Actual Safety Distance and

Winding Tension to Manufacture

Full Section Parts by Robotized
Filament Winding
Robotized filament winding technology allows one to manufacture workpieces of high
W. Polini performances as a result of a robot placing fibers impregnated by resin (known as roving)
L. Sorrentino1 along the directions of stresses the workpiece is subjected to in exercise; thus, robotized
filament winding favors rigidity and strength of a workpiece along some preferential
e-mail: [email protected]
directions. A proper value of the winding tension has to be chosen and kept constant
along the whole winding in order to limit the defects inside the composite workpieces. To
Dipartimento di Ingegneria Industriale,
keep the tension value on roving near to the nominal value, one must plan the value of the
Universit degli Studi di Cassino,
geometric parameters characterizing the winding trajectory. The same geometric param-
Via G. di Biasio, 43,
eters influence the value of the actual safety distance that may involve collisions among
03043 Cassino, Italy
the deposition system and the components of the robotized cell. This work shows how to
avoid the occurrence of collisions by planning the value of the actual safety distance
through the definition of geometric parameters that characterize the winding trajectory.
Moreover, the collision occurrence should be considered together with the control of the
winding tension on the roving in the robotized filament winding planning stage. The
present work shows how to solve both the problems previously defined (i.e., to keep the
winding tension on roving near to the nominal value and to avoid collision occurrence),
by the solution of a constrained optimization system. DOI: 10.1115/1.2203099

Keywords: actual safety distance, robotized filament winding, winding tension, winding
trajectory, full section parts

Introduction it implies the wrinkling and slippage of the roving that alter the
fibers alignment along the deposition direction, causing defects
A robotized filament winding system is composed of an indus-
and, consequently, the reduction of the resistance in the final com-
trial robot that is equipped with a feed and deposition system for
placing fibers impregnated by resin known as roving along the posite workpiece. In fact, the composite resistance against loads
directions of stresses the workpiece is subjected to in exercise applied along the roving deposition direction is due both to its
1,2; thus, robotized filament winding favors rigidity and strength fibers the higher fiber percentage is in a unitary volume, the
of a workpiece along some preferential directions. The wound greater the workpiece mechanical resistance is and to the absence
roving is polymerized in a furnace for thermo-set resin matrix. of defects in the workpiece. In literature, some studies show how
Robotized filament winding cell replaces the human operator that to avoid tension loosening by controlling the value of tension on
represented the only system that was previously used to manufac- roving for symmetric part shapes that are obtained by traditional
ture complex shape parts. It represents an advantage as regards filament winding 812.
process control, repeatability, and manufacturing times 3. In a previous work we discussed the problem to set the nominal
The present work focuses on the family of structural parts value of winding tension that gives parts of good quality 13.
whose shape may be obtained as a result of the sweeping of a full However, the tension on roving may move far from the nominal
section along a closed not auto-intersecting three-dimensional value during winding because of technological problems con-
3D curve. Some examples of parts belonging to the class con- nected with the process, such as the no-uniform unwinding of the
sidered in this paper are shown in Fig. 1. The planning of the roving from the spool, which involves defects inside the manufac-
winding trajectory is an important aspect of the robotized filament tured parts. We have demonstrated how to act on the geometric
winding process, since the mechanical performances of the manu- parameters of the winding trajectory in order to maintain the av-
factured composite part change according to the winding trajec- erage value of the winding tension on the roving near to the nomi-
tory geometry. Different alternative computer-aided design and nal value 14,15. The same geometric parameters may involve
computer-aided manufacturing CAD/CAM software packages collisions among the deposition head and the components of the
may be found in literature 47, but there is no method able to robotized cell.
optimize the generation of the winding trajectory or to compare This work shows how to avoid the occurrence of collisions
alternative winding trajectories in order to identify the best one. among the deposition head and the components of the robotized
The winding trajectory planning should take into account the cell and to keep the winding tension on roving near to the nominal
winding tension loosens and the possibility of collisions between value. The control of collisions is carried out by means of a pa-
the deposition system and the winding die. If the tension loosens, rameter, the actual safety distance.
The present work allows one to identify the values of the geo-
1
metric parameters that keep the winding tension constant in order
Corresponding author.
Contributed by the Materials Division of ASME for publication in the JOURNAL OF
to avoid defects inside the part, such as porosity and voids, and
ENGINEERING MATERIALS AND TECHNOLOGY. Manuscript received May 17, 2005; final that avoids collisions with further elements of the winding cell by
manuscript received December 23, 2005. Review conducted by Assimina Pelegri. solving a constrained optimization system.

