Robotic Weaving for Precise Conductive Strand Routing
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Solution Overview
Problem
Existing weaving technologies face challenges in creating desired signal paths and incorporating electrical components into woven fabric, as strands of material often fail to be routed along intended paths and components are not interconnected as desired.
Innovation Solution
The weaving equipment includes warp and weft strand positioning systems, a reed with a linear actuator, and individually controllable devices for strand tensioning and component insertion, allowing for independent operation of these components to accommodate component insertion operations and ensure precise placement of electrical components within the fabric.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional weaving equipment is used to form fabric with conductive strands, then fabric can be produced, but strands cannot be precisely routed along desired paths and electrical components cannot be properly interconnected
Solution Approach 1:
The weaving equipment is divided into multiple independently controllable units, including individual warp strand positioners, weft strand positioners, and component insertion equipment. Each unit can be controlled separately to achieve precise strand routing and component placement without requiring entire system synchronization, thereby improving manufacturing precision while managing device complexity through modular control.
Solution Approach 2:
The system employs dynamic control where warp and weft strand positioners can independently pause and resume operations based on real-time requirements. This dynamic capability allows the equipment to adapt its operation sequence to accommodate component insertion operations, enabling precise strand routing and component interconnection while maintaining operational flexibility.
2Ease of manufacture
If warp and weft strands are positioned simultaneously in synchronized motion, then weaving efficiency is maintained, but component insertion operations cannot be performed without disrupting the entire weaving process
Solution Approach 1:
The control system segments the weaving process into independently controllable operations. Warp strand positioners, weft strand positioners, and component insertion equipment can be controlled separately, allowing component insertion to occur at specific points in the weaving cycle without halting the entire process. This segmentation enables component insertion capability while minimizing disruption to overall production rate.
Solution Approach 2:
The system implements periodic pausing of strand positioning operations at predetermined intervals to accommodate component insertion. Rather than continuous synchronized operation, the equipment uses periodic action where positioning operations are temporarily suspended at appropriate moments, allowing component insertion without significantly impacting overall productivity.
3Manufacturing precision
If individual components are made controllable and pausable for component insertion, then precise component placement is achieved, but coordination complexity among multiple devices increases
Solution Approach 1:
The control system incorporates feedback mechanisms that monitor the positions and states of individual warp positioners, weft positioners, and component insertion equipment. This feedback enables the controller to coordinate these independently controllable devices, ensuring they operate in proper sequence and achieve precise component placement while managing coordination complexity through real-time information exchange.
Data Source
AI summary
Weaving equipment may include warp strand positioning equipment that positions warp strands and weft strand positioning equipment that inserts weft strands among the warp strands to form fabric. The fabric may include insulating strands and conductive strands. The conductive strands may be coupled to electrical components. The warp strand positioning equipment may position the warp strands to form a shed. Component insertion equipment may be used to insert electrical components into the shed. The weaving equipment may have a reed. The reed may be used to help position an electrical component in the fabric. The weaving equipment may have take-down equipment and individually controllable warp fiber positioning and tensioning devices.