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<p>Yarn tension is a key factor in manufacturing braids and braided composite parts. Tension variation can create fiber breakage, which negatively affects the mechanical properties of the final product. It can also create defects in the braided preform, rendering the part unsuitable and leading to material waste. Mechanical spool tensioners are widely used in braiding machines. However, their mechanism causes significant variations in the yarn tension. This study presents the design of an active spool tensioner, which regulates yarn tension. The yarn spool is directly mounted on an electric motor, which is torque-controlled. A lever arm measures the effective radius of the yarn spool to monitor and adjust the yarn tension. The ability to maintain constant tension was assessed and compared to a mechanical spool tensioner. Tests were conducted for constant unwinding speeds of 25&#xa0;mm/s and 100&#xa0;mm/s. Tensioning springs stiffness of 81, 130 and 425&#xa0;N/m were used for the mechanical spool tensioner, while targeted tension of 1, 2 and 3&#xa0;N were used for the active spool tensioner. Compared to the mechanical spool tensioner, the tension variations of the active spool tensioner remained constant, ranging from 0.21 ± 0.03&#xa0;N to 0.26 ± 0.06&#xa0;N, regardless of the yarn tension and the unwinding speed. In contrast, tension variations for the mechanical spool tensioner varied between 0.24 ± 0.04&#xa0;N to 1.69 ± 0.42&#xa0;N. These results highlight the ability of the active spool tensioner to maintain a steady tension under varying conditions.</p>

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Design and characterization of an active spool tensioner for braiding machines

  • 期刊论文

  • 发表日期：

    2025年11月22日

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  • Pascal Assi,
  • Cristian Stefan Talos,
  • Sofiane Achiche,
  • Louis Laberge Lebel

摘要

Yarn tension is a key factor in manufacturing braids and braided composite parts. Tension variation can create fiber breakage, which negatively affects the mechanical properties of the final product. It can also create defects in the braided preform, rendering the part unsuitable and leading to material waste. Mechanical spool tensioners are widely used in braiding machines. However, their mechanism causes significant variations in the yarn tension. This study presents the design of an active spool tensioner, which regulates yarn tension. The yarn spool is directly mounted on an electric motor, which is torque-controlled. A lever arm measures the effective radius of the yarn spool to monitor and adjust the yarn tension. The ability to maintain constant tension was assessed and compared to a mechanical spool tensioner. Tests were conducted for constant unwinding speeds of 25 mm/s and 100 mm/s. Tensioning springs stiffness of 81, 130 and 425 N/m were used for the mechanical spool tensioner, while targeted tension of 1, 2 and 3 N were used for the active spool tensioner. Compared to the mechanical spool tensioner, the tension variations of the active spool tensioner remained constant, ranging from 0.21 ± 0.03 N to 0.26 ± 0.06 N, regardless of the yarn tension and the unwinding speed. In contrast, tension variations for the mechanical spool tensioner varied between 0.24 ± 0.04 N to 1.69 ± 0.42 N. These results highlight the ability of the active spool tensioner to maintain a steady tension under varying conditions.