Braided Reinforcement for Aircraft Fuselage Frames
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Solution Overview
Problem
Existing braiding machines cannot apply braid symmetrically to mandrels with an irregularly varying radius of curvature, as the center point of the mandrel's cross-section cannot remain coaxial with the braiding point when the mandrel is rotated about an approximate center.
Innovation Solution
A braiding machine with a mandrel placement assembly that includes opposing drive/positioning wheels and a carriage system, allowing for the repositioning of the mandrel along its length to ensure the center point of the mandrel's cross-section is coincident with the braiding point, using a CNC controller to determine and adjust the mandrel's position based on the radius of curvature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a mandrel with irregularly varying radius of curvature is rotated about an approximate center, then the mandrel can be positioned for braiding, but the center point of the mandrel's cross-section cannot remain coaxial with the braiding point, resulting in asymmetric braid application
Solution Approach 1:
The mandrel placement assembly dynamically adjusts the mandrel's axial position based on the varying radius of curvature at different locations. The system transitions from a static positioning approach to a dynamic one where the mandrel is continuously repositioned along its axis to compensate for geometric variations, ensuring the center point remains coaxial with the braiding point throughout the braiding process
Solution Approach 2:
The system uses sensors to detect the actual position and geometry of the mandrel, and the control system automatically calculates and adjusts the mandrel placement accordingly. This self-regulating mechanism eliminates the need for manual intervention and ensures continuous symmetric braid application despite mandrel geometric variations
2Device complexity
If a simple rotation mechanism is used for the mandrel, then the device complexity is reduced, but the ability to maintain coaxial alignment with the braiding point on mandrels with varying radius of curvature is lost
Solution Approach 1:
A mandrel placement assembly acts as an intermediary between the simple rotation mechanism and the braiding apparatus. This intermediate component includes sensors to detect mandrel geometry, a control system to process the data, and actuation mechanisms to adjust mandrel positioning, thereby bridging the gap between simple mechanics and precision alignment requirements
Solution Approach 2:
The mandrel placement assembly serves multiple functions: it supports the mandrel during rotation, detects the mandrel's geometric characteristics through sensors, calculates the required positioning adjustments, and physically repositions the mandrel along its axis. This multi-functional approach consolidates several subsystems into one integrated assembly, managing overall system complexity while achieving precision alignment
3Manufacturing precision
If the mandrel is repositioned continuously along its length to maintain center point coincidence with the braiding point, then symmetric braid application is achieved, but the device complexity and positioning mechanism requirements increase
Solution Approach 1:
The system replaces complex mechanical positioning mechanisms with a combination of sensors, computer control, and simple actuation. Instead of using elaborate mechanical linkages and adjustment devices, the invention uses electronic sensing to detect mandrel geometry, computational algorithms to determine required adjustments, and straightforward actuation mechanisms to implement positioning changes, thereby reducing overall mechanical complexity while achieving high precision
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the symmetric application of braid to mandrels with irregularly varying radii of curvature, ensuring a uniform braid pattern along the circumferential length by accurately positioning the mandrel relative to the braiding point.
Implementation Method 1
The opposing drive/positioning wheels are operative to rotate in frictional contact at least one of the outer surfaces of the mandrel, thereby advancing the mandrel along its length
Data Source
AI summary
A method for applying a braided fabric over a mandrel using a braiding apparatus having a central axis and providing braiding yarns drawn toward a braiding point where a braid is formed on the mandrel, the method comprising the steps of advancing the mandrel through the braiding point of the braiding apparatus, determining a current position of the mandrel; and controlling the position of the mandrel transversely to the central axis of the braiding apparatus responsive to the current position such that a center point of a mandrel cross-section passing through the braiding apparatus is coincident with the braiding point.