Needle Punching & Winding
The HedraCAM Needle Punching & Winding process package provides a complete offline programming solution for composite preform robot needle punching and fiber winding. Supporting multi-axis coordinated motion (up to 7 axes), flexible zone-based path planning, and layer-by-layer needle coordinate management, it covers the entire workflow from CAD model import, mesh generation, trajectory planning to post-processor output. Successfully applied to rocket engine nozzles, radomes, brake discs, and other high-end composite preform manufacturing.
🔧 Core Features
CAD Model Import & Mesh Generation
Import preform CAD models in STEP/IGES and other mainstream 3D formats; built-in mesh generation toolbox with surface partitioning, regional meshing, and sequential extraction of needle point positions and pose information, including split-line tools, split-surface tools, and mesh density definition as a complete toolset
Batch Needle Point Extraction
Box-select discrete needle points, quickly select programming points, batch extract positions and robot pose information, and automatically generate sequential machining code; needle points generate poses along surface normals, ensuring needles always enter perpendicular to the preform surface
Flexible Zone-Based Path Planning
Adaptable to various external axis configurations, supporting four coordinated motion modes: robot-only, rotary table + robot, linear table + robot, and rotary + linear table + robot full coordination; zone needle punching automatically calculates table rotation angle θ or linear displacement L, seamlessly transitioning between zones
Multi-Axis External Axis Control
Support up to 3 external axes, including rotary table rotation axis, linear motion axis, and multi-DOF combination axes; robot-worktable coordination uses adaptive optimization, automatically establishing interaction relationships between table axes and between table and robot
Layer-by-Layer Needle Coordinate Management
Easily update needle coordinates after each layer, with configurable layup time intervals; automatic inter-layer needle step calculation, generating progressive needle trajectories along meridional and circumferential directions of the preform
Virtual Simulation & Motion Verification
Integrated virtual simulation with real-time needle cylinder animation; verify trajectory reachability, detect singular points and interference points, ensuring generated programs run reliably on actual equipment and avoiding repeated on-site debugging
HedraCAM SMF Needle Punching Simulation — Kawasaki Robot + Rotary Table + Conical Preform
🎯 Technical Challenges & Solutions
Complex Surface Normal Tracking for Rotary Bodies
Conical, quasi-conical and irregular rotary preform surfaces have continuously changing normals; HedraCAM automatically computes normal vectors at each needle point, ensuring needles always enter perpendicular to the workpiece surface; needle head swing axis automatically compensates for angular offsets, achieving precise normal tracking on any curved surface
7-Axis Coordinated Pose Synthesis
Quasi-rotary preforms have complex geometries requiring precise coordination of 6-joint robot + rotary table 7-axis system; HedraCAM automatically solves motion parameters, with rotary table step angles calculated from needle point coordinates (θ=2arcsin(s/2R)), enabling efficient needle point motion synthesis
Robot-PLC Coordinated Control
After needle punching completes, the robot sends a Boolean signal to the PLC, which controls table movement and returns a signal to start the next zone; HedraCAM-generated programs fully support this coordination logic with M-code and I/O signal configuration
Dual Process Mode: Needle Punching & Stitching
The same software platform supports both needle punching (cylinder moves, robot stationary) and stitching (robot drives needle head along trajectory), with automatic mode switching to accommodate different preform forming requirements
Small-Batch Multi-Variant Flexible Adaptation
For aerospace small-batch, multi-variant preform production, no hardware fixture changes needed — software parameter adjustments adapt to different rotary preform shapes and sizes; needle step, density, zone count and other process parameters are fully configurable
Open COM/API Secondary Development Platform
Complete COM and API interfaces for secondary development: new robot model adaptation (Kawasaki, KUKA, ABB, FANUC, Yaskawa), new worktable configuration development, new needle head component integration, and custom process flow extensions
🏭 Typical Applications
Aerospace
Rocket engine nozzle expansion sections, exit cones, throat liners, aircraft radomes, brake discs and other C/C and C/ceramic composite preforms
Defense & Military
Hypersonic vehicle thermal protection components, missile nozzles, radome covers and other irregular composite preforms
New Energy Equipment
Wind blade roots, energy storage flywheels and other rotary-structure composite preforms
Industrial Manufacturing
Corrosion-resistant pipe liners, pressure vessels, drive shaft sleeves and other cylindrical/conical composite component preforms