Geometric algorithms for collision-free trajectory generation in robotic filament winding of non-axisymmetric compact parts

Robotic filament winding is a new technological solution that enables the production of high-quality composite materials at reduced costs. It utilizes a robot to move and wind a tape onto a fixed die or a rotating spindle. Robotic filament winding has been primarily applied to produce plane, compact figures, such as tubular sections or rings, to date. Key applications in the manufacturing of 3D compact structures, such as helicopter tension links, sports goods (e.g., golf clubs), and fishing rods, have been identified in industry, especially in the aeronautical sector. These shapes can be identified by extruding a section along a closed and self-intersecting path. The manufacturing process of these components is generally characterised by very long production times. As it is semi-automatic, the operator must intervene continuously to correct the tape’s deposition. This work presents geometric algorithms for automatically defining the trajectory of the robot end-effector, enabling it to wind complex-shaped parts. Experimental validation on a complex helicopter tension link demonstrated that the proposed algorithm reduces the winding cycle time by 10.5% compared to standard procedures. Furthermore, the optimized collision-avoidance strategy significantly improved part quality, virtually eliminating fiber bridging (marcel) and minimizing delamination defects. This approach offers a robust solution for the automated manufacturing of non-axisymmetric composite structures.