🌀 RWC042-F – Precision Preparation Unit for FOG Supply Spools
The RWC042-F is a programmable rewinding and preparation unit for producing defined supply spools for the subsequent FOG winding process on the RWC201-Q1/Q2-FOG.
It is used to rewind optical fibers in a controlled process from a supply spool onto defined master and slave spools. This prepares the required fiber length for the final quadrupolar or octupolar winding process before the end product is produced on the main winding machine.
🔄 Bidirectional Rewinding Process
The RWC042-F is designed as a pay-off and take-up unit. Depending on the process step, each machine side can be used either as the pay-off axis or as the take-up axis.
The rewinding process can be stopped in both directions, moved in the reverse direction and then continued under process control. This allows flexible and controlled fiber preparation for demanding FOG applications.
⚙️ Preparation of Master and Slave Spools
For FOG coil production, the target total fiber length is first prepared on a master spool. This fiber length is then distributed onto the master and slave spools using the RWC042-F.
The two prepared spools then form a connected supply spool set for the RWC201-Q1/Q2-FOG. The fiber connection between both spools remains intact and is not separated before the final FOG winding process.
🧵 Controlled Fiber Guidance and Tension Control
The RWC042-F guides the fiber via defined traverse axes and a process-guided fiber tension control system. The fiber length is measured via a measuring roller. The actual length accuracy depends on calibration, fiber tension, fiber guidance, slip and process conditions.
Fiber spacing, spool width, traverse feed and winding speed are parameterized through the machine control system. The mechanical traverse accuracy depends on the mechanical design, calibration and the respective process conditions.
🖥️ Recipe-Based Control
Operation is carried out via a touchscreen interface with recipe-based parameterization. Process data such as fiber type, target fiber length, winding speed, fiber tension, traverse feed, spool width, direction of rotation as well as start and stop ramps can be set and stored depending on the machine configuration.
This allows recurring rewinding processes to be prepared and documented reproducibly.
🔧 Expansion Options
Various winding tools, spool bodies, adapters and guide roller sizes can be used optionally. The configuration depends on fiber diameter, fiber length, permissible bending radius, spool bore, spool width and flange diameter.
- Various winding tools and spool bodies
- Customer-specific adapters and spool holders
- Guide roller sizes depending on fiber diameter and bending radius
- Recipe-based adaptation to different fiber and spool combinations
✅ Conclusion
The RWC042-F is a specialized preparation unit for precision FOG winding processes. It enables controlled, reproducible and process-stable preparation of master and slave supply spools and therefore forms the basis for the subsequent production of high-quality FOG product coils on the RWC201-Q1/Q2-FOG.
Supply spool with master spool – application example
Master/slave spool application
* Technical changes, dimensional modifications and design adaptations reserved.
RWC042-F – Technical Data
| Feature | Unit | RWC042-F |
|---|---|---|
| Machine type | Programmable rewinding and preparation unit for FOG supply spools | |
| Function | Pay-off and take-up unit for preparing master and slave spools for the FOG winding process | |
| Application area | Preparation of defined fiber lengths for subsequent processing on the RWC201-Q1/Q2-FOG | |
| Fiber range | µm | 60 – 350, depending on fiber type, bending radius, guide rollers and spool body |
| Fiber length | m | Project-specific, depending on spool size, fiber type and application |
| Max. traverse width | mm | 100 * |
| Max. traverse feed | mm | 99.99 mm / spindle revolution ³ |
| Belt stage 0 – max. spindle speed | rpm | max. 750 |
| Spool concept | Preparation of a connected master/slave spool set for the final FOG winding process | |
| Operating mode | Bidirectional; each machine side can be used as pay-off or take-up axis depending on the process step | |
| Rewinding process | The process can be stopped, moved in reverse direction and then continued under process control | |
| Fiber tension | Process-controlled fiber tension regulation, depending on fiber type, spool body and machine configuration | |
| Fiber guidance | Controlled fiber guidance via traverse axes, guide rollers and defined fiber paths | |
| Fiber spacing / traverse feed | mm | Adjustable from 0 to 25 mm; software resolution 1 µm |
| Mechanical traverse accuracy | µm | Approx. ±5 µm over 300 mm travel distance, depending on mechanical design, calibration and process conditions |
| Parameterized spool width | mm | Pay-off and take-up spool widths can each be parameterized within a range of 0 to 150 mm; software resolution 1 µm |
| Mechanical positioning and traverse accuracy | Dependent on mechanical design, calibration and process conditions | |
| Length measurement | The fiber length is measured process-controlled via a measuring roller. The actual length accuracy depends on calibration, fiber tension, fiber guidance, slip and process conditions. | |
| Automatic stop | Automatic machine stop in case of fiber breakage, empty supply spool or project-specific process conditions | |
| Operator interface | Touchscreen operator interface for entering and managing process parameters | |
