Fiber Bundle Carrier Preparation via Suction Tensioning
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Solution Overview
Problem
The existing methods for producing carrier parts with fiber bundles are inefficient in terms of fiber bundle density and installation space, as they require significant manual intervention and lack a systematic approach to convey and insert fiber bundles into the carrier part.
Innovation Solution
A device equipped with a fiber bundle conveyor unit, suction channels, and a needle holding unit that uses air flow for tensioning and positioning fiber bundles, allowing for efficient conveyance and insertion of fiber bundles into the carrier part with minimal installation space, enabling high fiber bundle densities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fiber bundles are manually inserted through holes using a needle, then the carrier part can be produced, but the production efficiency is low and manual intervention is significant
Solution Approach 1:
The device segments the fiber bundle insertion process into distinct functional modules: a conveying unit that feeds fiber bundles, a suction unit that tensions and positions them, and a needle unit that inserts them through the carrier part. This segmentation enables automated operation while maintaining production efficiency.
Solution Approach 2:
The suction channel acts as an intermediary between the fiber bundle supply and the needle insertion point. It uses suction force to tension and position the fiber bundle strand before insertion, eliminating the need for manual positioning and enabling automated high-precision insertion.
2Productivity
If fiber bundles are conveyed and inserted systematically with automation, then production efficiency improves, but the device complexity increases
Solution Approach 1:
The suction channel serves multiple functions: it conveys the fiber bundle strand from the supply, tensions the strand using suction force, and positions it for needle insertion. This multi-functionality reduces the number of separate components needed, thereby reducing overall device complexity while maintaining automated production efficiency.
Solution Approach 2:
The conveying unit, suction unit, and needle unit are integrated into a single coordinated system that operates automatically. The suction channel merges the functions of fiber bundle handling and positioning, reducing device complexity compared to having separate systems for each function.
3Manufacturing precision
If high fiber bundle densities are achieved with minimal installation space, then the carrier part quality improves, but the space requirements for the insertion device increase
Solution Approach 1:
The suction channel is designed to be movable between a starting position within the working area and a working position outside the working area. This dimensional movement allows the suction channel to access fiber bundles from a compact supply while positioning them precisely in the working area for high-density insertion, achieving high manufacturing precision without requiring large installation space.
Solution Approach 2:
The suction channel can be retracted into or positioned within the working area when not in use, and extended to the working position when needed. This nesting capability allows the device to maintain a compact footprint while providing the necessary functionality for high-precision fiber bundle insertion.
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 device enables efficient production of carrier parts with high fiber bundle densities by systematically conveying and inserting fiber bundles, improving the overall production efficiency and reducing manual intervention.
Implementation Method 1
An airflow L away from the feed channel 28 is generated in the suction channel 37 by means of a suction unit 40, and an end section 26a of the at least one fiber bundle strand 26 is conveyed into the suction channel 37 by the suction force
Data Source
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AI summary
The invention relates to a device (20) and a method for manufacturing a carrier part (21) comprising several fiber bundles (22). At least one fiber bundle strand (26) is taken from a supply (25) by means of a fiber bundle conveying unit (27) and conveyed into an associated feed channel (28). Each feed channel (28) is associated with a suction channel (37), which is fluidically connected to the respective feed channel (28) in an initial position (I). An airflow (L) is generated in the suction channel (37) away from the feed channel (28) via a suction unit (40), and, assisted by the suction force, an end section (26a) of the at least one fiber bundle strand (26) is conveyed into the suction channel. By moving the at least one suction channel (37) into a working position (II), at least a part of the end section (26a) of the at least one fiber bundle strand (26) is exposed in a working area (31) of the device (20).A needle unit (52) with at least one needle (53) can capture the at least one end section (26a) in the working area (31) and, when moving through a carrier part (21), pull or push the at least one needle (53) through the carrier part (21).