Automated Braiding Machine Thread Angle Control
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Solution Overview
Problem
Manual braiding machines face challenges in maintaining a consistent weave pattern due to the need for constant operator attention and skill to manage thread tension and speed, especially when dealing with varying harness diameters and branches, leading to inefficiencies and ergonomic issues.
Innovation Solution
An automated braiding machine with a control system that uses robotic arms and sensors to maintain a desired thread angle and adjust pulling speed, incorporating branch and end detection sensors to automate the braiding process, allowing for consistent weave pattern formation and reduced operator fatigue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual operation is used to control thread tension and pulling speed, then the operator can adjust parameters in real-time, but the operator must maintain constant attention and skill to ensure consistent weave pattern
Solution Approach 1:
The patent implements feedback control by using sensors to detect thread angle and harness diameter, then automatically adjusting pulling speed to maintain desired thread angle. This closed-loop system ensures consistent weave pattern without requiring constant operator attention, resolving the contradiction between manual control flexibility and weave consistency.
Solution Approach 2:
The automated braiding machine performs self-adjustment of pulling speed based on real-time sensor measurements of thread angle and harness diameter. The system serves itself by automatically correcting deviations from desired parameters, eliminating the need for continuous manual intervention while maintaining reliable weave pattern consistency.
2Productivity
If automated robotic arms are used to pull the harness, then multiple machines can be operated simultaneously and operator fatigue is reduced, but the system complexity increases with sensors and control systems
Solution Approach 1:
The patent replaces manual mechanical operation with automated robotic arms controlled by electronic systems. Sensors detect thread angle and harness diameter, and motors automatically adjust pulling speed, substituting complex human-operated mechanical systems with programmable automated systems that can run multiple machines simultaneously with reduced operator fatigue.
Solution Approach 2:
The patent introduces sensors and control systems as intermediaries between the operator and the braiding process. These intermediaries automatically measure thread angle and harness diameter, then adjust pulling speed without direct operator intervention, enabling multiple machines to be operated simultaneously while managing system complexity through standardized control architecture.
3Device complexity
If constant pulling speed is maintained, then the braiding process is simple to control, but the thread angle varies when harness diameter changes, affecting weave quality
Solution Approach 1:
The patent implements dynamic speed adjustment where the pulling speed is continuously varied based on real-time measurements of harness diameter and thread angle. Instead of maintaining constant speed, the system adapts its operating parameters dynamically to maintain consistent thread angle and weave quality, resolving the contradiction between control simplicity and manufacturing precision.
Solution Approach 2:
The patent changes the pulling speed parameter in response to measured variations in harness diameter and thread angle. By adjusting speed as a variable parameter rather than keeping it constant, the system maintains consistent thread angle and weave quality despite changes in harness dimensions, resolving the contradiction between simple speed control and precise manufacturing.
4Reliability
If the operator manually monitors and adjusts thread tension, then the weave pattern can be maintained, but the operator experiences ergonomic issues and fatigue from constant attention
Solution Approach 1:
The automated braiding machine performs self-monitoring and self-adjustment of thread tension through sensors that detect thread angle and harness diameter. The system automatically corrects tension variations without operator intervention, maintaining reliable weave pattern while eliminating the ergonomic issues and fatigue associated with constant manual monitoring and adjustment.
Data Source
AI summary
An automated braiding machine for applying a braided cover to an elongate structure includes a barrel through which the elongate structure passes and a bobbin orbiting assembly configured to orbit a plurality of bobbins around the barrel. Each of the bobbins unwinds a corresponding thread having a portion extending between a rim of the barrel and the elongate structure. A first robotic arm assembly is configured to pull the elongate structure in a longitudinal direction thereof. A speed at which the elongate structure is pulled in the longitudinal direction thereof is dependent on a measured angle of one of the portions of the thread relative to a plane defined by the rim of the barrel.