Modeling and Optimizing for Fiber Bundle Tension in Braiding Carrier

ABSTRACT Braiding carrier acts as a braiding machine core component, and its fiber bundle tension stability critically influences preform quality. However, in actual production, the variety of carriers and complex working conditions make existing tension models difficult to construct and poorly generalized. To address these issues, this paper proposes a tension prediction method based on the slider‐balanced carrier. First, by analyzing the braiding process and carrier motion trajectory, the dynamic relationship between carrier unwinding speed and fiber bundle release length is revealed. Second, a fiber bundle tension simulation model is established based on carrier working principles and dynamic modeling methods. Then, a tension measuring platform is built to verify model accuracy, with experimental results showing prediction errors within 5%. Finally, the method is applied to compare the tension characteristics of different carrier types, and particle swarm optimization is used to optimize the carrier structure. The optimized carrier reduces tension amplitude by 14% and fluctuation range by 52%, effectively optimizing fiber bundle tension during the braiding process.