Tension fluctuation analysis and structure optimization of yarn carriers in the carbon fiber braiding machine

Abstract In the process of carbon fiber braiding, yarn carriers are the key component, and their ability to maintain stable tension is critical for producing high‐performance composite preforms. However, there are several issues with present yarn carriers, such as sudden changes in tension and excessive fluctuation, which often result in fiber breakage and seriously affect material qualities. To address these issues, the tension mathematical model is established based on the working principle of the slider‐type yarn carrier, which reveals that the separation of slider 2 and slider 1 caused by the ratchet and brake block structure is the root cause of the impact load. Second, the accuracy of the theoretical model is verified by dynamic simulation and the tension test, and the impact phenomenon is captured by a high‐speed camera. The research demonstrates that by decreasing the angle φ , the impact load can be efficiently decreased or removed. The amplitude of tension fluctuations is significantly influenced by the spring's elastic coefficient, preload, and friction coefficient. Finally, a genetic algorithm was used to optimize the structure, and the amplitude of tension fluctuation was reduced by 54.3% after optimization. This work offers significant guidance for enhancing the performance of yarn carriers. Highlights A theoretical model that describes the impact load generated by yarn carriers is developed. The origin of the impact load is revealed by a multi‐dimensional research method. Structural optimization for the issues of sudden tension changes and excessive fluctuations