Adjustable Braiding Rings for Complex Core Geometry
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Solution Overview
Problem
Conventional braiding machines with rigid braiding rings struggle to achieve a uniform meshwork structure and precise thread deposition on braiding cores with complex geometries, as the fixed braiding rings cannot adapt to non-symmetric cross-sectional changes or varying lateral lengths, leading to compromised braided product quality.
Innovation Solution
A braiding machine with at least two individually adjustable braiding rings having constant opening cross sections, positioned to create an overlapping geometry that approximates the braiding core's cross-section, allowing for precise adaptation of the meshwork structure and optimal thread guidance, with each ring being adjustable in a translational and rotational manner using spindle drives or timing belts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If rigid braiding rings with constant opening cross section are used, then the structural simplicity and ease of manufacture are improved, but the adaptability to complex braiding core geometries deteriorates
Solution Approach 1:
The braiding ring is divided into multiple individual segments (typically 4-8 segments) that can be independently adjusted. Each segment can be moved radially inward or outward relative to the others, allowing the overall opening cross-section to be modified to match complex braiding core geometries while maintaining the modular simplicity of individual rigid segments
Solution Approach 2:
The braiding ring transitions from a static rigid structure to a dynamic adjustable structure. The segments are equipped with adjustment mechanisms (manual or automated) that allow real-time modification of the opening cross-section during operation, enabling adaptation to different braiding core shapes and sizes
2Manufacturing precision
If adjustable braiding rings are provided to adapt to complex core geometries, then the manufacturing precision and meshwork uniformity are improved, but the device complexity increases
Solution Approach 1:
The adjustment system is segmented into independent control mechanisms for each braiding ring segment. This allows localized adjustment of specific segments to achieve precise geometric matching without requiring complex coordinated control of the entire ring structure
Solution Approach 2:
The adjustment mechanisms are designed with universal applicability, using standardized components (such as cam mechanisms, screw adjustments, or motorized actuators) that can control multiple segments with similar motion patterns, reducing the overall system complexity while maintaining precision
3Ease of operation
If segments of the braiding ring are adjusted simultaneously by the same angular increment, then the ease of operation is improved, but the adaptability to non-symmetric cross-sectional changes deteriorates
Solution Approach 1:
The control system is segmented to allow independent adjustment of each braiding ring segment. Operators can modify individual segments or groups of segments differently, enabling adaptation to non-symmetric cross-sectional geometries while maintaining simple individual control mechanisms
Solution Approach 2:
Different segments of the braiding ring can be adjusted with different displacement amounts and directions according to the local geometric requirements of the braiding core. This local customization of segment positions enables precise matching of complex non-symmetric core geometries
Data Source
AI summary
To ensure during the braiding of braiding cores, which have a complex braiding core geometry or vastly different side lengths, that the braiding threads are always correctly following the braiding core contour in terms of storage, at least two braiding rings are provided, which have a constant opening cross-section and are arranged in series directly adjacent to one another. The opening cross-sections delimited by the braiding rings overlap at least partially. The braiding rings are adjustable independently of one another.