Flexwind Manual

Version 1.3 – Aug 30, 2016

1
Contents
1 Introduction 3

2 User Accounts 4

3 Software/UI Overview 5

4 Initial Machine Motion 7

4.1 Order of Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 Notes on Homing [Reference Maneuver] . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5 Loading and Executing Files 12

5.1 Find Path Maneuver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2 Executing a Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

6 Manual Operation/Manual Jogging 14

7 Use of Offsets 15

8 Shut Down 17

9 Light Tower 18

10 Flexwind 19
10.1 Current Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
10.2 Settings Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
10.2.1 Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
10.2.2 Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10.2.3 Display Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10.2.4 Access Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10.2.5 Motion Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.3 Dr Blade / Scanner Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10.4 Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10.5 Auxillary Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
10.6 Tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

11 Troubleshooting 37
11.1 Error Strings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

12 Special File Types used in Flexwind 38

12.1 Buffer Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2
1 Introduction
This document is the user guide and reference manual for Flexwind, McClean
Anderson's current hardware/software control combination for operating its high-end,
multi-axis filament winders. The manual covers topics required to operate the McClean
Anderson winders, from start-up through part execution.

NOTE: This manual is not intended to offer guidance on machine maintenance, physical
and electrical machine installation, or connection of external McClean Anderson
hardware.

3
2 User Accounts
All McClean Anderson machines are pre installed and configured with Flexwind on a
Windows operating system. By default the system is configured with the following user
accounts – Programmer and Winding for access to different features in Flexwind.
Depending on the user, one of the Username and password mentioned below are to be
entered at the log on screen during a typical computer power up sequence.

User Name/ User Accounts Password

Programmer Programmer

Winding Winding

Table 1: User accounts

Description

Programmer
The Programmer account has access to all the features of Flexwind.

Winding [all others]

Machine operators typically use the winding account. The winding account has
restricted access to the features in Flexwind, the user cannot access the Settings
control tab in Flexwind.

It is highly recommended that the user not alter any of the User Accounts. Unless se-
curity is an issue, the user should not change the default password. The procedure to
change the password can be found on any good Windows resource. If additional user
accounts are needed please contact McCleanAnderson.

NOTE: All machines receive an additional account for use by McClean Anderson
service personnel. This service account can be used to perform various debugging
tasks on the machine. We suggest that administrators not alter this account during
machine configuration. Contact McClean Anderson for more information about its use.

4
3 Software/UI Overview
Flexwind can be started either by clicking on the Flexwind icon on the desktop or by
selecting it from the Windows start up entries. The main Flexwind control screen at
startup is as shown in the figure below. The main screen is divided into regions and
described below.

Figure 1: Main UI Flexwind Screenshot

Region A

This region contains the File Open, Machine control, Rate control buttons, Offset and
the Tension switch button. Each of these buttons are discussed in detail later in the
manual.
Region B

This region displays all the existing axes, their select buttons and the current state
information associated with them. See Display options under Settings tab and Manual
jogging for more information.
Region C

This region contains tabs to control and monitor various aspects of Flexwind and other
McClean Anderson hardware. Each of the tabs is discussed in great detail in the
Flexwind section [Section 10.2].

5
Region D

This region displays the instructions as well as Errors along with an error indicator.
Below the message line is a line displaying the currently loaded file and any
supplemental files loaded to control the auxiliary outputs, the tensioner, or the Dr.
Blade.[i.e, .aux, .ten and
.bld respectively].

Region E

This region contains the emergency stop button and a reset buttons to recover. More of
this is discussed later in the manual.

6
4 Initial Machine Motion
After Flexwind completes initialization, the machine's state will be set to emergency stop
[E-stop]. Typically, the user will clear this state clicking the Reset button and then home
the machine. Before proceeding, the user should first carry out a visual inspection of the
machine to ensure that all axes are clear to move (this need not imply removing any
mandrel). Also, any machine operator should be thoroughly familiar with axis names
and orientations. Figure below is of a 6-axis filament winder showing McClean
Anderson's conventions on naming and axis orientation.

Figure 2: Six Axis Winder, Axes Names and their Orientation

The arrows marked \+" denote the positive direction for the axis - the
direction obtained by using the Inc button.

7
The axis coordinates and orientations displayed by Flexwind are defined as follows
(refer to photo for axis names):

Axis No. Axis Name Zero Location Positive Motion Direction

0 Mandrel Fixed to a particular man- Counter-clockwise when ob-
drel point serving headstock
1 Carriage Such that fiber payout line Away from headstock
is tangential to surface of
headstock*
2 Elevation Such that fiber payout line Up
intersects mandrel's axis of
rotation
3 Crossfeed Such that tooling mounting Away from mandrel
°ange at end of crossfeed is
tangential to mandrel's axis
of rotation*
4 Eye Yaw Such that tooling mounting Clockwise when viewed from
°ange at end of crossfeed is top
parallel to mandrel's axis of
rotation
5 Eye Rotation Such that fiber payout plane Counter-clockwise when
is level (to ground) viewed from mandrel

Table 2: Six Axis Winder, Axes Names and their Orientation *Definition
assumes that the attached rotary axes are also at their zero location.

