Dynamic Braiding Path Generation for Variable Mandrel Cross-Sections
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Solution Overview
Problem
In braiding systems with mandrels of variable cross-sections, controlling wire coverage is challenging, leading to uneven strength in the final product.
Innovation Solution
A braiding path generating method and device that receive a mandrel model, calculate a target braiding angle based on the mandrel's outer diameter and target coverage rate, and dynamically adjust operating parameters to ensure the actual coverage rate meets the target, using a controller and driving device to adjust the braiding process in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a fixed braiding path is used on mandrels with variable cross-sections, then the braiding process is simple, but the wire coverage becomes uneven leading to inconsistent product strength
Solution Approach 1:
The patent implements dynamic adjustment of braiding parameters during the manufacturing process. The controller continuously monitors the actual coverage rate and adjusts the braiding angle and mandrel speed in real-time based on the variable cross-section geometry, transforming a static fixed path approach into a dynamic adaptive process that maintains uniform wire coverage throughout the braiding operation
Solution Approach 2:
The system incorporates a feedback mechanism where the actual coverage rate is measured during braiding and fed back to the controller. The controller compares the actual coverage with the target coverage rate and automatically adjusts operating parameters to correct deviations, ensuring consistent wire coverage and product strength across the entire mandrel length
2Manufacturing precision
If the braiding angle is adjusted to achieve target coverage rate, then wire coverage uniformity improves, but the device complexity increases due to real-time parameter adjustment
Solution Approach 1:
The controller receives actual coverage rate data from sensors during the braiding process and automatically adjusts the braiding angle and operating parameters to maintain target coverage. This closed-loop feedback system achieves precise coverage control while automating the complexity, reducing the need for manual intervention and operator skill
Solution Approach 2:
The system dynamically changes physical parameters including braiding angle, mandrel rotational speed, and wire feed rate based on real-time measurements of actual coverage rate. These parameter adjustments are automatically controlled to compensate for variable mandrel cross-sections, achieving uniform coverage without requiring complex mechanical modifications to the braiding machine
Data Source
AI summary
A braiding path generating method includes the following steps. Firstly, a mandrel model is received. Then, an outer diameter of the mandrel model is obtained. Then, a target braiding angle is obtained according to a target coverage rate and the outer diameter of the mandrel model. Then, a braiding simulation path is generated according to the target braiding angle.