Designing a filament winding machine involves two major components. First component is the designing of the mechanism which delivers appropriate winding pattern as specified by the user (i.e. the winding angle). The second component is the realization of an effective fiber tensioning system for ensuring consistent overall consolidation. Today, there exist a variety of sophisticated methods to achieve both these parameters; however the implementation of these techniques increases the price of a winding machine, making its acquisition very difficult for small scale applications. Sophisticated winding machine includes higher number of degrees of freedom, and high end CNC controlled algorithms. However for creating axi-symetric products with constant diameter, only a 2-axis winding is sufficient. On this note a novel cost effective method for fiber winding angle control and fiber winding tension control is designed, simulated, implemented into a low cost prototype 2-axis filament winding machine, and the scope for its? further improvement has also been discussed. The system designed, uses a cost effective PLC as the centralized controller of the system for implementing both fiber winding control and tension control through PID control. A novel actuator for tension control is designed and implemented. Also a comparison between the conventional PI controller and a Mamdani type Fuzzy inference based control system for controlling the fiber tension is made. In this process a novel technique for making PI controller capable of handling known nonlinearities in the system is introduced. Experimental system responses of the designed prototype are analyzed.

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Thesis (Ph. D.)--Virginia Polytechnic Institute and State University, 1997. / "UMI number: 9724066"--T.p. verso. Vita. Includes bibliographical references (p. 182-189). Available electronically via Internet.

Thesis (M.S.)--Brigham Young University. Dept. of Technology, 2004. / Includes bibliographical references (p. 191-195).

No description available.

Plastic filaments are used in a fastly growing industry of 3D printing using the Fused Filament Fabrication (FFF) method. A poor quality of spool winding can negatively impact the printing process. On the other hand, producing high-quality filament winding is surprisingly difficult to achieve consistently. The thesis proposes a holistic approach to inspect winding quality during the winding process. We suggest tracking reflections of bright visible light. This method seems robust enough to track filament color from black to white and even transparent materials. Furthermore, it is possible to run everything on cheap and widely available Raspberry Pi 4 B with Camera Module v2. The system uses classical computer vision approaches for filtering, segmentation, and inter-frame tracking of individual filament strands between video frames. It was confirmed to be fast enough to process 30 FPS footage directly on the Raspberry Pi in real-time. Additionally, the GUI tool for quick dataset annotation of spool winding images was created along with a small dataset. Both might be useful for the future development of a system, which would predict the quality issues earlier when corrective action can still be carried out to prevent them. 1

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The energy absorption capacity of a series of axially crushed composite tubes fabricated from high tow count graphite fiber is compared with those of similar tubes fabricated from aerospace-grade fiber to determine the viability of considering the use of such fibers in automotive applications. To that end, graphite-epoxy tubular specimens with circular and square cross-sectional geometries; stacking sequences with ±45° fibers and with both ±45° and 0° fibers; and two different fiber types were fabricated and crushed both statically and dynamically to examine the energy absorption characteristics. The fiber types, in the form of preimpregnated tow (towpreg) from Thiokol, were Akzo Fortafil 50k fiber and aerospace-grade T300 12k fiber. Using the towpreg, sixteen tubes were filament wound on aluminum mandrels. Three specimens were cut from each of these tubes for a total of forty-eight specimens. Twenty-four of these specimens were crushed statically in a load frame and twenty-four were crushed dynamically in a drop fixture. In order to characterize the tubes and specimens, a number of measurements were taken. These measurements included length, wall thickness, cross-sectional dimensions, volume, and mass. Two important energy absorption measures were examined: the specific energy absorption (SEA) and the ratio of the peak load to the average load. The geometry had a significant effect on the energy absorption but the stacking sequence did not. It was also found that the 50k material was less effective at absorbing energy than the 12k material, but the 50k still may be acceptable. / Master of Science

Neste trabalho são analisados os aspectos relacionados à otimização estrutural de cilindros de alta pressão em compósitos, a partir do estudo detalhado dos procedimentos de cálculo analítico, utilizando o método análise de rede (netting analysis), juntamente com procedimentos baseados em análise numérica pelo método dos Elementos Finitos, considerando modelos de comportamento ortotrópico do material compósito. São considerados cilindros utilizados para armazenamento de oxigênio, fabricados pelo processo de enrolamento filamentar (filament winding), comparados a cilindros confeccionados em metal quanto à sua aplicabilidade. Após análise de diferentes estudos de caso, conclui-se que os materiais compósitos podem ser aplicados com sucesso em cilindros de alta pressão, desde que estabelecidos alguns parâmetros decisivos ao projeto estrutural do vaso, tais como: critério de falha mais adequado; determinação de dados experimentais dos materiais utilizados; normas e códigos utilizados no projeto e dados da geometria final do vaso, dependentes do processo de fabricação. Propõe-se também a utilização de um ambiente integrado das atividades de projeto e fabricação do compósito. / In this work the aspects related to the structural optimization of composite high-pressure cylinders are analyzed from the thorough study of analytical calculation, by the use of netting analysis, along with procedures based on numerical analysis by the Finite Element method, considering models of composite materials with orthotropic behaviour. Cylinders used for oxygen containment, manufactured by filament winding process, are considered and compared to the cylinders manufactured in metal in terms of their application. The analyses of different case studies allowed to conclude that composite materials can be applied successfully in high pressure cylinders provided that some critical parameters have been established to the vessel structural design, such as: an adequate failure criteria; determination of experimental data for the composite materials used; standards and codes used in the design and the final vessel geometry data, dependent variables of the manufacturing process. An integrated environment of the design and manufacturing activities is proposed as well in order to embrace all of these aspects.

In this thesis, the effect of semi-geodesic winding on the free vibration characteristics of filament wound composite shells of revolution with variable radii of curvature is studied. The analysis is performed by a semi-analytical solution method which is based on the numerical integration of the finite exponential Fourier transform of the fundamental shell of revolution equations. The governing equations for the free vibration analysis are initially obtained in terms of fundamental shell variables, and they are reduced to a system of first order ordinary differential equations by the application of finite exponential Fourier Transform, resulting in a two point boundary value problem. The boundary value problem is then reduced to a series of initial value problems, and the multisegment numerical integration technique is used in combination with the frequency trial method in order to extract the natural frequencies and determine the mode shapes within a given range of natural frequencies. Previous studies on geodesic winding is extended such that the effect of semi-geodesic winding which rely on the preset friction between the fiber and the mandrel surface on the stiffness and vibration characteristics of filament wound shells of revolution is investigated. Additionally, finite element analysis is employed to compare the results obtained from semi-analytical model solved by numerical integration and finite element model solved by finite element method. Sample results are obtained for filament wound truncated conical and spherical shells of revolution and the effect of the winding pattern on the vibration characteristics of shells of revolution is investigated thoroughly.