Novel Warp Tension and Thickness Control Feedback Loop for Weaving of Thick 3D-TPS Preforms

Next generation, 3D-TPS heat shields based on 3D weaving technology offer potential for increased mass efficiency relative to legacy solutions.nbsp; However, width, thickness and unit cell size combinations of 3D-TPS designs being considered for future missions are pushing the limits of current 3D weaving looms and driving the need for new or significantly modified set-ups.nbsp; With this SBIR Phase 1 proposal, TEAM Inc. seeks to develop a warp tension control and as-woven thickness feedback loop for integration onto both current and future 3D weaving looms.nbsp; The proposed effort would significantly advance industry state of the art for monitoring, control and repeatability of thick, multi-layer 3D woven structures.nbsp; In Phase 1, manual warp yarn tension and thickness measurements will be obtained from a 3D loom set-up in order to quantify the basic relationship between warp yarn tension and as-woven fabric thickness for a relevant, dual layer 3D-TPS weave construction.nbsp; In parallel, off the shelf, electronic yarn tension and thickness sensors from the traditional 2D textile and web handling industries will be researched and evaluated for eventual integration onto a loom set-up.nbsp; Finally, a novel ldquo;mini-warp beamrdquo; mechanism will be designed and installed onto a 3D weaving loom set-up to demonstrate ability to successfully control and dial in warp yarn tension(s) in a cost effective manner.nbsp; Results of Phase 1 will inform design and implementation of a fully automated in-line tension / thickness control system in Phase 2 including scale of the mini-false beam concept to a full scale 3D-TPS set-up with tens of thousands of ends of warp fibers, and integration of the system with TEAM#39;snbsp;existing PLC controlled loom programming logic.nbsp;