The 5 axis post processors
The 5 axis post processor-1
The 5 axes post processor uses all axes except the ‘vertical’ axis. It uses the yaw axis to enable the fibre band to be laid much flatter over the mandrel end. It has a disadvantage (on most machines) that the yaw axis is normally limited in it travel either side of the straight ahead position. Thus, the yaw axis cannot accommodate low angle wind angles well. If the yaw axis is used to take out the fibre twist as in the full 6 axis post processing the machine head needs a large clearance to avoid hitting the mandrel shafts at the mandrel ends. The 6 axis post processor is recommended in preference to this one.
Operation of this post processor is identical to the standard 4 axis post processor. Using the correct value of payout eye extension is essential as when the yaw axis is moved there must be compensation in the carriage and cross-feed axes if this rotation is not centred about the end of the delivery eye. Note that using Robots (e.g. ABB/Kuka) it is normal to set tool data for the fibre delivery point (TCP) so payout eye length should not be set as the robot will make the compensatory motions automatically using the tool data.
The 5 axis post procrocessor-2
This uses all axes except the ‘vertical’ axis. This is similar to 5axis option one but the roles of the roll and yaw axes are reversed. The yaw axis is used to eliminate twist in the fibre and the roll to take up the wind angle and keep the band central on the payout roller.
Operation of this post processor is identical to the standard 4 axis post processor. Using the correct value of payout eye extension is essential as when the yaw axis is moved there must be compensation in the carriage and cross-feed axes if this rotation is not centred about the end of the delivery eye.
The 5 axis (3 plane) post processor
The 5 axis (3 plane) post processor can be used for most components where the user wishes to use a payout roller. It is selected (where supplied) from the Post-processing menu. It uses all axes except the yaw axis. The only real advantage over the standard 4 axis system is that the contact angle of the tape/tow around the roller is constant and equal to 90 Degrees. The operation of the software is identical to that of the standard 3 and 4 axis systems, except that the user is requested for additional input data, this being:
i) Control surface clearance. This clearance is added to the largest mandrel radius and is then used to define the distance of a plane of constant axis AX6 (vertical axis). This plane will be either above or below the mandrel depending on the direction of mandrel rotation.
ii) End plane clearance. This defines the distance of planes of constant AX4 (carriage) from the first and last mandrel points. These end planes are used to limit the carriage travel when winding lower winding angles.
The POE travels in the planes described above such that the POE is always on the positive cross-feed side of the mandrel. The Tape/tow is held such that the contact line from roller to mandrel is always in a 'vertical' plane. The roll axis motion is calculated to remove the sliding action of the tape against the roller. It does not remove any twist due to the slope of the component's surface. If the user is winding on a steep cone or near the top of an end dome, then there will be a temporary twist in the tape/tow that can cause problems. This problem can be reduced by increasing the POE clearance. This has the effect of reducing the twist per unit length in the fibres, but clearances may be too large and the accuracy of the fibre laying could decrease.
The message "Warning: read 3 plane PP help topic, with multi-pay files can give errors" can be given using this option with multiple .PAY files. The clearances values for the end planes are defined relative to the ends of the mandrel that is used for the first .PAY file in the list in the .CTL file. If this mandrel is a short 'dummy mandrel' for example if the first layer is a hoop winding parametric program the end planes could be defined inside the real mandrel and errors will result. In this case ensure the first mandrel is valid or use a different post-process option.