Journal of Engineering Materials and Technology JULY 2006, Vol. 128 / 393
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 The number of points n used to approximate the continuous
winding trajectory influences the regularity of the deposition head
movement. In fact, if the number of points is high, the movement
of the deposition head is continuous and harmonious during wind-
ing without sudden changes in heads direction. A continuous
movement of the deposition head avoids tension loosening during
winding, thus, increasing the accuracy and the repeatability in
performing the winding trajectory to place the roving along the
designed directions of deposition.
The deposition head moves from one point to the following one
of the trajectory during winding. The angle that the vector of the
deposition head movement from point to point forms with the
roving direction is very critical for winding. It is called trajectory
angle and is indicated by . The trajectory angle is responsible for
tension control of roving during winding. It aims to avoid de-
Fig. 1 Examples of parts belonging to the considered family
crease in the tension value of the roving during winding, i.e.,
roving loosens. Figure 2 shows the deposition of the roving from
point A1 to point A2 on the winding die: on the left the roving is
placed on point A1, while on the right it is on A2. To deposit the
First, the winding trajectory planning is introduced and the re-
roving between points A1 and A2, the deposition head moves from
lated CAM software is deeply described. Then, the actual safety
distance is defined and its importance is discussed. Finally, the point A1 to point A2. During its motion from A1 to point A2, the
actual safety distance is put into relationship with the geometric trajectory of the deposition head A1A2 has to form with the roving
parameters characterizing the winding trajectory. direction A1A1, a angle greater or equal to 90 deg, in order to
satisfy the condition A1A2 A1A1, which avoids roving loosening.
The deposition head moves along the trajectory points by keep-
Planning of Winding Trajectory by Geometric Param- ing at the safety distance d from the winding die in order to avoid
eters collisions between the robot arm and the die during winding see
The winding trajectory is constituted by the sequence of points Fig. 2. To plan the winding trajectory, the minimum value of the
A , A1 , A2 , . . . , ordered in space, along which the deposition safety distance is fixed.
head moves in order to deposit the composite roving on the wind- The value of the safety distance strongly depends on the value
ing die; see Fig. 2. It represents the image of the points of the of the trajectory angle. If the value of the safety distance does not
deposition trajectory, i.e., points A , A1 , A2 , . . . in Fig. 2. This allow one to satisfy the condition on the value of the trajectory
means that when the deposition head, i.e., the robot end-effector, angle previously introduced 90 deg, the value of the safety
performs the winding trajectory, it approximates the continuous distance should be increased as far as the trajectory angle to sat-
path by points. isfy its constraint. In fact, during its moving from A1 to point A2
The method to plan the winding trajectory, which is deeply along the control volume characterized by the nominal value of
discussed in 16, considers a set of geometric parameters that the safety distance d, the trajectory of the deposition head A1A2
strongly depends on the structural constraints of the robotized cell
does not form with the roving direction A1A1 an angle 1 greater
and on the technological requirements of the process. Those geo-
metric parameters are easy to numerically compute and graphi- or equal to 90 deg see Fig. 2, left. An increase of the safety
cally visualize. They are the number of points n used to approxi- distance to d* d allows one to have a trajectory angle 1 be-
mate the winding trajectory, the trajectory angle , and the safety tween the trajectory of the deposition head A1A2 and the roving
distance d. direction A1A1 at least equal to 90 deg see Fig. 2, right.

Fig. 2 Number of points n, trajectory angle , and safety distance d of the winding trajectory

394 / Vol. 128, JULY 2006 Transactions of the ASME

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 Fig. 3 Dimensions in millimeters of the irregular ring used as benchmark

