Abstract

Filament winding has emerged as the main process for carbon fiber reinforced plastic (CFRP) fabrication, and tension control plays a key role in enhancing the quality of the winding products. With the continuous improvement of product quality and efficiency, the precision of the tension control system is constantly improving. In this paper, a novel tension control method is proposed, which can regulate the fiber tension and transport speed of the winding process by governing the outputs of three different driven rollers (the torque of the unwind roll, the torque of the magnetic powder brake roller, and the speed of the master speed roller) in three levels. The mechanical structures and dynamic models of the driven rollers and idle rollers are established by considering the time-varying features of the roller radius and inertia. Moreover, the influence of parameters and speed variation on fiber tension is investigated using the increment model. Subsequently, the control method is proposed by applying fiber tension in three levels according to the features of the three driven rollers. An adaptive fuzzy controller is designed for tuning the PID parameters online to control the speed of the master speed roller. Simulation is conducted for verifying the performance and stability of the proposed tension control method by comparing with those of the conventional PID control method. The result reveals that the proposed method outperforms the conventional method. Finally, an experimental platform is constructed, and the proposed system is applied to a winding machine. The performance and stability of the tension control system are demonstrated via a series of experiments using carbon fiber under different reference speeds and tensions. This paper proposes a novel tension control method to regulate the fiber tension and transport speed.

Highlights

  • High modulus carbon fiber is an excellent industrial material, which is widely used in several fields such as satellite supporting cylinder, shells of rocket engine, and solar array

  • Filament winding has emerged as the main process for fabricating composite structures

  • In the filament winding process, the carbon fiber is delivered from the unwind roll and passed through the resin bath to mix with resin under different temperatures and wrap around the surface of the mandrel in the designed pattern

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Summary

Introduction

High modulus carbon fiber is an excellent industrial material, which is widely used in several fields such as satellite supporting cylinder, shells of rocket engine, and solar array. Most research focused on dynamic modeling and control strategy design, but the mechanical structure and the influence of parameter variation on fiber tension were ignored. According to the features of driven rollers and the influence of variation, the control method is proposed by regulating the outputs of the torque of unwind roll, the torque of magnetic powder brake roller, and the speed of the master speed roller in three levels. The control system can regulate the tension and speed of the filament winding process by governing the output of three different driven rolls—the torque of the unwind roll, the torque of the magnetic powder brake roller, and the speed of the.

Magnetic Brake Roller
Conventional Method
Experiments
Conclusions
Full Text
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