Weaving Assembly for Complex 3D Warp Fiber Shaping
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Solution Overview
Problem
Traditional weaving techniques struggle to manipulate planar woven structures into complex, three-dimensional shapes, particularly when used as preforms in components like jet engine components with varying contours, due to difficulties in accurately positioning and shaping warp fibers within molds.
Innovation Solution
A weaving assembly with a rotatable base, warp fiber support, and positional controllers that allow for precise movement and placement of warp fibers, using a weave control grid and movable segments to form picks and create three-dimensional woven structures with controlled spacing and orientation, enabling the formation of complex shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional weaving techniques are used to create planar woven structures, then the weaving process is simple and efficient, but the structures cannot be accurately shaped into complex three-dimensional forms
Solution Approach 1:
The warp fiber support is divided into multiple movable segments that can be independently positioned and shaped. Each segment can be adjusted to create different contours and three-dimensional forms, allowing the weaving apparatus to produce complex shapes without requiring complete redesign of the entire system.
Solution Approach 2:
The warp fiber support segments are made movable rather than fixed, allowing dynamic adjustment during the weaving process. This enables the apparatus to adapt to different three-dimensional shapes and contours, transforming from a static planar weaving system to a dynamic three-dimensional shaping system.
2Shape
If movable segments are added to the warp fiber support to enable three-dimensional shaping, then shape complexity improves, but the reliability of fiber positioning may deteriorate
Solution Approach 1:
A rim structure is introduced as an intermediary component that receives and secures the movable segments. The rim provides a stable reference framework that constrains the movement of individual segments, ensuring that while segments can be adjusted for shaping, they remain reliably positioned during the weaving operation.
Solution Approach 2:
The movable segments are pre-positioned and secured to the rim before the weaving process begins. This preliminary positioning ensures that the warp fibers are correctly located at the start of weaving, maintaining reliability throughout the process while enabling three-dimensional shaping capability.
3Productivity
If a rotatable base with weave control grid is used to reposition warp fibers, then productivity increases through continuous weaving, but the precision of fiber placement may decrease
Solution Approach 1:
The weave control grid on the rotatable base provides a reference framework that enables continuous monitoring and control of warp fiber positions during rotation. This feedback mechanism ensures that as the base rotates to enable continuous high-speed weaving, the precision of fiber placement is maintained through real-time positional control.
Solution Approach 2:
The rotatable base with weave control grid serves multiple functions: it enables continuous weaving operations for high productivity, maintains fiber placement precision through the control grid, and accommodates the movable segments for three-dimensional shaping. This multi-functional design resolves the contradiction between speed and precision.
Data Source
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AI summary
Disclosed is a weaving assembly (10) including a rotatable base (20), a base positional controller (54), a weave control grid (24), a warp fiber support (60), warp fiber arms (26), a warp fiber arm positional controller (50) and a fill fiber wand (18).