Sensor-Controlled Fiber Roving Impregnation for Robotic Winding
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Solution Overview
Problem
Conventional wet impregnation processes for fiber rovings are limited in automating complex three-dimensional parts due to restricted robot movement and increased collision risk, and suffer from crosslinking reactions in open matrix baths, restricting the use of certain matrix materials.
Innovation Solution
A system with a feed unit, impregnation unit, tension sensing, speed sensor, and control means to monitor and adapt fiber roving tension and speed, and regulate matrix material supply, ensuring homogeneous impregnation through continuous parameter adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bath of matrix material is used for wet impregnation, then fiber roving can be impregnated with matrix material, but the robot's freedom of movement is restricted and collision risk increases
Solution Approach 1:
The system divides the impregnation process into discrete segments: the matrix supply unit remains stationary while the impregnation unit with its applicator head can move independently with the robot. This segmentation allows the robot to move freely while maintaining continuous matrix supply to the impregnation zone.
Solution Approach 2:
The matrix supply is delivered through a flexible hose from a stationary supply unit, adding a dimensional degree of freedom. Instead of constraining the robot in a fixed bath, the matrix can be supplied through a flexible connection that accommodates robot movement in multiple axes.
2Reliability
If a bath of matrix material is used for wet impregnation, then fiber roving can be impregnated, but the risk of collision between winding tool and roving increases
Solution Approach 1:
By separating the matrix supply unit from the impregnation unit, the system allows the impregnation unit to be positioned optimally without the constraints of a fixed bath, reducing the likelihood of collisions between the winding tool and fiber roving.
Solution Approach 2:
The system employs dynamic positioning of the impregnation unit that can adapt to the robot's movement and winding tool position, maintaining optimal impregnation geometry while avoiding collision zones.
3Ease of manufacture
If an open process with a bath of matrix material is used, then impregnation can be performed, but crosslinking reactions occur changing viscosity and negatively impacting subsequent impregnation
Solution Approach 1:
The system uses periodic or controlled dispensing of matrix material through the impregnation unit, allowing fresh matrix to be supplied at regular intervals, preventing prolonged exposure that would lead to crosslinking and viscosity changes.
Solution Approach 2:
The harmful element (prolonged exposure to matrix in open bath) is removed by using a controlled impregnation unit that applies matrix only when needed and for the minimum necessary duration, extracting the problematic prolonged exposure from the process.
4Adaptability or versatility
If TowPreg is used for dry winding, then pre-impregnated fiber rovings are available, but storage in freezer and limited shelf life are required
Solution Approach 1:
The system performs preliminary impregnation on-demand just before winding, eliminating the need for pre-impregnated rovings with limited shelf life. The matrix is applied to the fiber roving immediately before use, ensuring maximum freshness and eliminating storage constraints.
Solution Approach 2:
The system enables self-service impregnation where the matrix is supplied and applied automatically at the point of use, eliminating dependency on pre-prepared TowPreg products with fixed shelf lives and enabling unlimited production duration.
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
Enables fully automated, high-quality impregnation of various fiber types with any matrix, achieving consistent impregnation across complex shapes, reducing collision risks, and maintaining matrix viscosity, thus enhancing production flexibility and repeatability.
Implementation Method 1
a tension sensing unit adapted to determine a tension of the fiber roving fed from the feed unit to the impregnation unit
Implementation Method 2
a speed sensor for determining a speed of the fiber roving fed from the feed unit to the impregnation unit
Implementation Method 3
a matrix supply unit fluidically connected to the impregnation unit for supplying liquid matrix material to the impregnation unit
Data Source
AI summary
A system for producing an impregnated fiber roving, the system including a feed unit having a spool with a fiber roving, an impregnation unit configured for applying liquid matrix material onto the moving fiber roving fed from the feed unit, a matrix supply unit fluidically connected to the impregnation unit for supplying liquid matrix material to the impregnation unit, a tension sensing unit adapted to determine a tension of the fiber roving fed from the feed unit to the impregnation unit, a speed sensor for determining a speed of the fiber roving fed from the feed unit to the impregnation unit, control means configured for monitoring the tension determined by the tension sensing unit and adapting the speed of the fiber roving depending on the monitored tension, monitoring the fiber roving speed determined by the speed sensor and adapting the supply of liquid matrix material based on the monitored fiber roving speed.