Analysis and Modeling of the System Boundaries of a High-Speed Direct-Yarn-Placement System for In Situ Impregnation of Carbon Fibre Heavy Tows as Textile Reinforcements for Concrete Parts

This study investigates a novel approach in modeling the system limits of a braked, high-speed yarn-laying process with in situ impregnation. Special attention is paid to the investigation of the yarn spool overrun after the robot has come to a standstill. This phenomenon occurs at low yarn tensions in combination with high traversing speed and/or acceleration. The modeling of the yarn spool overrun is carried out using physical equations, taking into account the travel speed, acceleration of the robot, and braking force of the spool brake. Previous research has confirmed various operating points of the yarn-laying process, but a comprehensive and complete analysis of the system limits at different operating points and speeds up to 2 m/s is missing. The result of the study is a novel model that describes the system boundaries of the direct-yarn-placement. Furthermore, models for robot braking time, carbon spool diameter, and spool mass are developed. The proposed models have an R-2 > 0.9674. Regarding the system stability boundaries, the calculations reveal that, as acceleration rises, the minimum tension requirement also increases. The same trend is found for system velocity. At a=12.5%, a minimum tension of 16 N suffices, compared to 23 N and 32 N at a=25% and 50%, respectively. The impact on tension of quadrupling the speed outweighs that of acceleration, with tension increasing by factors of up to 22.5 and 2, respectively.