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RESEARCH PAPERS

Actual Safety Distance and Winding Tension to Manufacture Full Section Parts by Robotized Filament Winding

[+] Author and Article Information
W. Polini

Dipartimento di Ingegneria Industriale, Università degli Studi di Cassino, Via G. di Biasio, 43, 03043 Cassino, Italy

L. Sorrentino1

Dipartimento di Ingegneria Industriale, Università degli Studi di Cassino, Via G. di Biasio, 43, 03043 Cassino, Italysorrentino@unicas.it

1

Corresponding author.

J. Eng. Mater. Technol 128(3), 393-400 (Dec 23, 2005) (8 pages) doi:10.1115/1.2203099 History: Received May 17, 2005; Revised December 23, 2005

Robotized filament winding technology allows one to manufacture workpieces of high performances as a result of a robot placing fibers impregnated by resin (known as roving) along the directions of stresses the workpiece is subjected to in exercise; thus, robotized filament winding favors rigidity and strength of a workpiece along some preferential directions. A proper value of the winding tension has to be chosen and kept constant along the whole winding in order to limit the defects inside the composite workpieces. To keep the tension value on roving near to the nominal value, one must plan the value of the geometric parameters characterizing the winding trajectory. The same geometric parameters influence the value of the actual safety distance that may involve collisions among the deposition system and the components of the robotized cell. This work shows how to avoid the occurrence of collisions by planning the value of the actual safety distance through the definition of geometric parameters that characterize the winding trajectory. Moreover, the collision occurrence should be considered together with the control of the winding tension on the roving in the robotized filament winding planning stage. The present work shows how to solve both the problems previously defined (i.e., to keep the winding tension on roving near to the nominal value and to avoid collision occurrence), by the solution of a constrained optimization system.

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Copyright © 2006 by American Society of Mechanical Engineers
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Figures

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Figure 1

Examples of parts belonging to the considered family

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Figure 2

Number of points n, trajectory angle θ, and safety distance d of the winding trajectory

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Figure 3

Dimensions (in millimeters) of the irregular ring used as benchmark

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Figure 4

(a) Full section and barycenter path of part “c” seen in Fig. 1; (b) whole part derived by sweeping the full section along the barycenter path

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Figure 5

(a) Winding die of benchmark, (b) fill of the full section of part by roving coils

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Figure 6

Wound roving layers

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Figure 7

3D view of two examples of winding trajectory planned with: (a) benchmark, on the left; (b) control volume (characterized by a safety distance d), on the right

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Figure 8

Winding trajectory farther than the nominal safety distance of 50mm(n=14,θ=90deg) from the winding die

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Figure 9

Values of the actual safety distance d* for each point of a winding trajectory characterized by the following nominal geometric parameters: n=14, d=50, and θ=90deg

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Figure 10

Maximum and minimum values of the actual safety distance d*

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Figure 11

Roving winding along the planned winding trajectory by the deposition system

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Figure 12

Main effect plots of the actual safety distance (d*) versus the geometric parameters of the winding trajectory (n, d, and θ)

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Figure 13

Winding trajectories for d=50mm; n=14,44; θ=90deg,100deg

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Figure 14

Winding trajectory to manufacture a fork

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