II.

Introduction


Overview of Situation
This project deals with the design and prototype of a wire winding machine.
It was divided into a design and prototype phase with each lasting approximately 15
weeks. A prototype capable of producing resistive wire with a fiberglass core was
completed, calibrated and delivered to Delta Heat Llc on May 2012. A second
prototype was also completed by May 2012 to be kept at the mechanical
engineering department for further research and development.

Company Background
Delta Heat LLC is a located in Rio Hondo, Texas that currently produces
heaters for freeze protection, condensation and viscosity control as well as
other applications. Their line of product includes flexible rubber heaters and
insulated fuel pipes. Current customers are from (but not limited to) markets in
military, aerospace, medical, automotive, and vending equipment due to the
multiple applications of each product line. [1,2,3]

Figure 3: Examples of some of the products that Delta Heat LLC produces using the Heating Resistance Wire: Drum Heaters,
Pad Heaters, Fuel Heaters. Courtesy of www.electroflex.com, and www.deltaheatllc.com.


Proposed Overall Design
The design of the wire‐winding machine should be able to wind resistance wire
around a fiber class core. It should be capable of using different type of wire
materials and measure the resistance of the wire very accurate. The user must be
able to control the motor velocities and sub sequentially control the amount of loops
around the fiberglass core. The machine will use a real time resistance
measurement device which the team is to design to ensure proper production.
Finally all parts used in the prototype should be easily obtained from the market.