Braiding Machine Diameter Feedback Control
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Solution Overview
Problem
Braiding machines lack the ability to account for variations in the diameter of the strand-like material, leading to inconsistent degree of coverage, which can result in suboptimal mechanical, electrical, or physical properties of the final product and increased production costs.
Innovation Solution
A method and machine configuration that measures the diameter of the strand-like material and adjusts the feed rate and rotational speed of the elongate material strands to maintain a predefined degree of coverage, using a control system to regulate the relative feed rate and twist angle based on the measured diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the braiding machine operates with fixed feed rate and rotational speed, then the machine structure remains simple, but the degree of coverage becomes inconsistent due to diameter variations
Solution Approach 1:
The patent implements dynamic adjustment of feed rate and rotational speed based on real-time diameter measurements. The feed rate and rotational speed are no longer fixed but vary dynamically to compensate for diameter fluctuations, ensuring consistent degree of coverage. This transforms the static braiding process into a dynamic adaptive process that responds to actual material variations.
Solution Approach 2:
The patent introduces a feedback control system where the measured diameter is fed back to the control unit, which then adjusts the feed rate and rotational speed accordingly. This closed-loop feedback mechanism ensures that any deviation from the target degree of coverage is detected and corrected in real-time, maintaining manufacturing precision despite material variations.
2Manufacturing precision
If the feed rate is increased to compensate for larger diameter variations, then coverage consistency improves, but material usage increases
Solution Approach 1:
The patent changes the operational parameters (feed rate and rotational speed) based on the actual diameter measurements. Instead of using a fixed conservative feed rate that would waste material, the system dynamically adjusts parameters to match the actual material dimensions, optimizing material usage while maintaining coverage consistency.
Solution Approach 2:
The patent applies different feed rates and rotational speeds to different sections of the braiding process based on local diameter variations. Each section receives customized processing parameters tailored to its specific dimensions, preventing both over-coverage (material waste) and under-coverage (quality defects).
Data Source
AI summary
The invention relates to a method for operating a braiding, winding or spiraling machine for braiding around, wrapping around or spiraling around a strand-like material, in particular a cable, with at least one elongate material strand formed from at least one elongate material fibre, in particular from at least one wire. In the method, a diameter of the strand-like material is measured and a feed rate of the strand-like material and/or a rotational speed at which the at least one elongate material strand moves about the longitudinal axis of the strand-like material is controlled by open-loop or closed-loop control depending on said diameter measured. A predefined degree of coverage of the strand-like material by the at least one elongate material strand can be kept substantially constant by means of an open-loop or closed-loop control of the relative feed rate of the strand-like material depending on the diameter measured.