Self-Propelled Braiding Carriers Virtual Path Control
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Solution Overview
Problem
Conventional braiding machines are limited by the number of tow carriers, restricting the range of braid structures that can be produced and requiring multiple machines for diverse customer requirements, which increases manufacturing complexity and space demands.
Innovation Solution
A braiding system utilizing self-propelled mobile tow carrier devices with wheels, motors, controllers, and pick-up units that move along predetermined virtual paths, allowing for greater flexibility and configurability without physical guides, enabling the use of a larger number of tow carriers and supporting various braid structures within the same manufacturing space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional braiding machines use a fixed number of tow carriers on a circular ring, then the machine structure is simple and stable, but the range of braid structures that can be produced is limited
Solution Approach 1:
The patent applies dynamics by transitioning from fixed, stationary tow carriers on a circular ring to mobile, self-propelled tow carriers that can dynamically change positions and paths. Each carrier has its own motor and controller, enabling real-time reconfiguration of the braiding pattern without changing the physical machine structure, thus achieving versatility while maintaining structural simplicity.
Solution Approach 2:
The patent replaces the traditional mechanical guide system (circular ring with tracks) with a control-based system. Mobile carriers use onboard motors and controllers to follow predetermined paths or receive real-time navigation commands, substituting physical mechanical constraints with electronic control, allowing flexible braid structure production without complex mechanical reconfiguration.
2Adaptability or versatility
If multiple conventional braiding machines are used to meet diverse customer requirements, then product variety is achieved, but manufacturing space and complexity increase
Solution Approach 1:
The patent implements universality by designing a single braiding machine platform that can produce multiple braid structures through software control. The mobile carriers can be programmed with different path sequences, and the system can adapt to various braid patterns (2D, 3D, interlocking) without requiring separate dedicated machines, thus achieving multi-functionality in one device and reducing manufacturing space requirements.
Solution Approach 2:
The system uses dynamic path programming and real-time carrier control to adapt to different product requirements. Instead of having fixed configurations for different braid types, the same physical system dynamically reconfigures by changing carrier trajectories and coordination patterns, enabling one machine to replace multiple specialized machines.
3Ease of manufacture
If conventional braiding machines use physical tracks and guides for tow carriers, then carrier movement is precise and controlled, but reconfiguration time and expense increase
Solution Approach 1:
The patent replaces physical tracks and mechanical guides with electronic path control. Mobile carriers use onboard motors controlled by programmed trajectories or real-time navigation commands to achieve precise movement. This substitution eliminates the need for physical reconfiguration of tracks while maintaining path accuracy through control algorithms, enabling rapid reconfiguration without sacrificing precision.
Solution Approach 2:
The system uses digital copies of braid patterns and paths stored in memory or transmitted via communication interfaces. Instead of physically reconfiguring mechanical guides for each braid type, the system loads digital path representations and guides carriers accordingly, enabling instant reconfiguration by copying new path data without physical changes to the machine structure.
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 solution enhances manufacturing flexibility, reduces the need for multiple machines, and allows for rapid production of diverse products, including one-off items, by enabling the use of a larger inventory of tow carriers and reducing setup time and expense for short-term production runs.
Implementation Method 1
A braiding system utilizing self-propelled mobile tow carrier devices with wheels, motors, controllers
Implementation Method 2
mobile carrier devices movable under its own power, each mobile carrier including a plurality of wheels
Data Source
AI summary
A braiding system having a plurality of mobile carrier devices movable under its own power, each mobile carrier including a plurality of wheels, a motor driving the wheels, a power source, a controller, and a pick-up unit having a receiver. Each of the plurality of mobile carriers has a tow carrier positioned in the receiver, and each mobile carrier is simultaneously movable along a virtual track-less path predetermined for each individual carrier, such that the simultaneous movement of the mobile carrier devices along their predetermined paths form a braid.