Tubular Braiding Machine with Synchronized Tube Drives
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Solution Overview
Problem
Existing braiding machines are unsuitable for forming medical braids with very fine wires due to breakage from impulse forces and are slow, lacking the ability to produce braids with varying dimensions at high speeds.
Innovation Solution
A braiding system with synchronized upper and lower drive units that constrain filaments within tubes, using weights for tension and moving them in discrete radial and arcuate paths to form braids without large impulse forces, enabling high-speed production of fine filaments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If spools of wire are moved to pay out wires for braiding, then the braiding process can be automated, but the wires are subject to large impulse forces that may break very fine wires with low tensile strength
Solution Approach 1:
The patent introduces an intermediary mechanism (the tube system with weights) between the wire source and the braiding process. Instead of directly moving spools and paying out wire under tension, the system uses tubes that guide individual wires and weights that provide gentle, constant tension, mediating the force application to prevent breakage of fine wires while enabling automated braiding.
2Reliability
If weights are used to tension wires without large impulse forces, then very fine wires can be braided, but the braiding speed becomes very slow
Solution Approach 1:
The patent applies dynamics by making the tube system movable rather than static. The tubes are actively positioned and moved during the braiding process, allowing the system to maintain gentle wire tension while achieving higher braiding speeds through coordinated motion control, rather than relying on slow, manual-style tensioning.
3Ease of operation
If hooks or gripping means are used to manipulate wires, then braiding can be performed, but the process becomes very slow and lacks versatility for varying braid specifications
Solution Approach 1:
The patent replaces the mechanical hook/gripping system with a tube-based guidance system. Instead of using hooks to actively grip and manipulate wires, the system uses smooth tubes that guide wires through their braiding paths, eliminating the need for gripping mechanisms and enabling faster, more versatile braiding operations.
4Productivity
If conventional braiding machines are used, then braiding can be performed, but they cannot produce braids with varying dimensions efficiently
Solution Approach 1:
The patent employs dynamic control of the tube positions and movements to accommodate varying braid specifications. The tube system can be repositioned and reconfigured during operation, allowing the same machine to produce braids with different dimensions, patterns, and characteristics without sacrificing production speed or capability.
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 system allows for the rapid formation of braids with fine filaments by minimizing sway and tangling, achieving higher production speeds and versatility in braid dimensions.
Implementation Method 1
The tubes can be constrained within the upper and lower drive units. Individual filaments can be attached to weights that slide within the tubes.
Data Source
AI summary
Systems and methods for forming a tubular braid are disclosed herein. A braiding system configured in accordance with embodiments of the present technology can include, for example, an upper drive unit, a lower drive unit, a mandrel coaxial with the upper and lower drive units, and a plurality of tubes extending between the upper drive unit and the lower drive unit. Each tube can be configured to receive individual filaments for forming the tubular braid, and the upper drive unit and the lower drive unit can act against the tubes in synchronization to cross the filaments over and under one another to form the tubular braid on the mandrel.