During the homing cycle the carriage hitting the mandrel is at the highest risk.
Therefore the carriage retracts and positions first and then all the other axes home
simultaneously. Careful attention should be paid through out the homing cycle to
prevent axes from a machine / mandrel strike. The user will also want to ensure that no
rotary axis is prevented from moving (e.g. chucks are clear and guards are in place).

Crossfeed

This axis moves first before all others, moves away from the mandrel center line,
remains nearly fully retracted.

Eye Yaw

Moves counter-clockwise when observed from the top, returns to zero - tooling
mounting °ange parallel to carriage and mandrel center line.

8
Eye Rotation

Moves clockwise when eye-yaw is at zero and observer is at mandrel center line, then
returns to zero: the tooling should payout level to the mandrel center line.

Elevation

Moves down, then returns to zero: the tooling fiber-payout line should intersect the
mandrel center line.

Carriage

Moves towards headstock, then reverses and moves to a fixed location - varies based on ma-
chine geometry Mandrel - rotates clockwise when looking at face of headstock; behavior after
finding zero switch varies, either slow-down to zero and stop or reverse to a fixed location.

Mandrel

Rotates clockwise when looking at the face of the headstock, beahvior might vary after
find-ing the zero switch, either slows down to zero and stops or reverses to a fixed
location.

In addition to visually checking the axis paths, the operator should also quickly check
that E-stop string is closed (i.e. nothing is causing an E-stop condition). The E-stop
string will vary from machine to machine. Besides the main E-stop button, it may include
whisker switches on large linear axes or slaved axes, and supplemental hardware to
protect optional (and even customer installed) hardware. It also includes various
hardware safeties. Gener-ally, the operator should not check hardware, although if the
machine cannot clear E-stop and no switch appears to be tripped, this could indicate
more serious problems in such a case please contact McClean Anderson service. To
clear E-stop, the operator should press the \Reset" pushbutton.

NOTE: Anytime the machine is in E-stop, no motion and program functions such as
loading a file can take place. Also, releasing a machine from E-stop should not generate
renewed motion (the machine will still be disabled). Both of these conditions may not
apply to ex-ternal devices attached to Flexwind.

Once E-stop is cleared, the operator can home the machine. To do this, press the
Enable pushbutton followed by the Reference button. The machine becomes enabled
and begins to execute the homing sequence as described in Section 4.2.

9
4.1 Order of Events
The most basic order of events from Flexwind startup to part execution is shown below.
Each of these have been discussed in detail in the manual.

Figure 3: Order of Events

4.2 Notes on Homing [Reference Maneuver]

A machine only needs to be referenced once per execution of the Flexwind program. The
hardware has the ability to track machine motion, even through an E-stop event. So, after
the initial reference sequence, anytime the machine is placed in E-stop, a new reference se-
quence is unnecessary (although the machine will need to backup the distance covered
during the E-stop to the last executed coordinate - this is a \Find Path" maneuver). The
hardware is reset every time Flexwind is executed, so at this point, a renewed reference
sequence is required. Also note: if the user needs to stop the machine during homing for
any reason, they need to use the E-stop button or the Hold button.

Once the machine is referenced, it will be aware of all axes' positions and will be able to
enforce limits on their motion. Using the machine configuration file, Flexwind will en-
force position limits on all linear axes and generally on the eye-yaw axis (if present).
The mandrel can move continuously in one direction while eye-rotation can typically do
the same on most machines (although it need not). Generally, Flexwind will either stop
the axis or throw an E-stop condition whenever a software or hardware limit is
encountered. On ma-chines with adjustable tailstocks mounted on the carriage's rails,
the machine is unaware of the tailstock's position so these use a movable limit-trip
device which engages the limit switch. In general, the program and/or operator would
typically not move the axis to the point where a software or hardware limit is engaged.

NOTE: The machine is not aware of its own envelope or the mandrel's envelope.
Be-yond axis limits, the operator should be aware that it is generally possible for the
machine to strike the mandrel and other machine components and should use caution
when jogging the machine and when executing a program (especially an unfamiliar
one).

In general, many commands require the machine to be enabled. To do this, the opera-
tor can either press and hold the \Enable" button while pressing the other button(s) of
the command, or release the \Enable" button and press the next command button within
about
10
two seconds. If no activity takes place, the enable state will time out (the yellow light will
go out) and the Enable button must be pressed again.

