Modeling of the Tension Node of the Prepreg Tape for Automated Placement Process

The problem of modeling the tension node of the prepreg tape in automated placement process is solved. It is shown that the feed unit is usually modeled as a mechanical system with a constant moment of inertia of the coil and a constant geometry of the feed section, which does not correspond to the actual unwinding process. A mathematical model is proposed that takes into account the winding of the material on the coil in a spiral, the change in the radius of the coil and the moment of inertia of the system, as well as the dependence of the length of the tape between the coil and the bypass roller on the angle of rotation of the coil. The effect of spring stiffness and the distance between the coil and the bypass roller on the tension force pulsations and the working stroke of the spring is analyzed. It is shown that reducing the spring stiffness reduces the amplitude of the pulsations, but increases the dimensions of the tension unit, and increasing the distance between the coil and the bypass roller reduces the required working stroke of the spring. An approach to choosing the spring stiffness and the distance between the coil and the bypass roller is presented, based on minimizing the dimensions of the tension unit while limiting the maximum allowable tension force pulsations. The developed model can be used in the design of prepreg tape tension systems and the selection of parameters for passive tension compensators.

1. Brasington A., Sacco Ch., Halbritter J., Wehbe R., Harik R. Automated Fiber Placement: A Review of History, Current Technologies, and Future Paths Forward // Composites Part C. 2021. Vol. 6. Art. no. 100182.

2. Dong Wei, Lin Chen, Jie-Sheng Wang, Xing Yao. Design of Automatic Control System for Constant Tension and Linear Speed of Rewinder Machine // Engineering Letters. 2021. Vol. 29, is. 1. Art. no. EL_29_1_25.

3. Yan Li, Zhe Che, Chenggan Zheng, Zhi Li, Han Wang, Liang Cheng, Junxia Jiang. Modeling of Precise Tension with Passive Dancers for Automated Fiber Placement // Actuators. 2024. Vol. 13, N 2. Р. 70. DOI: 10.3390/act13020070.

4. Yi Liu, Qiang Fang, Yinglin Ke. Modeling of Tension Control System with Passive Dancer Roll for Automated Fiber Placement // Mathematical Problems in Engineering. 2020. N 1. Р. 1–11. DOI: 10.1155/2020/9839341.

5. Wuxiang Zhang, Fei Liu, Tao Jiang, Minghui Yi, Weiqiang Chen, Xilun Ding. Overview of current design and analysis of potential theories for automated fibre placement mechanisms // Chinese Journal of Aeronautics. 2021. 17 p. https://doi.org/10.1016/J.CJA.2021.04.018.

6. Mengjuan Chen, Baolin Wu, Yao Chen, Tianyi Luo, Fengyu Yang. Design of Tension Control System for Automated Fibre Placement // 5th Intern. Conf. on Mechanical Engineering, Materials and Energy (5th ICMEME2016). 2016. DOI: 10.2991/icmeme-16.2016.16.

7. Kim S., Kim D. D., Anthony B. Dynamic Control of a Fiber Manufacturing Process using Deep Reinforcement Learning // arXiv:1911.10286v1 [eess.SY]. 23 Nov 2019. https://arxiv.org/pdf/1911.10286v1.

8. Cheng L., Zheng C., Li Y., Chen C., Zhang S., Wu J., Dong H., Ke Y. Fiber Tension Prediction and Control Methods in Automated Fiber Placement // Polymer Composites. 2024. Vol. 45, N 16. P. 14888–14904.

9. Liu Y., Fang Q, Ke Y. Modeling of Tension Control System with Passive Dancer Roll for Automated Fiber Placement // Mathematical Problems in Engineering. 2020. Vol. 2020, N 1. Art. no. 9839341. P. 1–11.

10. Han P., Wang W., Li Z., Zhang W., Pu J. Research on Unwinding Mechanism Design and Tension Control Strategy for Winding Machines // Processes. 2025. Vol. 13, N 8. Art. no. 2612.

11. Belhaj M., Hojjati M. Wrinkle Formation during Steering in Automated Fiber Placement: Modeling and Experimental Verification // Journal of Reinforced Plastics and Composites. 2018. Vol. 37, N 6. P. 396–409.

12. Zhang H., Tang H., Shi Y. Precision Tension Control Technology of Composite Fiber Tape Winding Molding // Journal of Thermoplastic Composite Materials. 2018. Vol. 31, N 7. P. 925–945.

13. Chen M., Wu B., Chen Y., Luo T., Yang F. Design of Tension Control System for Automated Fibre Placement // Proc. of the 5th Intern. Conf. on Mechanical Engineering, Materials and Energy (ICMEME 2016). 2016. P. 93–98.

14. Mahapatra S., Ivanov D., Hallett S. R., Belnoue J.-P. Numerical Simulation of Process-Induced Defects in Thermosetting Automated Fibre Placement (AFP): A Review // Composites Part A: Applied Science and Manufacturing. 2026. Vol. 200. Art. no. 109265.

15. Carosella S., Hügle S., Helber F., Middendorf P. A Short Review on Recent Advances in Automated Fiber Placement and Filament Winding Technologies // Composites Part B : Engineering. 2024. Vol. 287, N 3. Art. no. 111843.

16. Denkena B., Schmidt C., Weberb P. Automated Fiber Placement Head for Manufacturing of Innovative Aerospace Stiffening Structures // 16th Machining Innovations Conference for Aerospace Industry — MIC 2016. Procedia Manufacturing. 2016. Vol. 6. Р. 96–104.

17. Lezma Y. G. A. Prototyping a Combined Fiber Placement and Filament Winding Head (CFPH) using robots in collaboration: Master of Science in Mechanical Engineering Milano. 2023. 50 р.

18. Sabido A. M. Development of an Automated Fiber Placement Process for the Fabrication of Thermoplastic Composite Laminates: Master of Science in Aerospace Engineering. Florida, 2012. 84 р.

19. Halbritter J. A. Leveraging Automated Fiber Placement Computer Aided Process Planning Framework for Defect Validation and Dynamic Layup Strategies: Doct. Dis. … Mechanical Engineering. South Carolina, 2023. 205 р.