Development of an Impregnation End-Effector with Fiber Tension Monitoring for Robotic Coreless Filament Winding

Abstract

The manufacturing process of robotic coreless filament winding has great potential for efficient material usage and automation for long-span lightweight construction applications. Design methods and quality control rely on an adequate digital representation of the fabrication parameters. The most influencing parameters are related to the resin impregnation of the fibers and the applied fiber tension during winding. The end-effector developed in this study allows efficient resin impregnation, which is controlled online by monitoring the induced fiber tension. The textile equipment was fully integrated into an upscaled nine-axis robotic winding setup. The cyber-physical fabrication method was verified with an application-oriented large-scale proof-of-concept demonstrator. From the subsequent analysis of the obtained datasets, a characteristic pattern in the winding process parameters was identified.

Adaptive winding pin and hooking capacity model for coreless filament winding

“…Almost all the surface discontinuities could be removed, which improved the fiber deposition quality. 40 Additionally, a bottom-mounted 3D-printed adapter was introduced. It could be used to clamp the pin to profiles of a modular fixture system.…”

“…Sleeve/washer combinations 16 (see Figure 1 m and n), which can be fastened with an internal bolt, are most often used in CFW. The combination with metallic fixtures makes them suitable for high fiber tensions, 40 which are typical for large components. Release agents should be applied to washers and bolts.…”

Material Monitoring of a Composite Dome Pavilion Made by Robotic Coreless Filament Winding

“…The curing sequence started and ended at room temperature. The material system [29] of the component is presented in Table 1. The utilized materials fulfill their technical requirements, which are defined by their specific role in the material system.…”

Non-contact techniques based on a vision system for the inspection of composite material components: analysis of the influence quantities

“…Although this method has been in use for an extended period of time, the effect of processing parameters has been investigated to a limited extend and it is still an object of interest to researchers in the field [4].…”

“…In instances where these parameters are critical, it is imperative that tight controls be exercised over the void level and the fiber volume distribution through the thickness of the product. Given the complexity of the interaction between the different process parameters, it is important that these interactions be well understood and controlled to achieve the desired quality [3][4][5][6][7][8].…”