11
5 Loading and Executing Files
Selecting and loading of new motion files [.mmt and .chn] is done through a typical windows
file-open dialog box on clicking the Open button. Auxiliary output files [.aux] and/or Coor-
dinator files [.ten or .bld] with the same name, at the same location, are automatically
loaded together with the main motion file. If the user wishes to disable auxiliary output,
tensioner, or Dr. Blade control in a particular wind, they should rename or move the
correspond-ing files. They also can disable them through their disable buttons. Please see
individual sections in Settings tab [Section 10.2 ] for more information.

5.1 Find Path Maneuver

Once the file has been loaded, the operator may start machine execution. The first step is to
synchronize the machine's position to match the fiber path at the desired execution point.
This is known as a \Find Path" maneuver. To do this, press the Enable and then Find Path
button. A find path maneuver must always be executed before starting or continuing
program execution. This includes after any E-stop, after any manual machine motion, after
changing an axis offset, anytime a new file is loaded, and a file has completed execution
and is restarted. The only exception to this is when program execution is held.

NOTE: As with machine referencing, if the user needs to stop the machine for any rea-
son during a find path maneuver, they must use the E-stop button or the hold button. It
is always a good idea to be ready to E-stop the machine whenever executing a part for
the first time, in case entered clearances are insu±cient.

Once the find path maneuver has completed, the machine will be \On Path". This is
indicated by the green tower light (either constantly lit or °ashing if execution is held).
The user can now begin executing the motion program.

5.2 Executing a Program

Click the Enable button and then Increase button. Subsequent clicking of Increase button
will execute the program in incremental steps till a rate of 100% is reached. To slow down
execution, click on the Decrease button, this will reduce the rate in decremental steps. The
incremental and the decremental step are configurable (see Settings section). The
execution stops when the rate is 0%. An alternate to using the Increase and Decrease
buttons is sliding the mouse pointer on the Rate button Up [Increase] or Down [Decrease].

When winding a part, the user has various options to control execution. Increase and De-
crease have already been described. It is a good idea to use them to cautiously wind a first
part (e.g. to slow the machine down when approaching the domes of a bottle and execute
that region at 5% or less). If a program appears to be running out of clearance, the Hold

12
pushbutton will stop the machine rapidly. The E-stop button is, of course, the most rapid
method to stop the machine.

Note : When a machine is executing a part, it is enabled, so the user does not need to
press Enable before any other button. However, only a limited number of buttons (and
program features) will function: Increase, Decrease, Hold, and E-Stop.

Hold Button

The Hold button is generally used whenever the user wishes to stop a wind - it stops
part program execution, the referencing and the find path manuever. Once the machine
stops, it is disabled, which causes the motor-brakes to clamp. At this point, the operator
has various options. The operator can:

 Continue the wind, either using the Enable + Increase method described above or by
pressing Enable and Hold (Note: Enable + Decrease won't start a wind in reverse).
In the latter case, the machine will return to the execution rate it had before Hold
was pressed.

 The operator can load a new file using the method described at the start of this
section. In this case, the user will be prompted to make sure they wish to abandon
the current wind. Note: reloading the current file is the only way to restart execution
at the start of the program (without finishing the wind).

 The machine can be jogged. The operator has the option of using this jog to
generate a position offset from the original motion, otherwise the user must Find
Path which will return the machine to the state it had before jogging.

 An offset can be added to the machine's location .

Remember that if any machine motion takes place or new axis offsets are made, a
new Find Path must be carried out prior to resuming the wind.

Typically, after a few conservative program executions (and possibly minor alterations
to the program's motion), the operator becomes more familiar with the motion and can
run the machine at a high feed rate until part completion, and then start the next wind.

13
6 Manual Operation/Manual Jogging
The machine operator can jog/move individual axes any time the machine is not actively
executing a program and not in an E-stop state. Often this is used. For example, after a
wind, each axis might be moved away from the part to make mandrel insertion/removal
easier. The mandrel is often rotated for extended periods as the operator performs
various tasks on the part (e.g. removing excess resin).

To jog an axis, the user has to click the Enable button, then click on the desired axis
but-ton, and finally the Increase or Decrease button to control that axis. Increase and
Decrease are used to increase and decrease speed in a positive or a negative direction,
for example Decrease will move the axis in an increasingly negative direction.

If, prior to jogging, there was a file loaded and the machine was on-path (either a Find
Path command was executed or the machine was held during winding), then the
operator has the option of continuing motion from the new, jogged location. To do this,
click on the Reference button. The new coordinates will be accepted as the current path
location, the resulting offset will be displayed in the right-most column, and the user can
begin / continue winding via Enable + Increase (or Hold). The blue light will indicate that
the machine is using an offset. If the user does not wish to incorporate this jogged
motion and wants to return to the most recent location on the fiber path, he/she should
perform another Find Path. To get rid of an offset, the user can either set it to zero or
press Reference + Reset.

