the direction by entering
negative resolution values.
Axes
You have to enter the existing axes of the machine.

8.2 Characteristics of the control

Through the menu item MACHINE the characteristic parameters of the control of the winding
machine are entered.
Minimum processing time
This value represents the time which the controller needs to treat one block.
Format
You can generate the part programs in a user defined format or for the Baer-TCS84 machine
controller.
The structure of the user defined formats is described in a definition file. You can choose the
definition file with the FILE NAME button. Examples for the different machine controllers are on the
diskette (*.DEF). You can use them as a basis and adapt them for your needs.
The following terms are for the definition of the different program sections:
{BLOCKINC}

The next two digits represents the increment for the running
block number. (A value larger than 1 might be useful, if you
want to make insertions in a part program afterwards. This
avoids the time consuming need to change the block
numbering later.)

{BLOCK=}

This allows you to set a new value for the block number. The 4
digits after the mark represents the new block number.

50

MATERIAL
{SUBPROG}, {ENDSUBPROG}

This marks the definition of the subprogram. The subprogram

definition has to be before the main program definition. The line
after {SUBPROG} is taken as file name for the subprogram.
For an example see SINUM.DEF.

{LUCO}, {ENDLUCO}

This marks the layer.

{POS}, {ENDPOS}

This marks the definition of the position block. This position

block will be repeated for all positions. You can define other
position blocks by using {ENDPOS NEXT} instead of
{ENDPOS}. These will be written successively (see CTS.DEF).

{FB}, {ENDFB}

A statement which is marked with {FB} {ENDFB} will be written

only in the first position block (see SINUM.DEF).

{LB}, {ENDLB}

Like {FB} {ENDFB} for the last position block.

For the definition of loops, subprograms, block numbers etc. you can use the following variables:
{prg}

program number

{sub}

subprogram number

{name
}

data file name

{date}

date and time

{blo}

block number

{cyc}

number of cycles

{cyc-1} number of cycles - 1

{lbl}

label number

{bgn}

number of the block which is marked with {*B*}

{end}

number of the block which is marked with {*E*}

{*B*}

loop begin mark

{*E*}

loop end mark

{dma}

mandrel rotation offset in degrees after one cycle (0 ... 360)

{nblo}

number of the position blocks in the corresponding layer

For the positions of the axes you can use the following variables (in the order: mandrel (ma),
carriage
(ca), cross carriage (cc), pay-out rotation (po), vertical axis (ve), yaw axis (yw)):
{mapsp}, {capsp}, {ccpsp},
{popsp}, {vepsp}, {ywpsp}

relative pattern start position (psp)

{+/-mapsp}, {+/-capsp}, {+/-ccpsp}

{+/-popsp}, {+/-vepsp}, {+/-ywpsp}

relative pattern start position with sign

51

MATERIAL
{mapspabs}, {capspabs}, {ccpspabs},
{popspabs}, {vepspabs}, {ywpspabs}

absolute pattern start position

{ma}, {ca}, {cc},

{po}, {ve}, {yw}

relative position

{/ma/}, {/ca/}, {/cc/},

{/po/}, {/ve/}, {/yw/}

relativen position without "+" or "-" sign

{+/-ma}, {+/-ca}, {+/-cc},

{+/-po}, {+/-ve}, {+/-yw}

relative position with sign

{maabs}, {caabs}, {ccabs},

{poabs}, {veabs}, {ywabs}

absolute position

For the programming of the time or the feed you can use:
{t[s]}

relative time in seconds

{t[ms]}

relative time in milliseconds

{t[1/min]}

reciprocal, relative time in [1/min]

{tabs[s]}

absolute time in seconds

{tabs[ms]}

absolute time in milliseconds

{feed[inc/min]}

feed in increments/minute

Remark:
The velocity in increments/minute is calculated with the following formula:

F=

with

2
2
2
A1 + A2 + ... + A6
t
60

An = move distance of the axis in increments

t = time in seconds

The number of digits after the decimal point can be defined for every variable after a colon (e. g.
{+/- ma}:6). The default value is 4.
You can use special characters in the part program by entering #/ and the ASCII code. For example
for enter the code #/020.

