Robotic filament winding of advanced composite frames with complex geometrical shapes

Complex composite structure design is frequently practiced in today’s aerospace and automotive industries. This study deals with the winding optimization of polymer composite frames having complex 3D geometry using rovings, winding heads, and industrial robots. This problem is addressed mainly from a geometrical perspective using a novel mathematical model and approach. Attention is given to maintaining the required winding angles, avoiding gaps, minimizing roving overlaps during winding, and ensuring the homogeneity of the windings process. Determination of the optimal number of rovings used and their width during the winding process is solved first for the case of a straight frame, where the central axis of the wound roving forms a straight helix on the frame surface. The winding technology for curved parts of the frame is more complicated. In practice, the curved section of the frame often forms geometrically part of a ring torus. The central axis of the wound roving then forms a toroidal helix on the torus. Optimization procedures are also solved for this type of frame. The verification of the derived theoretical conclusions was done using practical examples is a part of the research.