Filament Winding System with Shape Compensation
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Solution Overview
Problem
The existing filament winding method for producing high-pressure fluid tanks does not adequately account for variations in the shape of the winding object, leading to potential winding errors and reduced strength of the tank.
Innovation Solution
A filament winding system that includes a storage unit for reference shapes and winding conditions, a movable guide for fiber placement, a rotating device, a measuring unit for shape measurement, and a controller to adjust winding conditions based on actual object shape, ensuring accurate fiber placement and reducing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the existing filament winding method is used without considering shape variations, then the winding process is simple and fast, but winding errors occur due to shape variations of the winding object
Solution Approach 1:
The system performs preliminary shape measurement of the winding object before the winding process begins. The measured shape data is stored and used to pre-calculate compensation values for winding position and angle. This preliminary action allows the system to account for shape variations before actual winding occurs, ensuring accurate fiber placement without adding complex real-time adjustment mechanisms during the winding process.
Solution Approach 2:
The system implements a feedback mechanism where the measured shape of the winding object is fed back to the control unit. The control unit compares the actual shape with the reference shape and automatically adjusts the winding position and angle parameters accordingly. This closed-loop feedback ensures that winding errors caused by shape variations are compensated, improving manufacturing precision without requiring complex manual intervention.
2Reliability
If the winding conditions are fixed based on reference shape, then the control process is simple, but winding errors occur when the actual shape differs from the reference shape
Solution Approach 1:
The system transitions from fixed winding conditions to dynamic adaptive control. The control unit automatically adjusts winding position and angle parameters based on the measured shape data of each specific winding object. This dynamic adjustment ensures that the winding process adapts to actual shape variations, maintaining consistent winding quality and reliability across different objects without requiring manual reconfiguration.
Solution Approach 2:
The system changes the winding parameters (position and angle) dynamically based on the measured shape characteristics. Instead of using fixed parameters from the reference shape, the control unit modifies these parameters according to the actual shape deviations detected during measurement. This parameter adaptation ensures reliable winding quality even when shape variations occur, balancing automation with quality consistency.
3Manufacturing precision
If shape measurement and correction are implemented, then winding accuracy is improved, but the measurement and control process becomes more complex
Solution Approach 1:
The system replaces complex mechanical adjustment mechanisms with automated measurement and control systems. Instead of using complex mechanical devices to physically adjust winding positions based on shape variations, the system uses shape measurement data to computationally determine and automatically apply correction parameters to the winding process. This substitution of mechanical complexity with automated control achieves high winding accuracy while maintaining relatively simple hardware.
Data Source
AI summary
A filament winding system includes a storage unit that stores in advance a reference shape of a winding object, and winding conditions including a winding position and a winding angle at which a fiber is wound around the winding object having the reference shape, a guide that is movable relative to the winding object, and feeds the fiber onto the winding object, a rotating device that rotates the winding object, such that the fiber fed from the guide is wound around the winding object, a measuring unit that measures a shape of the winding object, and a controller. When there is a difference between the reference shape stored in the storage unit, and the measured shape of the winding object, the controller corrects the winding conditions so as to reduce or eliminate the difference, and controls the guide according to the corrected conditions.