The machine can be jogged any time it is not actively executing a program and not in an
E-stop state. This includes when a program is held and prior to the initial homing of the
machine. If an axis is jogged prior to machine referencing, Flexwind will not display valid
axis positions and the machine will not use software limit enforcement - the operator will
be able to jog axes until a limit switch is encountered which will trigger an E-stop.
Remember that if the machine is jogged in the middle of part execution, it must return to
the previously held position (via a Find Path) before execution can continue.

14
7 Use of Offsets
Offsets are used to make minor adjustments in the machine's position to account for
irregu-larities in the mandrel's mounting location or clearance issues in the motion file.

Figure 4: Axis Offsets

To use offsets, the machine must first be on a program path and not actively
executing. Clicking on the Offset button opens up a box with text filds for the offsets to
be entered for one or more axes. Offsets follow the standard axis orientations and the
units are also displayed. In general, unless a mandrel has significant variations in
mounting location, off-sets are only used during program development. In production,
any adjustments to motion should be done via Composite Designer. The offset dialog
box also has a provision to zero all offsets, returning the machine to the original
program path.

If any offsets were changed, the user will need to perform a new Find Path (i.e. Enable
and the the Find Path buttons) before continuing with the wind. This is when the motion
actually takes place.

Any applied offset will turn on the the blue tower light.

NOTE: offsets are maintained until the operator removes them (e.g. when re-running
the same file or loading a new file). The operator can make use of this fact to add an
offset to a program before running it. Since offsets cannot be set until after the machine
completes a Find Path, this poses a problem if the Find Path itself brings the payout
system too close to the mandrel. To avoid this, a programmer may wish to install a
program for which the find-path moves the machine to a safe location where some
adjustment can be carried out. The operator would load this file, execute a find path,
then apply an offset, and finally load the desired file to be executed.

15
Offsets are not cumulative, so applying a 0.2-inch offset twice would cause no motion
the second time.

Function
Text Fields Takes in the offset values for one ore more axes.
Set Current Button Manual jogging of individual axes can be done to required posi-
tions, and this can be made into as a offsets. Manual jogging can
also be replaced partial axis manuevers during part execution.
Apply Button Applies the Offset values into the current program.
Zero Button Clears all the entered offset values.
Close Button (X) Closes the Offset window.

Table 3: Offset table

16
8 Shut Down
The operator has to shut down the machine after operation. There are no particular re-
quirements before a machine can be shutdown. The only common practice is to stop
the machine first and then close Windows. Flexwind is similar to many Windows
programs - it can be closed via clicking the “X" in the upper right corner of its window or
via the keystroke Alt-F4. In both cases, a window will popup asking the user to verify
this, and then the program exits. When Flexwind exits, the machine is placed into E-
stop and no further operation / commands is possible. Because of this E-stop, the user
is encouraged to first stop the machine prior to exiting Flexwind.

Note that in general, all direct machine motion is carried out by the on-board motion
control board and not by the industrial computer - this means the machine can remain
operational even if Windows crashes.

After exiting Flexwind the operator can now shut down Windows OS and finally throw
the main power switch on the machine to turn off the system (and also turn off any inde-
pendently powered systems such as the tensioners).

17
9 Light Tower
Above each winder is a light tower with 4 colored lights as shown in the Figure below.

Figure 5: Light Tower

These have the following meaning(s) if lit:

Red : The machine is in E-stop - motion is not possible until E-stop is cleared.

Yellow : The machine is enabled - it is either moving or is clear to move.

Green : If lit, the machine is on path - it is ready to wind a part (if yellow is also lit, then a
program is currently executing); if °ashing, machine is currently held (via the Hold
pushbutton).

Blue : If constantly lit, the machine currently has an offset applied - one or more axes
has been adjusted from its programmed position; if °ashing, the machine has not yet
been homed, no program can be loaded or run until a reference cycle has been carried
out.

18
10 Flexwind
10.1 Current Program
The current program tab allows the user to view aspects of the currently loaded winding
program. The user also can change the starting and the ending points of the motion
program based on the section, layer, etc.

Figure 6: Current Program

Please see Section 12.1 for information regarding Buffer files.

Function
View .BUF file but- If a .buf file is loaded as the motion file, clicking this button
ton will change the display to show all winding programs contained
in the .buf file. Clicking it again will change the display to the
standard motion file screen.
Forward button The forward button switches the direction of the winding pro-
gram. With the machine in Hold, clicking on this button will
reverse the direction of the program once it begins again. It
will go in reverse until the beginning of the program has been
reached. Clicking on the button again will have the program go
in its normal direction.
Set Start button - Set Set Start and Set End allow the user to change where the pro-
End Button gram starts and where it ends. Can choose by section, layer,
pass, or time.
Reset button Clears everything to the default values.
Abandon button Abandon removes the program from Flexwind. This must be
done first to load a new program. Flexwind must not be enabled
for this.