52

MATERIAL
9 Print / Plot
9.1 Print
Due to the key combination PRINT under WINDOWS it is quite easy to make a screen shot. With
ALT+PRINT it is possible to save the opened application into the clipboard as a screen shot which
can be pasted in every text, spreadsheet, ... document.

53

MATERIAL
10 The editor
Through the menu item EDIT you can use a text editor with the following commands:
Command

Key

cursor movements
character left
character right
line up
line down
word left
word right
page up
page down
begin of line
end of line
begin of file
end of file

^S
^D
^E
^X
^A
^F
^R
^C
^Q^S
^Q^D
^Q^R
^Q^C

or
or
or
or
or
or
or
or
or
or
or
or

=
+
[
^=
^PgUp
PgDn
Home
End
^ PgUp
^ PgDn

insert and delete

insert / overwrite
indent on / off
delete character left from cursor
delete character
insert line
delete line
delete until end of line
delete until begin of line

^V
^O
^H
^G
^M
^Y
^Q^Y
^Q^H

or

Ins

or
or
or

Backspace
Del
Enter

block commands
start block marking
copy block to clipboard
paste block from clipboard
delete clipboard
hide block marking

^K^B
^K^K
^K^C
^K^Y
^K^H

or

Shift =+-[

find and replace

find
replace
search again

^Q^F
^Q^A
^L

54

MATERIAL
11 Function summary

Info
Deutsch
English
Franais
Units

shows software info

changes the language of the program
dialogue for changing the units

Mandrel
Load
Create
Exit

loads an existing mandrel file

allows the user to create mandrel files
terminates the program

View
Draw
Parameters
Graphic

draws the loaded mandrel according to the actual view parameters

dialogue for entering the view parameters
displays the last graphic screen (only when using one single screen)

Winding
Start winding
Non-geodesic
T
Circumferential
Helical
Polar
Combination
Selection
Material parameters
Colour scale
Options
Load
Save

calculates the winding on the loaded mandrel according to the

actual winding and material parameters
dialogue for entering the parameters for non-geodesic winding
dialogue for entering the parameters for T winding
dialogue for entering the parameters for circumferential winding
dialogue for entering the parameters for helical winding
dialogue for entering the parameters for polar winding
dialogue for entering the parameters for the calculation of the
transition between two layers
dialogue for choosing a calculation method
dialogue for entering the material parameters
for activating the colour scale
dialogue for the selection of the different winding options
loads the winding and material parameters from a file
saves the actual winding and material parameters in a file

Postprocessing
Control data
Parameters
Source
Axes
Part program
CCDF -> part program
Display

calculates the control data of the last generated winding path

according to the actual postprocessing and machine parameters
dialogue for entering the postprocessing parameters
selection of the source of postprocessor
dialogue for entering the axes for which the control data shall be
calculated
dialogue for entering the part program parameters
conversion of a CCDF into a part program
displays the machine motion in X-Y-diagrams
55

MATERIAL
Machine
Reference point
Dimensions
Velocities
Accelerations
Minimum processing time
Resolutions
Axes
Format
Load
Save

dialogue for entering the reference point of the machine

dialogue for entering the maximum travel ranges, the pay-out eye
width, the eccentricity of the fibre guide and the yaw axis radius
dialogue for entering the maximum velocities of the axes
dialogue for entering the maximum admissible changes of velocity
between two control data records
dialogue for entering the time which the controller needs to treat one
block
dialogue for entering the incremental resolutions of the axes
dialogue for entering the existing machine axes
selection of the part program format
loads the machine parameters from a file
saves the machine parameters in a file

Edit
Open
New
Save
Save as
Close
Cut
Copy
Paste
Show clipboard
Find
Replace
Search again

opens an already existing file

creates a new edit window
saves an actual edit window under its name
saves the actual edit window under a new name
closes the actual edit window
copies the marked block into the clipboard and deletes the block in
the edit window
copies the marked block into the clipboard
copies the marked block in the clipboard into the actual edit window
opens the clipboard
finds a text in the actual edit window
finds and replaces a text in the actual edit window
repeats find and replace

56