Once that the geometric parameters n , , d have been set, the Solid Model Generation. This phase deals with the definition
winding trajectory is planned by means of software, called and the generation of the benchmark model and of the winding die
FILOCAD v.4 r.5 16. The software generates both the part pro- necessary to the deposition process. The elements characterizing
gram the robot has to execute and the values of both the actual this phase are: i the barycenter path that represents the geometric
safety distance d* and the actual trajectory angle in each point of axis of the piece to wind; ii the dimensions of the piece section;
the winding trajectory. and iii the surfaces of the winding die. The barycenter path of
the piece to wind can be constituted by a set of both arches and
Computer-Aided Planning of Winding Trajectory segments. Once the middle path has been defined, the software
checks if it is a closed wire and defines the piece section by the
The software used for the generation of the trajectories was
values of height and weight, as shown in Fig. 4a. Then, the piece
FILOCAD 4.5 program, a revised version of FILOCAD 4.0 discussed
section is extruded along the barycenter path in order to generate
in 16. It has been created by using the programing language C++
the piece, as seen in Fig. 4b. The last step is that to define the
with the Microsoft Visual C++ compiler together with the ACIS number of surfaces necessary to generate the winding die whose
solid modeling. The program allows: i to prepare a solid model dimensions correlate the piece to realize, as shown in Figs. 5a
of a workpiece with its winding die; ii to generate the deposition and 5b. The winding die gives the supporting walls for the most
trajectory; iii to generate the winding trajectory; and iv to gen- external of the reinforcement, and because of the shape of the
erate the part program the robot has to execute. After generation section, it is possible to take two or three retaining surfaces into
of the winding trajectory, it is possible to create both a file to be consideration.
used as part program for the robot and a check file containing all
data of the simulation process. In order to better understand the
steps of the software, based on the logic briefly described in the Generation of Deposition Trajectory and Definition of
previous paragraph and deeply discussed in 16, a benchmark has Deposition Sequence. In order to generate the deposition trajec-
been defined. The benchmark is an irregular ring, shown in Fig. 3. tory it is necessary to define the number of approximating points n
It is commonly used by an important Italian aeronautic company to which the points of the winding trajectory correspond and the
to test alternative composites manufacturing technologies and sys- number of the winding layers.
tems. To define the number of layers it is necessary to choose the
geometry and the dimensions of the roving. The roving used to
manufacture the component has an approximate rectangular sec-
tion smaller than the part full section. Therefore, the part full
section filling can be obtained by moving the roving section inside
the part full section in order to manufacture the 3D shape of the
part. The roving wound on the die is oriented as the barycenter
path that is the direction of stresses applied to the part in exercise.
A grid is positioned on the full section of the benchmark consid-
ered: it has cells with dimensions equal to the roving ones in the
Fig. 4 a Full section and barycenter path of part c seen in full section, placed over it see Fig. 5b. The cells represent the
Fig. 1; b whole part derived by sweeping the full section along various locations of the roving section, necessary to fill the whole
the barycenter path

Fig. 5 a Winding die of benchmark, b fill of the full section of part by roving coils

Journal of Engineering Materials and Technology JULY 2006, Vol. 128 / 395

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 Fig. 7 3D view of two examples of winding trajectory planned
with: a benchmark, on the left; b control volume character-
ized by a safety distance d, on the right

angle are set. The value of geometric parameters, which are

Fig. 6 Wound roving layers given as input to the program, represents the minimum value ad-
mitted for every point of the winding trajectory. In fact, these
values depend on the number of points n used to approximate the
part full section see Fig. 6. Each location corresponds to a coil to winding trajectory and on the logic used to generate the trajectory.
be wound by the sweeping of the roving section along the depo- The adopted logic may not find a solution for some values of the
sition trajectory. A continuous deposition is realized starting from safety distance and the trajectory angle, as demonstrated after-
one place such as 1 and ending, after a while winding round, in ward. Finally, the winding trajectory is generated as shown in Fig.
a new one such as 2 from which a new winding coil starts. It is 7. After generating a winding trajectory, it is possible to analyze
possible to define two main directions Y and X: Y determines the the assumed values of the parameters and d for every trajectory
growth of each single layer by approaching single coils while X, point by a check file, where all data of the simulation process are
which is perpendicular to the first one, constitutes the direction reported. Between the two geometric parameters, we pay attention
where the multiplication of the layers takes place. to the value of the safety distance d, in particular, to the variability
Once the number of approximating points n and the number of of this distance for every point of the winding trajectory; after-
the winding layers have been defined, the software carries out a ward, this value will be defined as actual safety distance and in-
test to check the possible concavity unacceptable by the deposi- dicated as d*.
tion trajectory. If concave parts are noted, the program highlights
them in red and stops the remaining analysis; otherwise, the gen- Actual Safety Distance and Trajectory Geometric Pa-
eration of the deposition trajectories is carried out. rameters
Generation of Winding Trajectory. The last step is the gen- The analysis of the file generated by the CAD/CAM software
eration of the winding trajectory along which the deposition head underlines how the values of the actual safety distance d* for each
should move in order to wind the roving along the defined depo- point of the planned winding trajectory are different from the
sition trajectory. It is a set of points ordered in space and repre- value of d that has been set initially see Fig. 8. The values of the
sents the image of the points of the deposition trajectory for each actual safety distance d* are higher than the value of d, which
coil. The existence of a relation of biuniqueness between the represents a minimum limit; Fig. 9 shows the values of the actual
points of the deposition trajectory and those of the winding tra- safety distance d* for each point of the winding trajectory. The
jectory, is absolutely necessary. To guarantee an accurate winding resulting winding trajectory places in a volume farther from the
of the roving on the die, the winding tension must be as constant winding die than that defined by the planned safety distance d, as
as possible, the deposition head and the robot arms should be shown in Fig. 10. Figure 11 shows the winding roving by the
moved on collision free trajectories, and the free tape must not deposition system along the planned trajectory. This is due to the
interfere with the support and the whole environment. Therefore, dependence of the actual safety distance from all the three geo-
once that the deposition trajectory is generated, two geometric metric parameters that characterize the winding trajectory and not
parameters previously defined as safety distance d and trajectory only from the nominal safety distance.