19
Layer, Pass, Time The large text box displays segmented information on the loaded
tabs winding program. Each line shows for a certain time: the posi-
tion of each axis, which pass the program is at, and which layer
is running. The 3 buttons at the top: Layer, Pass, and Time
allow the user to change how the lines are divided. Clicking
on Layer makes 1 line for the beginning and end of each layer.
Clicking on Pass makes 1 line for each pass of the carriage. Fi-
nally, clicking on time makes 1 line for every 0.05 seconds of the
program approximately

Table 4: Current Program Table

20
10.2 Settings Tab
The Flexwind Settings are available on clicking the Settings tab on the main interface.

Figure 7: Flexwind Settings

The following can be controlled through the Settings Tab. Each of these are
explained in subsequent subsections -

 Files

 Display Options

 Access Options

 Motion Options

 Logging Options

21
10.2.1 Files
Configuration Files

The File/Folder icon allows configuration scripts to be loaded through a standard

Windows File Open dialog box. The configuration scripts have the extension *.csc . The
configu-ration scripts contain information of the Configuraion Files used by the machine
and the interface of Flexwind. Flexwind comes pre configured with the configuration
scripts. No new configuration files should be loaded and old ones deleted before
contacting McClean Anderson.

The configuration script looks as below -

McClean Anderson Initialization Script

2 Files
mach J2473-mach-v1-full.cfg
hmi J2473-hmi-v1-full.cfg
Signature: FEDA5B76010A06152A3711832E68397B44AA4F53278E65C4DF89C95E0AA2A59DFC

Scanner Keys

If the machine uses scanner keys please contact McClean Anderson for the
documentation and the manual.

22
10.2.2 Logging

Figure 8: Logging Options

Data Logging

Various values can be sampled at regular or operator established intervals in the form
of logs. Flexwind creates logs as text files with the naming convention - MotionFile-
Name.mmtDateTTime.txt (Example - CircWind.mmt2007-08-14T15-03-08.txt). The
default directory for these log files is C:\Flexwind Logs\Winding Logs. The log files can
also be saved at a different location . The operator has the option of having Flexwind
create a dif-ferent log file for each execution (or everytime the Create Log button is
activated) or enter a filename for the log file. The operator can also sample additional
values like Axis Position, Layer / Circuit, AuxOut State, Blade opening, tension.

Event Logging

Significant events regarding the machine can be recorded with Date=Time Stamps into
Event logs. The Event logs are placed in files with *.elg extension. The default is an
event.elg file placed in C:\Flexwind Logs\Winding Logs. The oprator also has the option
of specifying a different filename and a different location for the event log file. There can
exist only one event log file per execution after event logging begins. If a different
motion file is executed and the operator chooses not to change the default filename or
the path, the old event.elg file gets appended with the events corresponding to the
current execution. If the operator wishes to restart, it can be done by deleting the
existing log file.

Sample Interval Period - Is the time interval between reports of information (can be
Events or Data) sent to the log files. The default is 1 DS ( Decisecond). Flexwind buffers
a buch of reports and then updates them into log files. If the sample interval period
specified is large it takes longer for the files to be updated.

23
 Function
Create Log button Creates data logs and places the log files in the default directory
C:\Flexwind Logs\Winding Logs or the directory specified by
the operator.
Path button Opens a standard Windows browse for folder dialog box, the log
files will now be placed in the selected directory.
Path text field Displays the path where the log files will be placed.
Sample Interval text Can be changed to operator specified time interval. The format
field is HH:MM:SS.DS. The default value is 1 DS i.e, 0:00:00.1
Always On button Lets log files to be updated during the entire duration of the
execution of the program.
Log Items Selecting an individual or a collection of individual buttons in-
cludes data log entries related to these items in the data log
file(s).
Event Log File icon Opens a Select Event Log file dialog box where the operator can
select a filename and directory for the event log.
Event Log Filename The event log filename entered by the operator, the event log
file is saved in the default directory unless a different filename
and directory is specified by using the Event Log File icon
Fixed Filename text The filename entered by the operator.
box
Append events to log Merges the event logs with the data logs. The file naming scheme
button remains the same.
Event Log button Creates event log files. The event log files are placed in the de-
fault directory C:\Flexwind Logs\Event Logs\ unless a different
directory is specified by the operator.
Create Filename / The arrow in the button determines whether a different file is
Use fixed filename generated evertime a program excutes or to use a user specified
button filename.

