Systems and Methods for Forming a Winding Structure

Abstract

An automated machine for forming winding structures without the use of a mandrel using a driven headstock and driven tailstock. The winding machine allows for selective orientation and selective layering of the filament as it is wound onto the pin rings. The winding structure can receive forms into a hollow center and the composite placed in a female mold. Alternatively the winding structure may be formed into a laminate which can be orientated and aligned on a form to achieve desired mechanical properties.

what is claimed is: 
     
         1 . An automated mandrel-less filament winding machine comprising:
 a driven headstock comprising a pin ring;   a driven tailstock comprising a pin ring wherein no mandrel connects the driven tailstock to the driven headstock;   a delivery eye configured to guide a filament in a winding pattern onto the headstock pin ring and the tailstock pin ring;   a drive mechanism to drive the headstock and drive the tailstock into positions wherein the filament is selectively wound onto the headstock pin ring and tailstock pin ring to create a winding structure.   
     
     
         2 . The winding machine of  claim 1  wherein the driven tailstock is slaved to the driven headstock. 
     
     
         3 . The winding machine of  claim 1  wherein the headstock pin ring and tailstock pin ring further comprise winding pins configured to receive a wind of a filament. 
     
     
         4 . The winding machine of  claim 3  wherein the delivery eye is configured to selectively guide the filament around the winding pins in a desired pattern. 
     
     
         5 . The winding machine of  claim 3  wherein the drive mechanism is software-controlled servo motors configured to automate the position of the winding pins in relation to the delivery eye. 
     
     
         6 . The winding machine of  claim 3  wherein the drive mechanism comprises mechanical members to drive and position the tailstock in response to the position and movement of the headstock. 
     
     
         7 . The winding machine of  claim 1  further comprising a filament and wherein the headstock pin ring and tailstock pin ring are cross-sectional templates wherein a winding structure is formed upon winding a filament on the headstock pin ring and the tailstock pin ring. 
     
     
         8 . The winding machine of  claim 7  wherein the winding structure further comprises a receiving portion. 
     
     
         9 . The winding structure of  claim 8  further comprising a form inserted into the receiving portion. 
     
     
         10 . The winding machine of  claim 4  wherein the headstock pin ring and the tailstock pin ring are configured to selectively position the winding pins to receive the filament in a predetermined direction. 
     
     
         11 . The winding machine of  claim 4  wherein the headstock pin ring and the tailstock pin ring are configured to selectively position the winding pins to receive the filament in a predetermined order. 
     
     
         12 . The winding structure of  claim 7  further comprising a plank configured to laminate a form. 
     
     
         13 . The winding machine of  claim 1  wherein the delivery eye comprises an articulation member to articulate the delivery on a plurality of axes and in a plurality of directions. 
     
     
         14 . The winding machine of  claim 1  further comprising a tensioning member to selectively adjust the tension applied to a filament. 
     
     
         15 . The winding machine of  claim 1  wherein the headstock pin ring and the tailstock pin ring are selectively releasable. 
     
     
         16 . An automated mandrel-less filament winding machine comprising:
 a driven headstock comprising a pin ring;   a driven tailstock comprising a pin ring wherein the driven tailstock is slaved to the driven headstock;   a driven articulating delivery eye configured to guide a filament onto the headstock pin ring and the tailstock pin ring in a predetermined winding pattern;   a drive mechanism to drive the headstock into positions wherein the filament is selectively wound onto the headstock pin ring and tailstock pin ring to create a winding structure.   
     
     
         17 . The winding machine of  claim 16  further comprising a filament. 
     
     
         18 . The winding machine of  claim 17  wherein the filament is wound to form a winding structure. 
     
     
         19 . The winding machine of  claim 17  wherein the filament material is interchangeable without removing the winding structure from the winding machine. 
     
     
         20 . A method of making a mandrel-less filament winding machine comprising:
 providing a driven headstock comprising a pin ring;   providing a driven tailstock comprising a pin ring wherein the driven tailstock is slaved to the driven headstock;   providing a driven articulating delivery eye configured to selectively guide a filament onto desired winding pins on the headstock pin ring guiding the filament onto desired winding pins on the tailstock pin ring in a predetermined winding pattern to selectively provide and position filament layers and orientations;   providing a drive mechanism to drive the headstock into positions wherein the filament is selectively wound onto the headstock pin ring and tailstock pin ring to create a winding structure;   
       inserting a form into a receiving portion formed in the winding structure; and
 placing the winding structure and form into a mold.