Double-Hinge Yarn Carrier for 3D Braided Composites
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Solution Overview
Problem
Current 3D braiding technologies face inefficiencies in automating the insertion of yarns into complex rotary preforms, particularly in four-directional, five-directional, and more-directional braided structures, which limits the mechanical performance and efficiency of 3D braided composite materials.
Innovation Solution
An automatic circumferential insertion apparatus and method utilizing a double-hinge yarn carrier and U-shaped bracket with electromagnets and tension springs to enable efficient hand-changing and circumferential yarn arrangement, enhancing the mechanical properties and interlaminar shear strength of 3D braided composites.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual yarn insertion is used in 3D braiding, then the braided structure can be formed, but the braiding efficiency is low and labor intensity is high
Solution Approach 1:
The yarn carrier is designed with self-service capabilities through automatic yarn feeding mechanisms and self-adjusting tensioning systems. The double-hinge structure enables the yarn carrier to automatically adapt to position changes during braiding, reducing the need for external intervention and manual adjustment, thereby improving braiding efficiency while maintaining operational simplicity
Solution Approach 2:
The patent replaces manual mechanical operations with automated control systems. The electromagnet-driven double-hinge mechanism automatically controls the yarn carrier's movement and positioning, substituting manual labor with electrically actuated mechanical systems. This increases automation level while maintaining the mechanical precision required for complex braided structures
2Strength
If simple braided structure is used, then the manufacturing process is simple, but the mechanical performance is limited
Solution Approach 1:
The braided structure is segmented into multiple independent yarn carriers, each capable of holding and feeding yarns in different directions. The double-hinge yarn carrier system divides the complex multi-directional braiding task into manageable segments, with each yarn carrier independently controlling a specific yarn path. This segmentation enables the formation of complex 5-directional and 6-directional braided structures while maintaining manufacturing feasibility
Solution Approach 2:
The patent transitions from traditional planar braiding to three-dimensional multi-directional braiding by introducing vertical and diagonal yarn paths in addition to horizontal directions. The double-hinge mechanism enables yarn carriers to move in multiple spatial dimensions, creating complex 3D braided structures with enhanced mechanical properties including improved interlaminar shear strength and circumferential performance
3Strength
If circumferential yarn insertion is added to 3D braiding, then the interlaminar shear strength is enhanced, but the device complexity increases
Solution Approach 1:
The double-hinge yarn carrier system is designed with multi-functionality to perform both radial and circumferential yarn insertion tasks. The same electromagnet-driven mechanism that controls radial yarn feeding also enables circumferential yarn placement through coordinated hinge movement. This universality allows the apparatus to achieve enhanced interlaminar shear strength through circumferential yarns without requiring separate dedicated mechanisms, thereby limiting the increase in device complexity
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
The apparatus significantly increases the efficiency of 3D braiding and enhances the mechanical performance of 3D braided composites by enabling automatic circumferential yarn arrangement, improving interlaminar shear strength and overall mechanical properties.
Implementation Method 1
One side of the U-shaped bracket where the outer clamping buckle is arranged is provided with a first electromagnet, and one side of the U-shaped bracket where the inner clamping buckle is arranged is provided with a second electromagnet; the first electromagnet and the second electromagnet are respectively matched with an electromagnet arranged on the double-hinge yarn carrier to achieve a handshake motion between the double-hinge yarn carrier and the U-shaped bracket
Data Source
AI summary
An automatic circumferential insertion apparatus and method for a complex rotary preform. The apparatus includes a double-hinge yarn carrier and a U-shaped bracket. Two ends of the double-hinge yarn carrier are respectively provided with a cylindrical hinge structure. One cylindrical hinge structure is in revolving pair connection with an outer clamping buckle at one end of the U-shaped bracket, and the other cylindrical hinge structure is in revolving pair connection with an inner clamping buckle at the other end of the U-shaped bracket. Two sides of the U-shaped bracket are provided with an electromagnet, respectively. The outer clamping buckle is provided with a pin, which is controlled by triggering, and is triggered simultaneously with the electromagnet at the side where the outer clamping buckle is arranged.