Laser Guided Rod Wrapper Operating Manual V 1.2 Quinchat Rods LLC Machines for Makers of Bamboo Rods www.quinchat.webs.com V 1.2 page 1
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Table of Contents 1. Laser Guided Rod Wrapper Features 2. Assembly Instructions 3. Set Up Procedures 4. Rod Wrapping V 1.2 page 3
1. Laser Guided Rod Wrapper Features Constant thread tension Easily adjustable magnetic thread tension combined with matched weight system for unwinding Rod rotates during wrapping Rotating the rod, rather than the tread, allows visual inspection of the entire wrap. Also much easier to pack the wraps using reverse rotation. Rod is rotated by hand. Climb angle control Repeatable climb angle setting assures tightest possible wrap Un-wrapping capability Wrap counter Unlimited unwinding capability to correct problems Digital encoder counts each rotation, forward or back, to assure both feet have wraps of identical width Easy to graduate width as the guide size changes Collet type chuck Self centering keyless chuck securely grips both the male and female ferrule Laser beam accurately locates guides An overhead line generating laser easily transfers guide location from a story stick to the blank, or from another tip for perfect matching Simplifies layout of evenly spaced intermediate wraps Accurate mapping of component locations prior to starting a restoration project V 1.2 page 4
2. Assembly Instructions The wrapper is shipped in two packages. After removing all packaging material, insert the right end of the 6 alulminum carriage into the left end of linear bearing. As you push it in, the gear rack will engage the pinion gear. Push the carriage about half way thru and then clamp down the wrapper base plate to you work bench as the unit will tip when the carriage is at either end of it s travel. Now slide the headstock into the left hand end of the carriage to the position indicated. The laser is powered by (4) AAA batteries. There is a slide switch on the battery case. This case is mounted to the frame with double-sided tape and is easily removed to change batteries. The counter is powered by a 9 Volt dc wall adaptor. Plug it into the rear of the box and it is ready to go. If power is inadvertently interrupted, the count is retained when power is restored. When you power the counter, a Cub4 logo will be displayed briefly followed the version number of the software. Next, count numerals to two decimal places will be displayed which represents the number of wraps. If perchance an R is displayed at the left hand edge of the screen, push the Sel button and the screen will revert to counts. The R indicates the tachometer feature is active. It will not come up again unless the Sel button is inadvertently pushed. This electronic counter is programmable for many uses. The programming mode is locked-out to prevent inadvertent changes. The counter s manual is provided with the wrapper and we will provide the access code if you wish to make changes. The basic version of the Laser Guided Rod Wrapper is supplied without the electronic counter. It can be added at a later date by returning the headstock to Quinchat Rods for a retrofit. V 1.2 page 5
1. Set Up The ferrule end of the rod section to be wrapped is mounted in the collet chuck and the outboard end is supported in one or more V block stations. A second smaller chuck is provided for the smaller male ferrules on 3 piece rods. The rod section to be copied is mounted in the lower V-groove and secured with the toggle clamp. Alternately a story stick can be mounted in the V-groove. The laser needs to be aligned. First we set up the angle of the laser line in the horizontal plane using the white setup block. Thumb Wheel Vert angle Adjustment Nylon Set Screw Adjust horizontal angle to 90 deg by turning the thumb wheel on the laser housing. Lock in place with the nylon set screw. Adjust vertical angle to 90 deg by rotating the block holding the laser. Lock in place with the black knob. V 1.2 page 6
The entire laser assembly can be moved left or right on the aluminum track and locked in place with the small black knob. Thread spools are mounted on a spindle and secured with the steel thumb wheel. Tapered copper ferrules are used on each side to keep the spool perfectly centered on the spindle. The spindle is mounted on a 1/8 dia rod and the magnet pulls it up against the gap adjustment disc. Thread tension is changed by moving the disc closer or farther away from the magnet. The disc is a tight fit on the rod and it takes some effort to move it. The thread routing is shown here. The counter weight provides take-up when unwinding a wrap. The steel knob on the spool carriage can be used to rewind thread on the spool and return the weight to the up position. Weight can be increased by adding 3/8-16 nuts. Note that the tip tops have slits for ease of threading. The right hand thread goes thru the lower final guide and the left thread thru the upper guide. I like to adjust the tension such that the weight almost allows the spool to unwind. V 1.2 page 7
