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Apparatus and method for controlling tension of one or more fiber tows preferably including a support frame having a spool holder, a motor for driving the spool holder, a dancer arm having a free end with a redirect roller mounted thereon and a fixed end pivotally mounted to coact with an angular-po

Apparatus and method for controlling tension of one or more fiber tows preferably including a support frame having a spool holder, a motor for driving the spool holder, a dancer arm having a free end with a redirect roller mounted thereon and a fixed end pivotally mounted to coact with an angular-position sensor, a low-friction pneumatic cylinder mounted to the dancer arm and a support plate to exert a force thereon, a second redirect roller mounted to coact with a second angular-position sensor, and a controller and associated circuitry to control the tension of the fiber by controlling the motor in response to the position of the dancer arm.Preferably, a microcontroller mounted on a single printed circuit board (PCB) having signal buffering circuitry to control a plurality of individual tensioners is provided. The PCB preferably plugs into a backplane which allows communication between several microcontrollers, thereby allowing the control of at least 32 individual tensioners. Communication between a fiber placement machine main, or master, controller and each tensioner controller is also provided. The second angular position sensor coacting with its respective redirect roller provides fiber speed, allowing better control of the dancer position, estimation of current spool diameter to better track fiber usage, and to detect any malfunctions in fiber travel.

대표청구항 ▼

1. An apparatus for controlling tension of a fiber comprising:a spool holder for rotatably holding a spool of fiber; a stepper motor for driving the spool holder; redirect guides for redirecting and guiding the fiber within the apparatus; a dancer arm having a fixed end cooperatively attached to a f

1. An apparatus for controlling tension of a fiber comprising:a spool holder for rotatably holding a spool of fiber; a stepper motor for driving the spool holder; redirect guides for redirecting and guiding the fiber within the apparatus; a dancer arm having a fixed end cooperatively attached to a first angular sensor for sensing a relative angular position of the dancer arm; and a free end having a fiber redirect guide mounted on the dancer arm for guiding the fiber and redirecting a path of the fiber; a low-friction preloadable pneumatic cylinder being connectable to a pressurized pneumatic supply, the pneumatic cylinder having a first end pivotably mounted at a preselected point along the dancer arm and a second end pivotably mounted to a support structure; a second angular sensor for sensing a relative speed of the fiber; and a process controller having circuitry to control fiber tension by adjusting stepper motor speed responsive to dancer arm position information provided by said first angular sensor.