Follower Roller Backing System for Crease-Free Fiber Preform Winding
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Solution Overview
Problem
The existing methods for shaping fiber preforms for composite material parts with varying radial sections are prone to creases due to deviations in weaving, deformation, and sliding over sloping surfaces, leading to time-consuming manual corrections and interruptions in the tensioning process.
Innovation Solution
An installation comprising a storage mandrel, follower rollers with sloping profiles, and complementary backing rollers that apply contact pressure or maintain a predetermined distance to prevent creases, increasing friction and adapting to changes in thickness, thereby preventing crease formation during the winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the fiber texture is wound under tension over sloping portions of follower rollers, then the yarn-length ratios are conserved and the profile is maintained, but creases form in the texture due to deviations in weaving, deformation, and sliding
Solution Approach 1:
A backing roller is introduced as an intermediary element between the follower roller and the fiber texture. This backing roller supports the fiber texture from behind, preventing it from sliding and creasing over the sloping portion of the follower roller while maintaining the necessary tension and profile accuracy.
Solution Approach 2:
The backing roller applies preliminary counteracting force to prevent the harmful effect of sliding and creasing before they can occur. By positioning the backing roller to contact the fiber texture at the sloping portion, the system preemptively eliminates the condition that would lead to crease formation.
2Reliability
If manual correction of creases is performed during winding, then the texture can be made flat again, but the process becomes time-consuming and requires interruption of tensioning
Solution Approach 1:
The backing roller enables the system to prevent creases automatically during the winding process, eliminating the need for manual intervention. The continuous support provided by the backing roller ensures that the fiber texture remains crease-free throughout winding without requiring stopping or manual flattening.
Solution Approach 2:
The backing roller maintains continuous support and tension on the fiber texture throughout the winding process, ensuring that the useful action of winding proceeds without interruption. This continuous support prevents creases from forming in the first place, maintaining both surface quality and productivity.
3Adaptability or versatility
If follower rollers have sloping profiles to conserve yarn-length ratios, then the varying profile of the part is achieved, but the texture slides and deforms causing creases
Solution Approach 1:
The backing roller serves as a mediator that allows the sloping profile of the follower roller to function for profile variation while simultaneously preventing texture deformation. It provides the necessary support to maintain texture uniformity during passage over the sloping portion.
Solution Approach 2:
The backing roller provides localized support specifically at the sloping portion of the follower roller where creases would form. This local intervention maintains texture uniformity at the critical location while allowing the overall sloping profile to remain for adaptability to varying part geometries.
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
Significantly reduces the risk of creases in the fiber texture, ensuring continuous tensioning and efficient shaping of axisymmetric fiber preforms with varying profiles, eliminating the need for manual corrections and improving fabrication efficiency.
Implementation Method 1
The installation includes holder means for said at least one backing roller configured to hold said backing roller at a predetermined distance from the first slope and the portion adjacent to said first slope or configured to apply contact pressure from the backing roller against the first slope and the portion adjacent to said first slope
Implementation Method 2
the texture is tensioned by the storage mandrel, also referred to as the 'takeup' mandrel, with one or more follower rollers being placed between the storage mandrel and the injection mold
Data Source
AI summary
An installation for forming a fiber preform, includes a follower roller. The follower roller presents a profile in section that has at least a first slope forming an angle with the axis of the follower roller and a second slope forming a second angle with the axis of the follower roller that is different from the first angle. The installation also has at least one backing roller presenting a shape complementary to the first and second slopes, the installation including a holder for holding each backing roller and configured to hold the backing roller at a predetermined distance from the first and second slopes or configured to apply contact pressure from the backing roller against the first and second slopes.