Fig. 8 Winding trajectory farther than the nominal safety distance of 50 mm n

= 14, = 90 deg from the winding die

396 / Vol. 128, JULY 2006 Transactions of the ASME

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 Fig. 9 Values of the actual safety distance d* for each point of a winding trajectory
characterized by the following nominal geometric parameters: n = 14, d = 50, and
= 90 deg

In order to understand the influence of the trajectory geometric valid trajectory, since it increases indefinitely the safety distance
parameters on actual safety distance d*, a set of winding trajecto- in order to satisfy the constraints on the trajectory angle.
ries has been planned by the previously described CAD/CAM For each of the 17 planned trajectories, the values of the actual
software. An irregular ring has been used as benchmark see Fig. safety distance d* have been taken by the check file. Those values
5. The material used for the experimental tests is carbon roving have been put into relationship with the geometric parameters of
impregnated by epoxy resin. The slip roving consists of 12,000 the winding trajectory.
12k filament-count tows. Polyacrilonite pan precursor graphite The average value of the actual safety distance d* significantly
fibers are used. The slip roving has a 3.2 0.8 mm width and a depends on the nominal values of both the trajectory angle and the
0.76 0.85 g / m yield. safety distance that have been set before planning the trajectory
The number of points n, the safety distance d, and the trajectory see Fig. 12. An increase of both those parameters involves an
angle have been considered variable parameters; the used values increase of the actual safety distance, since the winding trajectory
of the geometric parameters are shown in Tables 1 and 2. Seven- diverges from the winding die. The average value of the actual
teen trajectories of the deposition head have been planned instead safety distance is not significantly influenced by the number of
of 18, since for some combinations of the trajectory variables the points used to approximate the winding trajectory, as shown in
software does not find a closed path that satisfies the constraints Fig. 12. In fact, Fig. 13 shows how an increase of the trajectory
about the geometric parameters of the trajectory described in the angle from 90 deg to 100 deg to avoid roving loosening removes
second paragraph trajectory 6 in Table 2 does not converge to- the trajectory from the die and renders fundamental the control of
ward a valid solution. The CAD/CAM software does not find a collisions. However, an increase of the number of points from 14

Fig. 10 Maximum and minimum values of the actual safety distance d*

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 d* = k1 + k2 + k3d + k4n 1
where k1 , . . . , k4 are constants that in this case are equal to: k1
= 1.51, k2 = 0.0176, k3 = 0.0219, k4 = 0.000163. The lack of fit test
demonstrates that Eq. 1 is adapt to describe the collected data
with a I type error equal to 0.01. The hypotheses to apply the
regression theory are completely satisfied. The determination co-
efficient is unfortunately low 50% , since the dispersion of
data around the average trend is very high.

