Composite Winding Machine Tension Control
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Solution Overview
Problem
The production of composite material gas turbine casings for aeronautical engines faces challenges in transferring and winding fibrous textures onto impregnation mandrels, requiring precise placement and controlled tension to ensure proper compaction and fiber content, which existing machines fail to consistently achieve.
Innovation Solution
A winding machine with a control unit for electric motors to manage winding tension, optical sighting means for alignment, and optional heating and water spraying systems to facilitate the transfer and shaping of fibrous textures onto impregnation mandrels, enabling automated and precise winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual transfer and winding of fibrous texture is used, then placement flexibility is maintained, but manufacturing precision and consistency deteriorate
Solution Approach 1:
The system uses optical sighting means that automatically detect misalignment and trigger correction movements of the take-up mandrel without human intervention. The control unit autonomously processes optical signals and actuates correction mechanisms, enabling the system to self-correct placement errors and maintain high precision throughout the winding operation.
Solution Approach 2:
Manual mechanical alignment and tension control are replaced by an automated system combining optical detection means, electronic control units, and motorized correction mechanisms. This substitution of manual mechanical operations with automated sensor-actuator systems achieves consistent high precision while managing device complexity through integrated control.
2Manufacturing precision
If winding tension is not controlled, then operation simplicity is maintained, but manufacturing precision and fiber content consistency deteriorate
Solution Approach 1:
The control unit continuously monitors winding parameters and adjusts motor operation to maintain constant tension during the winding process. This feedback control ensures consistent compaction and fiber content throughout the fibrous preform, achieving manufacturing precision while automating tension management to preserve operational simplicity.
3Productivity
If automated winding control is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The control unit performs multiple functions: it controls motor speed and tension, processes optical alignment signals, triggers correction movements, and monitors winding parameters. By consolidating these diverse control functions into a single multi-functional controller, the system achieves high productivity through full automation while managing device complexity through functional integration.
Data Source
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AI summary
A winding machine for winding a fiber texture on an impregnation mandrel, the winding machine including: a takeup mandrel for storing a fiber texture, the takeup mandrel having an axis of rotation; an impregnation mandrel for having superposed layers of the fiber texture stored on the takeup mandrel wound thereon, the impregnation mandrel having an axis of rotation that is substantially parallel to the axis of rotation of the takeup mandrel; at least one electric motor for driving the mandrels in rotation about their respective axes of rotation; and a control unit for controlling the at least one electric motor for driving the mandrels in rotation.