Automated Composite Bat Wrapping System
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Solution Overview
Problem
The manufacturing process of graphite baseball bats is labor-intensive and slow, requiring significant human effort and resulting in high production costs.
Innovation Solution
An automated bat fabrication system using rotating wrapping mechanisms to apply layers of composite materials onto a mandrel, with a binding material like fusible thread to fuse the layers, allowing for efficient production of both bat barrels and handles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manual methods are used to cut and assemble graphite pieces, then manufacturing precision can be maintained, but productivity is low and labor effort is high
Solution Approach 1:
The patent replaces manual mechanical cutting and assembly operations with an automated wrapping mechanism that uses a mandrel and continuous material winding system. The wrapping mechanism automatically applies graphite material in layers around the mandrel, eliminating the need for manual cutting, shaping, and assembly of individual graphite pieces, thereby dramatically increasing productivity while reducing labor effort
Solution Approach 2:
The patent changes the manufacturing approach from discrete piece assembly to continuous material deposition. By controlling the wrapping parameters (layer thickness, winding speed, tension), the system achieves both high productivity and manufacturing precision simultaneously, resolving the contradiction between production speed and process complexity
2Productivity
If automated wrapping mechanisms are used, then productivity increases and labor effort decreases, but manufacturing precision must be maintained
Solution Approach 1:
The wrapping mechanism incorporates control systems that monitor and adjust wrapping parameters in real-time, ensuring consistent layer thickness, tension, and alignment. This feedback control maintains manufacturing precision while enabling automated high-speed production, resolving the contradiction between productivity and quality consistency
Solution Approach 2:
The patent divides the bat structure into multiple wrapped layers applied in sequence around the mandrel. Each layer can be independently controlled for precision, while the cumulative effect builds the complete bat structure. This segmentation allows automated precision control at each stage, maintaining overall manufacturing quality while enabling continuous production
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
This method significantly reduces human effort and production time, enabling the cost-effective manufacturing of high-quality graphite bats by automating the wrapping process and subsequent resin transfer molding.
Implementation Method 1
a binding material such as fusible thread may be applied to fuse wrapping layers together
Data Source
AI summary
A bat is created using efficient and automated techniques to apply layers of composite materials onto a mandrel. The system includes a plurality of rotating wrapping mechanisms binding stages. Each wrapping mechanism rotates along a central axis while a mandrel is driven through the axis. The rotational motion allows each wrapping mechanism to wrap one or more material strips along the outer surface of the mandrel. Between each wrapping layer, a binding material such as fusible thread may be applied to fuse wrapping layers together. The wrapping may be performed for the bat barrel and bat handle. Each mandrel may form two bats, and multiple mandrels can be connected together to maximize wrapping efficiency. The wrapped mandrels are separated into bat units, a resin transfer molding is performed, and the bats are completed.