Wire Weave Winding With Rotating Spool Carrier for Fragile Wires
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Solution Overview
Problem
Manufacturing thin wire weaves for electric sails is challenging due to the fragility of the wires and the need for a reliable, cost-efficient, and space-tolerant production method that minimizes strain and deformation, especially when deploying in space where meteor or debris damage is a concern.
Innovation Solution
A system that uses a winder and spool carrier with adjustable longitudinal wire spools and a crossing wire to form loops around each longitudinal wire, allowing for automatic and steady joint production, with adjustable tension and minimal contact to maintain weave integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional weaving devices are used to manufacture thin wire weaves, then the manufacturing process can be completed, but the wires suffer from excessive strain and deformation due to contact with manufacturing mechanisms
Solution Approach 1:
The patent replaces traditional mechanical weaving mechanisms that physically contact and manipulate individual wires with a system that uses tension control and guided wire feeding. The wires are fed through guides and around pulleys with controlled tension, minimizing mechanical contact and deformation while maintaining weaving precision.
Solution Approach 2:
The patent changes the physical parameters of the manufacturing process by controlling wire tension within specific ranges (0.1-10 N) and adjusting the speed of wire feeding. This parameter control allows the fragile thin wires to be woven without excessive strain, maintaining both wire integrity and weave quality.
2Stability of the object's composition
If the manufacturing process applies high tension to maintain weave stability, then the weave structure is maintained, but the thin wires suffer from strain and potential damage
Solution Approach 1:
The patent implements dynamic tension control that adjusts the force applied to wires during manufacturing. By maintaining tension within the optimized range of 0.1-10 N, the system preserves weave structural stability while preventing wire damage, achieving both structure integrity and wire durability.
Solution Approach 2:
The patent introduces intermediary elements such as pulleys, guides, and tensioning mechanisms that mediate between the weaving process and the fragile wires. These intermediaries distribute and control the forces applied to the wires, preventing concentrated strain while maintaining overall weave stability.
3Ease of operation
If manual or semi-automated weaving processes are used, then flexibility in handling fragile wires is maintained, but manufacturing speed and cost-efficiency are reduced
Solution Approach 1:
The patent implements an automated system where the wire spools, guides, and tensioning mechanisms work together autonomously to feed and weave the thin wires. The system self-regulates tension and wire feeding without requiring manual intervention, maintaining ease of handling while dramatically increasing manufacturing speed and cost-efficiency.
Solution Approach 2:
The patent replaces manual handling operations with an automated mechanical system that uses controlled tension and guided wire feeding. This substitution maintains the gentle handling needed for fragile wires while enabling continuous high-speed automated manufacturing.
Data Source
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AI summary
A device for manufacturing a weave, comprising a winder (1) for reeling the manufactured weave to a rotating reel (14), wire spools (2) arranged to release longitudinal wires (6) to said winder (1), a wire spool carrier (3) comprising a wheel (7) and a slit (8) extending through the wheel (7) from a centre of the wire spool carrier (3) to the circumference, an additional wire spool (4) releasably attached to the wire spool carrier (3) and arranged to release a crossing wire (9), and an actuator (5) configured to move the wire spool carrier (3) between the longitudinal wires (6) such that the additional wire spool (3) in turns moves to each longitudinal wire (6) to a position where the respective longitudinal wire (6) is located in said slit (8) at which stage the wheel (7) rotates around said respective longitudinal wire (6) before moving towards a following longitudinal wire (6) in such way that a predetermined path of the crossing wire (9) from the additional wire spool (4) forms the weave with the longitudinal wires (6) from the wire spools (2).