Coil Winder has machine vision.
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Press Release Summary:
Double Vision device winds fine filaments around spinning mandrel to produce micro coils, stents and catheters. It has menu-selectable variables, digital readout of parameter set points and values, and closed-loop tension and slack control. It provides wind speeds up to 6,000 mandrel rpm. Maintaining steady tension of 0.2 g and wind angle of 0.1 deg make it possible to produce coil with 0.0004 in. dia platinum wire.Original Press Release:
New Double Vision Winder Features Non-contact Wind Angle Detection That Improves Process Control
San Jose, CA. - April, 2002 - ENGINEERING BY DESIGN, of San Jose, CA, pushes the process control envelope to new levels with wind angle detection within 0.02 degrees. Previous designs measured wind angle by feeding the wire through a mechanical arm with an angle sensor. As the wires get smaller, contact with the mechanical sensor arm changes the wind angle and introduces an error of as much as 2 degrees.
"By using machine vision, we not only eliminate the error due to contacting the wire but also improve control accuracy by a factor of 100," states Dale Henson, P.E. and President of Engineering By Design. "This new winder has improved all process control variables to help device manufacturers make more consistent products with less waste. Maintaining a steady tension of 0.2 grams and a wind angle of 0.1 degrees made it possible to produce a coil with 0.0004" diameter platinum wire."
This latest machine in our line features menu-selectable variable, fixed-pitch and tight-pitch wind capability with automatic mandrel and filament tensioning. It also has closed-loop tension and slack control that makes wind speeds of up to 6,000 mandrel RPM possible. Two independent machines are stacked on one frame to double production for a given floor space. The machine is so smooth and quiet that it cannot be heard running in a normal production environment.
ENGINEERING BY DESIGN maintains design, production and sales offices in San Jose, CA. For more information contact Dale Henson, P.E. at 408.452.0256 or visit www.ebdesign.com.
DOUBLE VISION COIL WINDER
Description:
This Coil Winder uses vision systems to wind fine filaments around a spinning mandrel and produce micro coils. The wound coils can be made smaller than a hair. After the coils are produced they are processed and eventually used for medical and electronic products. Two independent machines run on the same platform.
Application:
Coil stents and catheters are the primary products but the powerful programming capabilities enable the machine to produce everything from motor coils to heating elements. Anytime a small coil is needed, this machine can produce it.
Design Highlights:
The precise control of all process variables is increasingly important, as the materials get smaller. Programmable wind tensions of less than 1 gram and wind angles of less than 1 degree require the use of control systems that were not associated with coil winding - until now. The unique use of machine vision to measure wind angle without touching the filament and state-of-the-art control systems makes this the most precise machine ever. Statistical data is also reported for each run making it possible to verify product quality and use the information to refine the manufacturing process.
Benefit:
By improving the accuracy of all controlled parameters, this machine can increase productivity through reduced rejects and faster wind speeds. The programming is flexible to allow new products to be made with the same machine. With the availability of better technology, product designers are finding they can build better products. The twin winding machines operate independently so the production for a given amount of floorspace is doubled.
SPECIFICATIONS:
- INPUT POWER: 208-240 VAC, single phase, 50/60 Hz. Full load 16A, 20A service.
- WEIGHT: 1,100 pounds.
- DIMENSIONS: L x W x H = 100" x 28" x 59"
- MANDREL SIZE: .001 to .188" diameter, 65" long (different mandrel lengths optional).
- FILAMENT SIZE: .0004" to .025" round solid or tube, or ribbon, metal or plastic.
- WIND SPEED: Up to 6,000 mandrel RPM (higher speeds optional).
- FILAMENT TENSION: 0 to 80 grams with +/- 0.1 gram resolution.
- MANDREL TENSION: 75 to 4,000 grams with +/- 2 gram resolution.
- ANGLE CONTROL: +/- 3 degrees with a +/- 0.02 degree resolution with vision.
- COMPLIANCE: Built to CE and NFPA 79 standards.
FEATURES:
- Winds stacked (tight pitch) or loose (variable or fixed pitch) coils on a spinning mandrel.
- Programmable speed, tension and pitch, or optional angle settings.
- Variable pitch entry menu allows multiple repeating combinations of any pitch, direction and length.
- Digital readout of parameter set points and actual values.
- Records of mean & STD deviation of all measured variables on each wind.
- Filament slack control that maintains tension at all wind speeds.
- Brushless servo drives on traverse and both ends of mandrel (no back shaft).
- Alphanumeric color touchscreen display for program entry and status displays.
- Acrylic enclosure with individual doors to isolate each winder from the room.
- Ethernet communication for factory integration capability.