Actual Safety Distance and Winding Tension

In a previous work we have demonstrated that it is possible to
maintain the average value of the winding tension near to the
nominal one that has been planned to have good composite parts,
by opportunely setting the value of the actual trajectory angle
15. The actual trajectory angle is a unique parameter connected
with the planned trajectory that allows a quick and easy estimation
of the average value of the actual winding tension. The value of
the actual trajectory angle may be set by means of the geometric
Fig. 11 Roving winding along the planned winding trajectory parameters n , d , characterizing the winding trajectory 15. In-
by the deposition system creasing the number of points n used to approximate the winding
trajectory or the trajectory angle over 90 deg makes the move-
ment of the deposition system more continuous, thus, making the
to 44 eliminates the sudden changes in heads direction and avoids occurrence of tension loosening unlikely during winding. The re-
a decrease in the tension value of the roving during winding with- duction in tension loosening implies the tension average value to
out increasing the probability of collisions since the control vol- maintain near to the nominal value. Increasing the safety distance
ume increases not much. d involves a longer roving that is unwound between the die and
The dependence among the actual safety distance and the geo- the deposition system and, therefore, an average value of tension
metric parameters of the winding trajectory may be expressed by lower than the nominal one.
a linear regression However, when the geometric parameters of the winding trajec-
tory such as n or are modified in order to keep the winding
tension near to the nominal value, it is necessary to consider that
Table 1 Experimental plan any modification may involve the presence of collisions among
the deposition head and the other elements of the robotized cell
Trajectory variables Values
during winding, since the actual safety distance is modified. The
n, number of points 14-30-44 collisions detection is a very critical problem if the shape to wind
, trajectory angle deg 90100 is characterized by many different 3D directions along which to
d, safety distance mm 50-70-90 deposit the roving. In Fig. 14 we show the winding trajectory to
Winding trajectories 18 manufacture a fork. It appears clear that the winding trajectory

Table 2 Eighteen trajectories planned by CAD/CAM software

Trajectory 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

n 14 14 14 14 14 14 30 30 30 30 30 30 44 44 44 44 44 44
deg 90 90 90 100 100 100 90 90 90 100 100 100 90 90 90 100 100 100
d mm 50 70 90 50 70 90 50 70 90 50 70 90 50 70 90 50 70 90

Fig. 12 Main effect plots of the actual safety distance d* versus the geometric parameters of
the winding trajectory n, d, and

398 / Vol. 128, JULY 2006 Transactions of the ASME

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 Fig. 13 Winding trajectories for d = 50 mm; n = 14, 44; = 90 deg, 100 deg

places in a volume that may have interferences with the robotized The choice of the geometric parameters to plan the winding
cell components, such as the die, the die support, and so on. trajectory means to solve the following constrained optimization
An increase of the nominal trajectory angle or of the number of system:
points involves an increase of the actual safety distance, according
max lnT = j1 + j2 ln* 2
to Eq. 1, which may imply collisions during winding. Therefore,
one needs to consider the influence of both the winding tension subject to
and the actual safety distance to choose the value of the geometric
parameters characterizing the winding trajectory. d* = k1 + k2 + k3d + k4n + k5nd d 3
with
* = h1 + h2n + h3 h4d 4
where j1, j2, h1 , . . . , h4, k1 , . . . , k5 are constant and d is the maxi-
mum value of the safety distance that avoids collisions among the
robot arm and the components of the robotized cell. Equation 2
shows the regression relationship between the tension value and
the actual trajectory angle 15. Equation 4 presents the regres-
sion equation among the actual trajectory angle and the geometric
parameters characterizing the winding trajectory 16.

Conclusions
This work represents a first step to optimize the planning of the
winding trajectory to realize full section composite parts by robot-
ized filament winding. The aim is both to avoid collisions between
the deposition system and the elements of the winding cell by
choosing a proper value of the actual safety distance d* and to
keep the winding tension on roving near the nominal value. To
achieve this aim, a study on the influence of the geometric param-
eters on both the actual safety distance d*, which characterizes the
dimension of the winding trajectory, and the winding tension,
which characterizes the quality of composite parts, has been car-
ried out.
The value of the actual safety distance may be set by means of
Fig. 14 Winding trajectory to manufacture a fork the geometric parameters characterizing the winding trajectory.

Journal of Engineering Materials and Technology JULY 2006, Vol. 128 / 399

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This work has been carried out with the funding of the Italian pp. 313.
13 Carrino, L., Polini, W., and Sorrentino, L., 2002, Experimental Validation of
MIUR Ministry of University and Research and CNR National a New Fiber Deposition Device for a Robotized Filament Winding Cell,
Research Council of Italy. The authors are grateful to Anagni ECCM10 10th European Conference on Composite Materials, Brugge, Bel-
Agusta-Westland, especially, and also to F. Natalizia, E. Anama- gium, June 3-7, Abstract 311.
teros, and G. Paris for supporting this work. 14 Polini, W., and Sorrentino, L., 2005, Influence of Winding Speed and Wind-
ing Trajectory on Tension in Robotized Filament Winding of Full Section
Parts, Compos. Sci. Technol., 6510, pp. 15741581.
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