Analytical modeling of the winding trajectory of the multi-wire needle winding process

The multi-axis-needle-winding process is very flexible, but the tensile force control during the process is a big challenge. A new approach is a model-based control of the tensile force along the winding trajectory. Therefore an analytical model will be presented to calculate the winding trajectory of the multi-axis-needle-winding process. Thus, a parametric model of the stator and the winding tools will be presented. With this model, the free wire length can be computed. Thereafter, the necessary amount of wire can be determined and the necessary turning of the brake wheel to release the wire will be calculated.