Table 5: Logging Options table

24
Sample of an Event Log

11/2/2007 9:53:19 AM Event log started. (StartEvLog) 9:53:32

AM Machine enabled. (Enable)
9:53:32 AM Rate increased. (Inc)
9:53:33 AM Start program. (Run)
9:53:33 AM Executing program motion. (Run2)
9:53:33 AM Rate set to: 0% (Rate1 Rate2) 9:53:33
AM Rate increased. (Inc)
9:53:33 AM Rate set to: 5% (Rate1 Rate2)
9:53:34 AM Rate increased. (Inc)
9:53:34 AM Rate set to: 50% (Rate1 Rate2)
.
.
9:54:58 AM File: \C:\Documents and Settings\McClean\Desktop\Two.mmt\ opened. (Open1 Open2) 9:55:08
AM Machine enabled. (Enable)
9:55:09 AM Moving to program target location. (Target) 9:55:10
AM Rate set to: 96% (Rate1 Rate2)
9:55:20 AM Machine holding. (Hold) 9:55:22
AM Machine disabled. (Disable)
11/2/2007 9:55:38 AM Event log stopped. (StopEvLog)
11/2/2007 9:55:39 AM Event log started. (StartEvLog) 9:55:44
AM Machine enabled. (Enable)
9:56:14 AM Emergency Stop.-code:7 (EStop) 11/2/2007
9:56:20 AM Flexwind shut down. (Close) 11/2/2007 9:56:20
AM Event log stopped. (StopEvLog)

Sample of Data Log

Data-logging file - continuously appended file.

Starting time: 2007-11-02T09:50:28. (Real-time entries relative to rounded start time:9:50:28.40). Sample
rate:0:00:00.10. Sampling only during program execution. No status messages.
Name:
Real-time from start \ Units: 0:00:13.49 Data-logging file
- continuously appended file.
Starting time: 2007-11-02T09:50:47. (Real-time entries relative to rounded start time:9:50:47.10). Sample
rate:0:00:00.10. Sampling only during program execution. No status messages.
Name: Rate Program Time Layer Circuit Mandrel Carriage Crossfeed Eye Rotation
DrBlade link status Dr. Blade 1 Tensioner link status Tensioner 1 Tensioner 2 Tensioner 3 Tensioner 4 Real-time from
start \ Units: \% scaled seconds unitless unitless inch inch
0=good/1=bad in 0=good/1=bad lbf lbf lbf lbf
0:02:46.01 0 0:00:00.00 0 0 0.05 20.000 12.000 0.01 1 0.039 1 0.5 0.5 0.5 0.5 0:02:46.10 4
0:00:00.00 0 0 0.04 20.000 12.000 0.00 1 0.039 1 0.5 0.5 0.5 0.5 0:02:46.20 5 0:00:00.00 0 0
0.03 20.000 12.000 0.00 1 0.039 1 0.5 0.5 0.5 0.5 0:02:46.30 8 0:00:00.00 0 0 0.02 20.000
12.000 0.00 1 0.039 1 0.5 0.5 0.5 0.5 0:02:46.40 10 0:00:00.10 0 0 0.01 20.000 12.000 0.00 1
0.039 1 0.5 0.5 0.5 0.5 0:02:46.50 13 0:00:00.10 0 0 -0.01 20.000 12.000 0.00 1 0.039 1 0.5
0.5 0.5 0.5 0:02:46.60 15 0:00:00.10 0 0 -0.00 20.000 12.000 0.00 1 0.039 1 0.5 0.5 0.5 0.5
0:02:46.70 18 0:00:00.15 0 0 -0.00 20.000 12.000 0.00 1 0.039 1 0.5 0.5 0.5 0.5 0:02:46.80
20 0:00:00.15 0 0 0.00 20.000 12.000 0.00 1 0.039 1 0.5 0.5 0.5 0.5 0:02:46.90 25 0:00:00.15
0 0 -0.00 20.000 12.000 0.00 1 0.039 1 0.5 0.5 0.5 0.5

.
.
.
.

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10.2.3 Display Options

Figure 9: Display Options

The operator can generate textual and graphical views of the information regarding
the current state of machine motion for each of the existing axes. The operator has the
option of choosing one of Position, Position Error, Velocity and Acceleration for all the
axes to be displayed in graphs. The operator can choose two of Axis Offset, Position
Error, Velocity and Acceleration to be displayed in the text format along with the position
of each axis which is always displayed. The operator also has the option of choosing
the display units to be used for graphical and text based displays.

Figure 10: Axis Info Display

Axis Information Display shown above consists of an Axis graph [Graphical view] and
axis text [Textual view] - information regarding the current state of the machine motion.

Function
Display Units button Operators can choose the display units for the graphical and text
displays by clicking the button and selecting from the generated
drop down menu.
Axis Graph display Operators can choose the information to be displayed as graphs.
button This can be achieved by clicking the button and selecting from
one of Position, Position Error, Velocity and Acceleration.
Axis Text display - Operators can choose the information to be displayed in the
Bottom Left button bottom left text field shown in the figure above. This can be
achieved by clicking the button and selecting from one of Axis
Offset, Position Error, Velocity and Acceleration.

26
 Axis Text display - Operators can choose the information to be displayed in the
Bottom Right button bottom right text field shown in the figure above. This can be
achieved by clicking the button and selecting from one of Axis
Offset, Position Error, Velocity and Acceleration.

