Variable Lay Angle Braided Yarn Coating via Dynamic Spindle Rotation

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Solution Overview

Problem

Conventional braiding machines cannot independently vary the lay angles of braided yarns along a product, limiting the ability to create sections with different mechanical and dynamic properties such as high tensile strength, elasticity, or breaking points, which are required in applications like nautical and aerodynamic uses.

Innovation Solution

Implementing unidirectional or bidirectional rotation of the product and spindles within the braiding machine, allowing for variable lay angles of the rightward- and leftward-twisted wefts by controlling rotation speed and direction, and synchronizing this with the feed rate to create specific mechanical and aesthetic effects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional braiding machines are used with fixed spindle rotation, then the coating process is simple and stable, but the lay angles of the braided yarns cannot be varied along the product length, limiting mechanical property variation

Engineering Contradiction:

Improveability to create sections with different mechanical propertiesVSAvoidcomplexity of rotation control system

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The invention transforms the static spindle rotation system into a dynamic one by enabling the spindles to rotate in both directions around the product axis. This dynamic capability allows the lay angles of the braided yarns to be varied along the product length, creating sections with different mechanical properties such as tensile strength and elasticity, thereby resolving the contradiction between adaptability and device complexity

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention changes the rotational parameters of the spindles by introducing bidirectional rotation capability with controllable rotation speeds in each direction. By varying the rotation speed and direction of the spindles during the braiding process, different lay angles are achieved along the product, enabling customization of mechanical properties without requiring complete system redesign

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If the spindles rotate only in one direction, then the control system is simpler, but the product cannot have varying mechanical properties such as breaking points and elasticity along its length

Engineering Contradiction:

Improveability to create breaking points and elasticity variationsVSAvoidease of controlling rotation direction and speed

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The invention introduces dynamic bidirectional rotation control of the spindles, allowing them to rotate in both directions around the product axis. This enables the creation of varying mechanical properties along the product length, including breaking points and elasticity variations, by programmatically controlling the rotation direction and speed at different positions

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention implements a control system that coordinates the bidirectional rotation of multiple spindles based on programmed parameters. The system monitors and adjusts the rotation speed and direction of each spindle to achieve the desired lay angle variations, providing precise control over the mechanical properties along the product length

Inventive Principle:

Principle #23Feedback

3Manufacturing precision

If the product moves through the braiding machine without rotation, then the braiding process is stable, but the lay angles remain constant throughout the product

Engineering Contradiction:

Improveprecision of lay angle control along productVSAvoidcomplexity of synchronized rotation system

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The invention transforms the static braiding process into a dynamic one by introducing synchronized rotation of the product and bidirectional rotation of the spindles. This coordinated dynamic motion enables precise control of lay angles along the product length while maintaining braiding stability through synchronized control mechanisms

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention makes the braiding machine multi-functional by enabling it to produce products with constant or variable lay angles through the synchronized rotation system. The same machine can accommodate different braiding patterns and mechanical property distributions along the product, increasing its versatility without requiring multiple specialized machines

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11332860B2Method and apparatus for forming a braided yarn coating over a product, and product thus obtained

Publication Date: 2022.05.17 ISOLET IND SRL

AI summary

A method of forming a braided coating over a product (2, 2A), in particular a flexible product such as a cable, a rope, a pipe, etc., is provided, in which the product (2, 2A), while leaving a coating zone (17) of a braiding machine (100), is submitted to a continuous rotation about its longitudinal axis. A braiding machine (100) for carrying out the method and a coated product obtained with the method are also provided.