• Travel on X-axis:
• Table length = 3657.6mm (144"). [Existing track is 1600 mm long. Additional track will be 2020 mm or 2080 mm long. ] Track length = 3620mm or 3680mm long. Carriage length over blocks = 333mm. Travel = 3287mm (129.4")
• Travel on Y and Z-axii: If the intention is only to make blades (& other smaller items) at this workstation then the travel of the Y-axis and the Z-axis can probably be the maximum distance from the blades pitch axis to the trailing edge at the location of the greatest chord. This is so that the complete blade can be continuously rotated when winding the skin.
• The travel on the Y-axis should be a little greater, say the greatest perceivable chord, so that work can be done on a complete blade.
• The Y and Z travels will have to be slightly greater, of course, due to clearances and the unforeseen.
• October 2, 2005 ~ The complete blade probably does not have to be turned, there for the Y-axis travel need only be the width (choedwise) of the widest component, plus allowances for the cutter etc.
• October 29, 2005 ~ Consider putting the rack on the load side of the two rails. This will minimize the moment about the vertical axis on the blocks.
• If the worktable is open at one side (i.e. the X-axis guide tracks are on the same side) then it will be possible to route item that have a width that is just about twice the Y-axis travel, by routing in two setups.
• Consider having two A-axis locations, a long X-axis one for the blades and a shorter X-axis one for the rotor hub.
• Motor: Consider using a ball screw because of its efficiency. The will result in a lower total power consumption and, hopefully, 115VAC, 1-phase electrical input.
• There maybe a cleanliness problem if the workstation is used for both 'machining' and 'filament winding'.
• Try to keep total power within that used at a household. 1HP = 735 W The maximum power for one circuit is 115V * 15A = 1725 W = 2.3 HP
• The working length (X-axis) must be a minimum of 10 feet, or more. This may be fine for blades but it might have to be longer if it is to be used for winding the tail boom(s).
• Note that the cores for the blade will be approximately 6'-10" long. If the blade's male or female mold was made outside then all in-house routing might be 6'-10" and less.
• Could there be a 2;1 or 3:1 gear change on the X-axis drive. This should allow the spar winder to travel fast under light load where as the torque tube winder and routing will travel slower with more force.
• A carriage and track that can traverse the length of the table
• Not accurate but fast. Consider pulleys and cable (clothesline) or rack and pinion (2 speed?).
• For threading pultruded spar
• Accurate but slow. Consider screw feed or rack and pinion (2 speed?).
• For milling honeycomb
• For milling composite spar etc.
• For wrapping torque tube.
• For hot wire foam cores?
• A chuck at one end or both ends?
• Portable vacuum pump below.
• Longitudinal carriage under table

Refrigeration: To eliminate any curing during winding.

Heating: For curing of composite.

• Combined ball screw and stepper motor. ~ http://www.directindustry.com/comm/linear_actuator_with_ball_screw_4837.html
• Techno-isel ~ http://www.techno-isel.com/

Build Your Own Custom CNC Router http://www.techno-isel.com/CNC_Routers/Custom/Custom_Routers.htm

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