Accuracy-speed relationships of a robotic filament winding cell.

Abstract

This thesis describes the background research and the development of a robot based filament winding cell. The cell was implemented using an industrial robot (ASEA IRB 6/2) and an in-house mandrel drive mechanism, both being coordinated by a personal computer. Filament winding is a process in which continuous fibres are placed on a rotating mandrel to cover the entire surface, under controlled tension forming a composite component. Traditionally, filament winding is carried out on multi-axis numerically controlled lathe-like machines. There are two major parts in this research. The first part deals with the cell control structure theory and the second deals with the experimental validation of the control structure. Communication protocols, user interface software, control hardware specifications and procedures are elaborated in detail. To simplify the experimental work, a highly automated robotic control software program was written. This program reduces the complexities of operating the robot and ensures accurate repeatable results. The applications program was based upon an expert system approach. The factors studied were the speed versus the accuracy, the accuracy of the payout eye position, the effects of the segment's length and winding speed used for the approximation of the fibre path. Validation of the control theory is tested experimentally using a simple cylindrical mandrel in various configurations and an asymmetrical S-mandrel.