| Recipe management | Recipe-based parameterization for recurring spool and fiber combinations | |
| Configurable process data | Fiber type, target fiber length, winding speed, fiber tension, traverse feed, spool width, direction of rotation as well as start and stop ramps | |
| Shafts and adapters | Project-specific adapters for different spool bore diameters, flange diameters and spool widths | |
| Guide rollers | Different guide roller sizes depending on fiber diameter and permissible bending radius | |
| Winding tools / spool bodies | Different winding tools and spool bodies available for different fiber diameters and fiber lengths | |
| Machine design | Bench-top machine; version on base frame with lockable and leveling castors possible on a project-specific basis | |
| Safety | Safety equipment and safety interlock according to the final machine configuration | |
| Conformity | CE conformity according to the final machine version | |
| Optional components | Winding tools, spool bodies, adapters, guide rollers and customer-specific fixtures | |
| Control system | Industrial PC with single-core or dual-core processor ** | |
| Languages | DE, EN, AL, IT, FR, ES, CS, HU, SU, RU, PL, NL, EL, PT, ZH ... | |
| Interfaces | 2× USB 2.0, 1× Ethernet (RJ45), 2× serial (RS232), 1× VGA, foot pedal, digital I/O, 2× PS/2 | |
| Operating system | Robust real-time operating system | |
| Data backup / update | Via USB and Ethernet | |
| Printer connection, optional | USB / parallel ** | |
| Digital/analog I/O, optional | Expandable *** | |
| Display | 15" touchscreen in metal housing as standard *, 12.1" and 15" IP65 touchscreen optional ** | |
| Keyboard | USB wireless keyboard 2.4 GHz ** | |
| Storage | Local: approx. 5,000 winding programs ² Network: approx. 20,000 winding programs *** |
|
| Extensions | Integrated PLC interface for external control available ** | |
| Joystick / teach function | Teach function for manual axis control: CW/CCW spindle rotation, traverse axis left/right | |
| Power consumption | kVA | 1.3 |
| Machine dimensions (W×D×H) | mm | 930 × 563 × 715 |
| Power supply | AC | 230 V – 50 Hz / 16 A |
| Weight | kg | approx. 97 |
** Optional, on request or depending on final machine configuration
*** Expandable on request
² Depending on program size, parameterization and storage/network configuration
³ Technical limits depend on spindle speed, traverse feed, fiber, spool body and process conditions
Intuitive Touch Software for Winding Machines – Powerful & Versatile
The user interface was specially developed for intuitive and efficient touch operation on winding machines.
In addition to essential functions such as Open, Save, Copy, Delete, Edit, and Print winding programs, the software offers numerous advanced features:
- Integrated language switch for international use
- Extensive configuration options
- Service-relevant diagnostic tools
- Tools for system optimization and machine customization
Thanks to its clearly structured interface, the software supports both machine operators in daily production and technical staff during machine configuration and customization.
Home screen – central user interface
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Display of main winding parameters and activated setup functions
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Display of main winding parameters and special functions
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Manual functions
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Programming page for entering all relevant winding parameters
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Programming page with example – copying the right reversal point
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Programming page for entering all relevant winding parameters
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Programming functions & control, winding types extension
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Display and acknowledgment of already corrected errors
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Overview of active error messages
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INPUTS: Configuration of programmable inputs and outputs with various options
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Language switching – also supports Cyrillic and Chinese
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I/O diagnostics incl. forcing function, status queries, and live diagnostics
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Language texts for individual adaptation of interface texts
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System update function for software maintenance
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Backup function
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PLC integration for external control and data exchange
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PLC integration incl. I/O forcing, status monitoring, and live diagnostics
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System settings – basic info
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Network settings
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Process step management
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This interface allows users to open winding programs from various storage sources: internal iSATA drive, USB stick, network drive (FTP server), or USB floppy disk drive.
