Resin-Impregnated Fiber Bundle Winding Control
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Solution Overview
Problem
In the filament winding process, the fiber bundles experience tension during conveyance and rolling, leading to an uneven distribution of resin, resulting in a surplus resin layer that does not contribute to product performance, causing slippage and quality issues due to imbalanced process tension and resin viscosity.
Innovation Solution
A method involving an unwinding step, a winding step with resin adhesion and fiber content calculation, and surplus resin layer thickness measurement to control resin adhesion amount, winding tension, and resin viscosity, ensuring accurate fiber content and layer thickness calculation using outer diameter measurements to improve product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If fiber bundles are given tension during conveyance and rolling to maintain stable formation and prevent loosening, then fiber bundle stability is improved, but resin distribution becomes uneven causing surplus resin layer and slippage
Solution Approach 1:
The patent applies preliminary action by pre-calculating the required resin adhesion amount based on the fiber bundle tension state before the winding process begins. This allows the resin impregnation to be optimized in advance, ensuring that the resin distribution remains uniform even when tension is applied to maintain fiber bundle stability during conveyance and rolling.
Solution Approach 2:
The patent implements feedback control by continuously monitoring the fiber content in the resin-impregnated fiber bundle during the winding process. The measured fiber content is fed back to adjust the resin adhesion amount in real-time, compensating for the uneven resin distribution caused by fiber bundle tension and preventing the formation of surplus resin layer.
2Reliability
If resin adhesion amount is increased to ensure sufficient impregnation, then fiber impregnation quality is improved, but surplus resin layer is generated on the outer surface
Solution Approach 1:
The patent applies partial action by calculating and applying only the necessary amount of resin required for adequate fiber impregnation, avoiding excessive resin application. The resin adhesion amount is precisely controlled based on the fiber bundle characteristics and winding conditions, ensuring sufficient impregnation quality without generating surplus resin layer on the outer surface.
Solution Approach 2:
The patent changes the resin adhesion amount parameter dynamically based on the measured fiber content and winding conditions. By adjusting this parameter in real-time, the system achieves optimal impregnation quality while minimizing surplus resin generation, resolving the contradiction between adequate impregnation and resin waste.
3Manufacturing precision
If fiber content is precisely controlled to meet product specifications, then product quality is improved, but process complexity increases due to multiple measurements and calculations
Solution Approach 1:
The patent applies universality by designing a measurement and control system that performs multiple functions: it measures fiber content, calculates resin adhesion amount, and controls the winding process parameters all within a single integrated system. This multi-functional approach achieves precise fiber content control while minimizing the increase in overall process complexity.
Solution Approach 2:
The system applies self-service by automatically calculating the required resin adhesion amount and adjusting process parameters based on real-time fiber content measurements, without requiring complex external intervention. The control system serves itself by using its own measurement data to make adjustments, simplifying the overall control architecture while maintaining high manufacturing precision.
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 method ensures improved product quality by stabilizing fiber content and resin distribution, preventing slippage and resin loss, and optimizing production conditions based on the resin-impregnated fiber bundle after winding.
Implementation Method 1
the capacitance of the fibers impregnated with the resin is measured, and the amount of the impregnating resin in the fibers is measured on the basis of the measurement results. Specifically, by measuring a change in the capacitance by making the fibers impregnated with the resin travel between two parallel plates constituting a capacitance sensor in no contact
Data Source
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Figure 6~8(B)
AI summary
Provided is a method for producing a resin-impregnated fiber bundle roll body, the method comprising at least an unwinding step in which a fiber bundle is unwound from a bobbin and a winding step in which a winding head moves freely with respect to a winding core rotating on a fixed shaft and a product is obtained by winding the fiber bundle on the winding core, wherein, between the unwinding step and the winding step, a guiding step is provided in which a guide member for guiding the fiber bundle unwound in the unwinding step to the winding step. In either the guiding step or the winding step, a resin attaching operation for impregnating the fiber bundle with a resin is performed, and, a fiber content calculating operation for calculating the fiber content Vf [%] of a resin-impregnated fiber bundle layer in an intermediate product, on which a winding operation of winding the resin-impregnated fiber bundle on the winding core is being performed in the winding step, is additionally performed. One or more among the amount of the resin attached in the resin attaching operation, the winding tension of the fiber bundle on the intermediate product, the removed amount of surplus resin layer generated on the outer surface of the intermediate product, and the viscosity of the resin on the intermediate product are controlled according to the value of the fiber content Vf [%]. According to the present invention, the state of the resin-impregnated fiber bundle layer after winding is recognized and reflected in the production conditions, and thus the method contributes to improving product quality.