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Winding Machine Optimisation_Composite Braiding Ltd.pdf

We have a 2 axis X-Winder helping in winding 1 mandrel at a time.

Could we add another motor to the current setup and winding 2 mandrels simultaneously? We can add another control box if required.

I have drawn schematics of our current and desired setup and the image of our current setup to help understand my query,

Look forward to any advice. 


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I am using the 4.16 version. As the carrier reaches the left and right ends of the mandrel, the DH does not advance to the left or right DH advance point. It stays at the DH Offset from mandrel surface. After the [CW ELLIPSE AT LEFT END] move, I then get the error shown above. This repeats until I stop the wind. However, if I pause the wind at either end during the wind, after a minute or so, the DH will advance to said point. 

If anyone has any comments or suggestion, please let me know :)

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Hi there everyone,


my buddy and I have started doing trial winds for our composite-overwrapped pressure vessel with 3D printed mandrels, just to get the hang of the machine. 

BUT we are having problems - does anyone know a fix to these? 

1) The DH rotary or the DH linear motor do not respond to software inputs and don't move sometimes (not even when when winding - sometimes even when we just say "go home"). At times, everything will work fine and then suddenly either the rotary or linear will conk out. This has  not happened while winding (sometimes it works fine) yet - only when we turn the machine on some motors will not respond, even if everything worked fine just 5 minutes ago. Yet the software sometimes finds the boards of the non-working motors. The rotary / linear motors have sometimes also started working again after some time! (after being idle for a couple of minutes)

2) When trying to troubleshoot this, the setup wizard will sometimes not find all 4 boards. At times 3, at times only 2. 

3) We get an error: "Set Axes Accels" (image below). It won't do anything after we get this message and we get this message in most cases while attempting to wind.  

4) We also get the error: DETACHED: PhidgetStepper

Are these symptoms known? Does this look like a hardware problem? 


Thanks in advance!




Here are screenshots of the error messages: 



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Hi there,

I have just purchased a 4X-23 for a student project, ARIS Space, at ETH Zürich. I have a question regarding the X-Winder Designer Software. Our (me and my teams') aim is to manufacture a filament-wound composite-overwrapped pressure vessel with two polar openings. 

When generating winding patterns and visualizing them in the Designer Software, there is always at least one path which strikes across the polar opening, as in the following image: 3707931714?profile=RESIZE_710xSome of the generated winding patterns are just plain nonsensical and I am a little confused and not at all sure how to interpret the output of the software - I would appreciate very much if somebody could answer the following questions: 

- do the lines shown in the image represent the middle of the filament? (in my case, the filament is 7mm wide). Or do they represent the inner/outer edge of the filament? 

- Does the number of groups have something to do with the filament traveling across the polar opening? This may not be possible in our design, as there are threaded valves protruding from the polar openings. Does the filament need to be reattached to the mandrel after each "group" has been wound? Or does this happen continually?

- How is the best way to design a proper winding pattern in the X Winder Designer software? I have just been experimenting with the "phi" angle input in the software and trial-and errored it :)  For a polar winding pattern, there are analytical formulas to determine the winding angle depending on mandrel geometry to obtain full coverage. But I don't see any possibility to manually implement a winding angle in the Designer Software - am I doing something wrong? Is there also the possibility to implement friction parameters?

- Is there better Software available online to design the winding pattern without blowing the budget while being compatible with the X Winder?


Thanks a lot for your feedback!!





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Anyone Still has filament gaps?

Hi everyone,

     awhile back ago I posted about how I was gettiing gaps. I thought winding slow would minimize those gaps, but I still end up with lots of huge gaps. Most of them seem to occure on the L602 returns. As for the L601 returns they all land perfectly where they are supposed to be. Attached is a photo of a 3 inch fiberglass and kevlar combination. Note the kevlar wind on the L601 returns are perfect while the L602 returns have huge gaps in them. 


Has anyone figured out what could be the causing this? I am currently using version 4.17 as version 4.20 would cause a glitch where the carriage would slam into the limit switch. Even though my Z-offsets were correct it would still slam into the limit switch.



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Detached:phidgetStepper Phidget

Dear sir/madam,

 please anybody let me know how I should handle this error

Error is like that

“Detached:phidgetStepper Phidget

Bipolar Stepper Controller 1-motor 507314202”


This error occurs frequently,


Thanks, and best regards



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Does anyone us a filament modeling software?

Hello, I'm having some issues with my fiber placement. Trying to wind dry fiber onto a smaller spool with flanges, and the winder is dwelling on  one side of the spool and not the other or will switch back and forth. Wondering if there is any modeling software that will work with the xwinder for filament winding. 


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End Angle

Can anyone explain to me what the "add'l end angle" does for the winding?  I have tried it at multiple settings and can't determine how the instrument is using this setting.

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Filament Skipping

Hi everyone this is my first time posting here. I am noticing an issue with the start of the second pass of a helical wind. On the second pass it tends to space out a good distance from the first pass going from right to left. On the return from left to right everything starts falling into place from there on.

Is there a reason why it does this and is there a way to fix it? I’ll get a picture tomorrow when I make a tube.

Your help is most appreciated.

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Y-Axis Offset

I am having some trouble correctly setting my Y-Axis offset on my 4-axis X-Winder.  I am told to measure from the centerline of the mandrel to the delivery head.  I am told that the default is 4.625 inch.  What I am not sure of is, where on the delivery head do I measure to?  I have tried measuring just to the face of the steel roller, to the centerline of the roller and to the point on the roller fartheest from the mandrel centerline and, when I run my code, the roller on the delivery head seems to want to come in contact with my mandrel.  I would appreciate any helpful hints.  Tim.

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Carbon tow size

I will start using the X-winder with my students. I wish to make very simple parts , with is the esiest tow size to use, I saw some 3 to 6 avalaible, other size are more difficult to have.

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Hi, I am new to filament winding and is trying to wrap an aluminium cylinderical shape. I am facing issues with the delivery head angle. The angle of the delivery head is inversed throughout the winding. [Example: When moving the carriage from Right to Left (G1), looking from the direction of the delivery head, the angle it +45 deg instead of -45 deg.] This causes the filament to slip off the delivery head, causing issues at the end wrap and during its return, the filament would not be resting on the roller anymore.

I would be able to make the changes in the G code. However if anyone could identify what is wrong, where the software generates angles of the delivery head inverse if what it should be.

I had upoaded a picture of the start position of the wrap to illustrate the issue of the delivery head angle.

Would greatly appreciate your help.


Best Regards,


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Windings are too tight

I'm new around these parts. 
I recently purchased an X winder second hand and ive been playing around with it. 

Obviously im learning as i go, but one of the biggest issues that im having now is that my mandrel, even though its wrapped in receipt paper and packing tape, my windings are impossible to remove from the mandrel. 

Am i missing something? Is my brake too tight? From the video i watched there was no struggle in removing them part from the mandrel. 

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More Torque?

I am using my X-Winder to make test panels. The mandrel is square peice of aluminium flat stock. as a cosequence the torque value changes as the mandrel spins. I need to increase the size of the motor to get more torque, Going from the original Nema 23 stepper 57HSG76-3004JA what motor could I get that would increase my torque but still mate with the original gear box?

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oval sizing

if I'm wrapping a oval shaped mandrel thats about 80mm by 30mm what do i set at the mandrel size in the software?  80mm? or do i have to calculate the circumference? 

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