Table 6: Display Options Table

27
10.2.4 Access Options
Access to certain features and buttons in Flexwind can be controlled through the
Access options.

Figure 11: Display Options

Function
Aux-out control but- Gives the option of Direct control in the Aux Output control
ton panel. More of this is discussed indetail in the Aux Output
section.
Tension control but- The user can get two additional options in the Tensioner control
ton panel by clicking the button. The user can navigate to the
Tensioner controls by clicking on the Tensioner tab where they
can select Disable tension progrm andor Direct tension control.
This is discussed in the Tensioner section.
Dr. Blade control Same as the Tension control button, gives control options to the
button Dr. Blade panel.
Start Start Options Disables the Start Stop button in the Current Program panel.
Offset button The Offset button on tha main panel can be disabled by making
it invisible by clicking the Offset button.
Open File Button Once the motion program is loaded, the Open File button in the
main panel can be disabled so that no new files are loaded.
Open file dialog box The file load window can be disabled.
Path Folder location to show programs with Select button

Table 7: Access Options

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10.2.5 Motion Options
The user has the option of controlling the rate at which the motion changes
automatically or when done manually. Increase and the decrease buttons have already
been discussed. The amount by which they alter the speed is set at a default 5% i,e, the
motion is altered in incremental or decremental steps of 5% depending on the button
pressed. This default value can be changed so that everytime a button is pressed there
is the specified percentage speed change. The default rate at which the machine does a
Home or a Find Path maneuver is at a 50% of its capability. This default value can be
altered so that a machine does a faster or a slower Home or a Find Path maneuver
depending on the users needs.

Figure 12: Display Options

29
10.3 Dr Blade / Scanner Tab
Dr Blade

Figure 13: Dr Blade and Scanner

Flexwind control computers are capable of interfacing McClean Anderson hardware

devices like the digital Dr. Blade and Scanner.

NOTE: when using Flexwind to control a Dr. Blade unit, power-up sequence is
important. To properly establish communications, first turn-on the winder and start
Flexwind, then turn on the Dr. Blade control via the main switch.
Function
Current The current value of the blade opening.
Target The value of the blade opening we wish to achieve.
New The field the user would input the new value of the blade open-
ing. To set a gap size, simply enter its value and press the Enter
key.
Apply One can also set both the blades to the same value simultane-
ously by using the "Set Dr. Blades * through * to *" box and
hitting the "apply" button.
Disable Dr. Blade Disables *.bld Dr. Blade file.
Pgm button
Direct Dr. Blade Disables the Dr. Blade console allowing the gap levels to be
control button manually set.
Dr. Blade link status Shows red if there is a fault in the link between the Dr. Blade
and the Computer. If it is good to go, it shows green.
Table 8: Dr. Blade Table

In addition to setting values via these boxes, supplemental files can be added to the wind-
ing programs themselves to automatically control the Dr. Blade settings. These files are

30
generated using the Coordinator software. The file loaded portion of Flexwind will
indicate that the supplemental files are loaded via the \+.bld" string.

NOTE: Control of the Dr. Blade is non-hierarchical - requests are executed in sequence.
For example, if a particular wind program sets gap opening levels on a repeating basis
and the operator manually sets different levels at the Dr. Blade, those manual levels will
be used until the next time the wind-program triggers the condition and generates a new
request.

Scanner

Flexwind support a 2D/1D Scanner/barcode reader. It allows the machine operator to

scan a barcode and cause the machine to load a specific motion file.

Text including comments is displayed in the Scanned Data dialog box. Please contact
Mc-Clean Anderson for additional documentation regarding the scanner.

31
10.4 Status

Figure 14: Status

There are 7 states associated with the axes -

Home

Positive Limit [+Lim]

Negative Limit [-Lim]

Fault

Positive Over Flow [+Lim]

Negative Over Flow [-Lim]

Following Error [Fllw]

During the homing manuever a blue Home indicator indicates that the axis has reached
its reference position. A red +Lim or a red -Lim indicates that the axis is at its maximum
or the minimum position, and can travel no further. Please contact McClean Anderson
for assistance if any of the other indicators turn Red.

As discussed earlier, the E-Stop String Status should be green for proper functioning of
Flexwind. If red, the E-Stop String must be checked to find a fault. This is normally open
but closes and latches when any E-Stop component is triggered. Triggers include the
main E-Stop switch, any protective switch and some intelligent componentry such as
the Flexwind computer itself and motor drives. The E-Stop string is latched so that once
triggered it re-mains so until all items in the string are clear to proceed and an explicit
signal is issued (by pressing Reset) to clear the state. When in E-Stop, the string is
closed and the display will

32
show red.

This tab also shows the Tensioner Link status, Dr.Blade Link Status and the Fiber Break
Status. Red on any of these would indicate a fault, i.e. when the link to the Tensioner is
lost or that to the Dr. Blade is lost, or if the fiber breaks respectively.