Between wraps, thread is parked on the small extension spring. Simply pull the thread up against and into the spring while bending it with a free finger. Once secured, cut the thread on the knife edge embedded in the frame. The cylindrical thread alignment gage is used to adjust the climb angle of the wraps. Here we are using oversize orange thread for clarity. First this alignment gage must be calibrated. Hold the white setup block against the rod and move the carriage to get a perfect 90 degree angle of thread to rod. Now raise the cylindrical gage up against the thread. If the thread is not aligned with the center red mark, screw the cylinder in or out to achieve alignment. Once aligned, you can adjust the climb angle by moving the carriage left or right of the red line to get the proper climb for the tightest possible wraps. The center line (red line) on the gage is at 90 degrees which is zero climb angle. Note from the photos that the tiptop guiding the thread is mounted on a hex head screw and there is a second tiptop above that guides the thread from the left hand spool. You can rotate the hex head screws to make sure both threads are on the same centerline. V 1.2 page 8
2. Rod Wrapping Here we discuss the mechanics of operating the Laser Guided Rod Wrapper. The techniques described are the methods that I use. Your techniques should be made easier using this wrapper. The ferrule end of either the butt or tip sections are chucked in the collet. Two collets are provide with the machine, a large one for 2 pc rods and a smaller one for the smaller tip ferrules of 3 pc rods. Collets are change by loosening the set screw that secures the collet to the encoder shaft. The ferrule is inserted into the collet and tightened by hand. Be sure to push the ferrule all the way into the collet. A couple of layers of masking tape on the ferrule will improve the grip. Mount your story stick marked with the guide locations in the V groove at the base of the head stock. Now move the carriage left or right to align the laser on the ferrule tips. Now move the story stick to align the end of ferrule mark with the laser and clamp in place with the miniature toggle clamp. Since the laser does have some width, do your alignment with either the right or left edge of the beam. There are two outboard supports to hold the free end. Secure with the fabric covered elastic bands. V 1.2 page 9
Mount a small rubber band on the rod using a crochet hook. Loop it thru twice and then roll it up on the guide foot. Using the laser, align the guide with the guide location mark on the story stick. If you want to be double sure that the guide does not move, apply some automotive detailing tape to the tip of the left hand foot. Now make 2 wraps by hand over the foot and overlap the thread over these two wraps. Now reset the counter to zero and start wrapping. I generally go about 10 wraps and then push the wraps tight with my thumbnail on each flat while reversing the rotation. I then cut the tag end. The counter resolves each rotation into 100 steps and subtracts counts when reversing. You can use the thread angle guide to set the climb angle which determines how tight the current wrap is crowded against the previous wrap. When the thread is directly over the red line, it is being applied at a right angle to the rod. Obviously, too much climb angle result in over wrapping and too little produces a open V 1.2 page 10
spiral. You adjust the climb angle by moving the carriage with the fine adjustment knob. For this guide I have wrapped 2 manual turns plus 25 on the counter. Now I will make the single trim wrap. First I mark the thread for the end of the trim wrap. Then unwind to place the mark over the alignment rod. Check the counter and unwind exactly one turn and mark the thread again over the alignment rod. Now ink the tread between the two marks. Now wrap forward to 31 on the meter and pack tightly. Back up to turn 27, insert the pull loop, return to 30, cut the thread and pull thru. Now we have a completed wrap with 27 turns of the base color, the 28 th wrap is black plus 5 additional wraps of the base color. I generally wrap all the left hand feet first and then come back and wrap the right hand feet. V 1.2 page 11
3. Notes The laser is powered by (4) AAA batteries. There is a slide switch on the battery case. This case is mounted to the frame with double-sided tape and is easily removed to change batteries. The counter is powered by a 9 Volt dc wall adaptor. Plug it into the rear of the box and it is ready to go. If power is inadvertently interrupted, the count is retained when power is restored. This electronic counter is programmable for many uses. The programming mode is locked-out to prevent inadvertent changes. The counter s manual is provided with the wrapper and we will provide the access code if you wish to make changes. I generally wrap with the least amount of thread tension as measured at the rod about 10 to 15 grams. This makes it easier to flatten the wraps with a burnisher. The pinion gear is secured to the shaft with a set screw. It can be accessed thru the half moon slot in the platform when the carriage is removed. We also offer a Wrap Finishing Station that handles 4 sections from start to finish. Check it out at www.quinchat.webs.com. V 1.2 page 12