Fiber Scrim Web Tension Control via Secondary Drive Feedback
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Solution Overview
Problem
The automated production of glass fiber-reinforced and carbon fiber-reinforced components faces challenges due to tension and distortion issues in fiber scrim webs, leading to uneven conveying and potential delamination of layers during processing, which requires manual corrections and results in rejects.
Innovation Solution
The implementation of a secondary drive with a force sensor for feedback-control, combined with a primary drive, ensures stable and uniform conveying of the fiber scrim web by measuring and adjusting web tension, and the use of elastic drive rollers to compensate for thickness fluctuations, preventing delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single drive is used to convey the fiber scrim web, then the device structure is simple, but tensions and distortions arise in the web
Solution Approach 1:
The single drive system is segmented into multiple independent drives (primary drive and secondary drive) that can operate separately. Each drive has its own control loop, allowing independent optimization of tension control while maintaining overall system simplicity through modular architecture.
Solution Approach 2:
Force sensors are integrated into both drive systems to provide real-time feedback on web tension. The control units receive this feedback and automatically adjust drive parameters to maintain uniform tension, eliminating distortions without requiring complex manual intervention.
2Ease of operation
If manual processing is used to handle variations in web tension, then processing flexibility is maintained, but productivity decreases and rejects increase
Solution Approach 1:
The drive systems are equipped with self-regulating capabilities through feedback control. The force sensors and control units automatically detect and correct tension variations without requiring manual intervention, enabling the system to self-service and maintain optimal processing conditions continuously.
Solution Approach 2:
Real-time feedback from force sensors enables automatic adjustment of drive parameters, allowing the system to respond dynamically to web tension variations. This eliminates the need for manual monitoring and correction, significantly improving productivity while maintaining processing flexibility.
3Device complexity
If web tension is not uniformly controlled, then the conveying process is simple, but delamination of layers occurs
Solution Approach 1:
The tension control system is divided into multiple independent control loops for different drive systems. Each loop independently monitors and controls tension in its section, ensuring uniform overall tension distribution. This segmented approach prevents localized stress concentrations that could cause delamination.
Solution Approach 2:
Force sensors provide continuous feedback on web tension to control units, which automatically adjust drive parameters to maintain uniform tension throughout the conveying process. This feedback mechanism ensures consistent layer bonding by preventing tension variations that could lead to delamination.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution achieves uniform web tension control and reduces manual intervention, minimizing delamination and rejects by optimizing web tension across the processing device, enhancing the efficiency of fiber-reinforced plastic production.
Implementation Method 1
a force-measuring assembly, assigned to the secondary drive, having a force sensor for measuring a web tension of the fiber scrim web
Implementation Method 2
a drive roller of a drive has a casing of an elastic material, in particular a foam material, by means of which thickness fluctuations of the fiber scrim web can be compensated in a conveying direction
Data Source
AI summary
The invention relates to a device for processing fibre-reinforced plastic, more particularly for producing structural components for aircraft (2) or preforms for same, said device comprising at least two functional units (4), the functional units (4) comprising at least one feed unit (5) for feeding a laid fibre scrim web (6) and a processing unit (8) for processing the laid fibre scrim web (6), with a primary drive (9) for driving the laid fibre scrim web (6), with a control arrangement (10) for open-loop or closed-loop control of the primary drive (9). According to the invention the device (3) has at least one secondary drive (11) for driving the laid fibre scrim web (6), the device (3) has a force-measuring device (12) associated with the secondary drive (11), with a force sensor (13) for measuring a web tension in the laid fibre scrim web (6) by means of the control arrangement (10), the control arrangement (10) controls the secondary drive (11) in a feedback control routine, the feedback control routine comprises a secondary feedback circuit (14) to control the secondary drive (11), the control arrangement (10) in the feedback control routine supplies the web tension measured by the force-measuring device (12) associated with the secondary drive (11) as an actual value (15) to the secondary feedback circuit (14) and determines and sets a controlled variable (16) for the secondary drive (11) on the basis of the web tension in the secondary feedback circuit (14).