The Status Messages dialogue Box displays automatic messages after tracking
significant events regarding the machine like those pertaining to the Communication
between the ma-chine and Flexwind.

This screen is updated every time there is an event logged, the most recent one being
on top. Logging generates a time/date stamp for each entry and includes things such as
Flexwind startup/shutdown, clearing and tripping of the EStop, the programs loaded,
pushbutton se-quences (ex: Find Path, Reference, Jog), Increase or decrease the rate,
position errors etc.

The event log entries are always appended to any existing log file. If the user wishes to
restart the log, they should simply delete the current log file.

33
10.5 Auxillary Outputs

Figure 15: Auxillary Outputs

Optional auxiliary outputs can be used to control outside procedures. This can be
done automatically with a winding program from Composite Designer or the outputs can
be forced on and off by the user.

The optimal way to use the auxiliary outputs is to make a .aux file with Composite De-
signer to work with a winding program. With that, an automated program can be
generated to control the outputs.

By clicking on Direct Control, a user can manually change the outputs. Clicking on
Disable Program, the user can completely bypass a running .aux file. Once Direct
Control is enabled the user then can then make changes to an output. Clicking a Digital
Output's light will turn it on or off. New values can be entered for Timers. Timers operate
entirely as conditions within the .aux file. Clicking on Lock freezes the state of the output
so that it cannot be changed, where Unlock will remove that freeze. The outputs can
also be cleared by clicking the respective Clear buttons.

34
10.6 Tensioner
The digital fiber tensioning system can be controlled through the Tensioner console of
Flexwind. The Tensioner system as a whole is explained in detail in a separate
Tensioner System section, See section No. 123. Explained here is a four spool
tensioning system i.e, there are four different individual tensioning units which make up
the tensioning system. Individual tensioning units can be controlled separately or
controlled as a group. Status buttons indicate if there is a fiber brake during winding or a
communication breakdown between the tensioning system and Flexwind.

Figure 16: Tensioner

Function
Current text box The actual tension detected on the fiber by the tensioner.
Target text box The tension level set by the operator. The deafult tension for
all existing individual units is 0.5 lbs.
New text box The operator can set a new target tension level, by entering the
values and hitting `Enter' key on the keyboard.
Set tensioners and A group of tensioning units can be set to a particular tension.
Apply Take for example, having 2 through 4 set at 2 lbs will set the
units 2,3 and 4 each at 2 lbs.
Disable tension pro- Separate tensioner files :ten can be loaded like anyother file
gram button Flexwind accepts, the loaded file can be disabled and let the
operators load values manually.
Direct tension con- Disables the tension console allowing the tension levels to be
trol manually entered at the tensioning unit.
Tensioner link status The status button indicates if there is active communication
button between the the tensioning system and Flexwind. If it is red,
please check if the Tensioner is powered up or Tensioner trouble
shooting explained in section No. 123.

35
Fiber Break status This indicates if there is a fiber breakage during the macine
button motion. The program will go into a Hold state.

Table 9: Tensioner Table

36
11 Troubleshooting
11.1 Error Strings
When the machine goes into an E-Stop stage the error strings are displayed next to the
E-Stop indicator. These error strings are self explanatory. The user can do a check and
take necessary steps and then clear the E-Stop condition by pressing the Reset button.
If the user is not able to release the E-stop and no hardware safety switches are tripped
[Eg. , Whisker switches] please contact McClean Anderson.

37
12 Special File Types used in Flexwind
12.1 Buffer Files
Sometimes chaining of two motion files may not be possible [for example chaining of
two already chained files (*.chn) or a chained file(*.chn) with a regular motion
file(*.mmt)]. In such cases the user has the option of running files in succession using
buffer files. Buffer files are text files with a .BUF extension. They contain the path
information of the motion files and optional commands, the use of the commands are
explained in detail below.
Sample of Buffer File

c:\FileFolder\MotionFileOne.chn
c:\FileFolder\MotionFileTwo.chn
c:\FileFolder\MotionFileThree.mmt /AUTO_FP_ONLY

Notes on Buffer File Commands -

1. Buffer file command /PAUSE@END, Each line with the this switch will make the
machine do a pause at the end of the motion file and wait the operator to press RESET
button to continue. Then it will automatically load the next line of motion, do auto find
path and ram up to previous machine rate and start winding

2. Buffer file command /AUTO_FP_ONLY. Each line with switch will do an auto Find
Path then wait for the user to press ENABLE+INC to start winding.

3. Buffer file command /MANUAL_FP_AND_START. Each line with this switch will need
the user to manually do Find Path and then press ENABLE+INC to start winding.

4. Without a switch, the first line of the buffer file always behaves the same as if it has
the /MANUAL_FP_AND_START switch. The other lines without a switch will do auto
Find Path and start winding with the previous machine rate.

The buffer file commands are placed at the end of the line for the file it is intended for.

38