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As the number of stored programs increases over time, a built-in search function helps streamline selection. By entering the first three characters, the program list is automatically filtered to show relevant matches.
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Programs can also be saved to all of the above storage media, internal iSATA drive, USB stick, network (FTP), and floppy disk drive.
|
RWC042-F – Precision Preparation Unit for FOG Supply Spools
The RWC042-F is a programmable rewinding and preparation unit for optical fibers. It is used to rewind defined fiber lengths from a supply spool onto master and slave spools and to prepare the subsequent FOG winding process on the RWC201-Q1/Q2-FOG.
The final product is not produced on the RWC042-F. The system is used as a process-safe preparation unit for the subsequent production of high-quality FOG product coils using quadrupolar or octupolar winding methods.
🔄 Rewinding from Supply Spools onto Smaller Spool Bodies
In addition to preparing connected master/slave supply spools, the RWC042-F can also be used as a controlled rewinding unit for transferring optical fibers from larger fiber supply spools onto smaller spool bodies. The configuration depends on fiber type, fiber diameter, permissible bending radius, spool geometry and process requirements.
🌀 Applications for FOG, iFOG, rFOG and dFOG
Typical application areas include spool preparation for fiber optic gyroscopes, including FOG (Fiber Optic Gyroscope), iFOG (Interferometric Fiber Optic Gyroscope), rFOG (Resonant Fiber Optic Gyroscope) and dFOG (Digital Fiber Optic Gyroscope), as well as further high-end applications in optical fiber technology, sensor technology, telecommunications and industrial research.
⚙️ Preparation of Master and Slave Spools
For final FOG coil production, the optical fiber must be prepared in a defined way and distributed onto two connected supply spools. The RWC042-F performs this preparation step in a controlled, reproducible and recipe-based process.
This creates a connected supply spool set which is then used on the RWC201-Q1/Q2-FOG for the final FOG winding process.
Preparation of master and slave spools
Controlled rewinding process
Master/slave spool set
🧵 Controlled Fiber Guidance and Length Preparation
The RWC042-F guides the fiber via defined fiber paths, guide rollers and traverse axes. Fiber spacing, spool width, traverse feed, winding speed, direction of rotation as well as start and stop ramps can be parameterized depending on the machine configuration.
The fiber length is measured process-controlled via a measuring roller. The actual length accuracy depends on calibration, fiber tension, fiber guidance, slip and process conditions.
🔁 Bidirectional Operation
The RWC042-F is designed as a bidirectional pay-off and take-up unit. Depending on the process step, each machine side can be used as the pay-off or take-up axis.
The rewinding process can be stopped, moved in reverse direction and then continued under process control. This makes the system particularly suitable for applications requiring flexible process control and defined fiber placement.
🖥️ Recipe-Based Process Control
Operation is carried out via a touchscreen interface with recipe-based parameterization. Recurring spool and fiber combinations can be stored and reused for later applications.
- Fiber type and target fiber length
- Fiber tension and winding speed
- Traverse feed, spool width and traverse parameters
- Direction of rotation as well as start and stop ramps
- Process-dependent winding and rewinding parameters
🧭 Typical Application Areas
- Preparation of supply spools for FOG, iFOG, rFOG and dFOG applications
- Length preparation of optical fibers for master/slave spool sets
- Rewinding from large fiber supply spools onto smaller spool bodies
- Prototype production and laboratory applications for optical fiber systems
- Preparation of fiber spools for aerospace applications
- Preparation of components for defense and security technology
- Fiber optic sensing, delay lines and special fiber applications
- Small-series and series preparation for high-precision fiber winding processes
⭐ Your Advantages at a Glance
- Process-safe preparation of master and slave supply spools
- Controlled rewinding from larger supply spools onto smaller spool bodies
- Bidirectional pay-off and take-up operation
- Recipe-based control for repeatable rewinding processes
- Controlled fiber guidance and process-guided fiber tension control
- Flexible adaptation to different fiber diameters, spool bodies and bending radii
- Ideal preparation unit for the RWC201-Q1/Q2-FOG main winding machine
- Made in Germany – development and manufacturing according to high quality standards
* Technical changes, dimensional modifications and design adaptations reserved.
We will be pleased to advise you individually on your application.