Adjustable Roller Segments for Fibrous Preform Winding
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Solution Overview
Problem
The shaping of fibrous preforms with evolving profiles in composite material reinforcement is hindered by tension imbalances, leading to defects like waviness, fiber buckling, and uneven thickness, which complicates the winding process and results in suboptimal part quality.
Innovation Solution
An installation with follower rollers featuring adjustable roller segments and tension sensors allows for real-time modification of the external surface profile, maintaining uniform tension and reducing defects by locally adapting the tension during the winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If follower rollers with fixed variable radius are used to maintain yarn length ratios during winding, then consistent tension can be maintained initially, but tension imbalances and defects (waves, fiber buckling, pinching) occur when the fibrous texture is wound around itself multiple times and profile ratios change significantly
Solution Approach 1:
The follower roller is designed with adjustable roller segments that can dynamically modify their external surface profile during the winding process. Each roller segment can be independently adjusted to compensate for changing tension requirements as the fibrous texture is wound around itself multiple times, maintaining both tension consistency and profile accuracy throughout the entire winding operation
Solution Approach 2:
The follower roller is divided into multiple independent roller segments, each capable of individual adjustment. This segmentation allows different portions of the roller to be optimized for different stages of the winding process, enabling precise control over tension distribution and profile formation as the fibrous texture undergoes repeated winding cycles
2Shape
If the fibrous texture is wound around itself several times to create evolving profile, then the final part shape can be achieved, but tension losses and misalignment occur at certain axial positions leading to defects
Solution Approach 1:
The system incorporates tension sensors that continuously monitor the tension in the fibrous texture during winding. This feedback information is used to adjust the roller segments in real-time, compensating for tension losses and misalignment that occur as the texture is wound around itself multiple times, thereby maintaining tension uniformity while achieving the desired evolving profile
3Device complexity
If fixed follower rollers are used for the entire winding process, then the device complexity is low, but the process requires stopping and replacing rollers when profile changes require different tension characteristics
Solution Approach 1:
The follower roller segments are designed to be adjustable during operation, eliminating the need to stop production for roller replacement. The segments can be modified in real-time to match changing profile requirements, enabling continuous production while maintaining the simplicity of a single roller component structure
Data Source
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AI summary
Installation for forming an axisymmetric fibrous preform having, in radial cross-section, an evolving profile, comprising a storage mandrel (300) intended to store a fibrous texture (210) in the form of a wound strip, one or several follower rollers (400, 500) and an axisymmetric mould (600), the storage mandrel, each follower roller and the mould having on their axial width a variable radius defining an outer surface that has a raised profile, at least one follower roller comprising a plurality of roller segments, each extending over a part of the axial width of the follower roller, each roller segment comprising a skirt defining a part of the outer surface of the follower roller; and an actuation system able to move the skirt in a radial direction in relation to the axis of the follower roller.