U.S. patent application number 14/669941 was filed with the patent office on 2016-03-17 for apparatus and method for manufacture of braided preforms.
The applicant listed for this patent is A&P TECHNOLOGY, INC.. Invention is credited to Andrew A. Head, Victor M. Ivers.
Application Number | 20160076178 14/669941 |
Document ID | / |
Family ID | 55454203 |
Filed Date | 2016-03-17 |
United States Patent
Application |
20160076178 |
Kind Code |
A1 |
Head; Andrew A. ; et
al. |
March 17, 2016 |
APPARATUS AND METHOD FOR MANUFACTURE OF BRAIDED PREFORMS
Abstract
A braiding apparatus may comprise a braiding machine, a lower
guide mechanism, and an upper guide mechanism. The lower guide
mechanism may comprise a multiple-axis robot or a multiple
axis-mechanism. The upper guide mechanism may comprise a
multiple-axis robot or a multiple axis-mechanism.
Inventors: |
Head; Andrew A.;
(Cincinnati, OH) ; Ivers; Victor M.; (Amelia,
OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
A&P TECHNOLOGY, INC. |
Cincinnati |
OH |
US |
|
|
Family ID: |
55454203 |
Appl. No.: |
14/669941 |
Filed: |
March 26, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61970643 |
Mar 26, 2014 |
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61970671 |
Mar 26, 2014 |
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61970677 |
Mar 26, 2014 |
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61970668 |
Mar 26, 2014 |
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61970623 |
Mar 26, 2014 |
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61970952 |
Mar 27, 2014 |
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Current U.S.
Class: |
87/32 ; 87/34;
87/54 |
Current CPC
Class: |
D04C 3/48 20130101; D04C
3/40 20130101 |
International
Class: |
D04C 3/48 20060101
D04C003/48; D04C 3/42 20060101 D04C003/42 |
Claims
1. A braiding apparatus comprising, a braiding machine a lower
guide mechanism comprising either a multiple-axis robot; or a
multiple axis-mechanism; and an upper guide mechanism comprising
either a multiple-axis robot; or a multiple axis-mechanism.
2. The braiding apparatus of claim 1, wherein the braiding
apparatus is adapted for operational engagement with an overbraid
form assembly, said overbraid form assembly comprising an overbraid
form having a leading form edge, a lead guide tool affixed to the
leading edge, and a trailing guide tool; and said operational
engagement with the overbraid form assembly comprising the forming
of a braid over the overbraid form by the braiding machine, and
either engagement of the trailing guide tool by the lower guide
mechanism, or engagement of the lead guide tool by the upper guide
mechanism.
3. The braiding apparatus of claim 2, wherein the braiding
apparatus is adapted for operational engagement with a start
assembly, said start assembly comprising an elongated mandrel; a
start guide tool having a leading start edge; and a start
interlocking tool; and said operational engagement with the start
assembly comprising the forming of a braid over the elongated
mandrel by the braiding machine, and either engagement of the start
interlocking tool by the lower guide mechanism, or engagement of
the start guide tool by the upper guide mechanism.
4. The braiding apparatus of claim 3, wherein said braiding machine
is a maypole braider.
5. The braiding apparatus of claim 4, wherein said lead guide tool
comprises a lead grasp feature adapted for being grasped by the
upper guide mechanism; and a lead interlocking feature.
6. The braiding apparatus of claim 5, wherein said trailing guide
tool comprises a graspable feature adapted for being grasped by the
lower guide mechanism; and a trailing interlocking feature.
7. The braiding apparatus of claim 6, wherein said lead guide tool
comprises a cutting facilitation feature.
8. The braiding apparatus of claim 7, wherein said trailing guide
tool comprises a cutting facilitation feature.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to, and the benefit of,
U.S. Provisional Patent Application No. 61/970,643 filed Mar. 26,
2014, and U.S. Provisional Patent Application No. 61/970,671 filed
Mar. 26, 2014, and U.S. Provisional Patent Application No.
61/970,677 filed Mar. 26, 2014, and U.S. Provisional Patent
Application No. 61/970,668 filed Mar. 26, 2014, and U.S.
Provisional Patent Application No. 61/970,623 filed Mar. 26, 2014,
and U.S. Provisional Patent Application No. 61/970,952 filed Mar.
27, 2014, all of which were filed with the United States Patent and
Trademark Office, and each of which is hereby incorporated herein
by reference.
TECHNICAL FIELD
[0002] The present subject matter relates generally to a braiding
apparatus. More specifically, the present subject matter relates to
an apparatus and method for manufacturing braided articles. In some
embodiments the braided articles may be preforms.
SUMMARY AND BACKGROUND
[0003] The manufacture of braided articles is of substantial
interest. Development of new methods and apparatus to conduct the
braiding of article including, preforms, remains of interest.
[0004] Provided is a braiding apparatus that may comprise a
braiding machine, a lower guide mechanism, and an upper guide
mechanism. The lower guide mechanism may comprise a multiple-axis
robot or a multiple axis-mechanism. The upper guide mechanism may
comprise a multiple-axis robot or a multiple axis-mechanism.
BRIEF DESCRIPTION OF THE FIGURES
[0005] FIG. 1 is an elevation view of a braiding apparatus.
[0006] FIG. 2 is elevation view of a braiding apparatus braiding a
start assembly.
[0007] FIG. 3 is an elevation view of a braiding apparatus cutting
an overbraid on an overbraid form assembly.
[0008] FIG. 4 is a view of an overbraid form assembly.
[0009] FIG. 5 is a view of a start assembly.
[0010] FIG. 6 is an elevation view of a braiding apparatus
operating on an interconnected overbraid form assembly.
[0011] FIG. 7 shows multiple views of the various orientations of
an interconnected overbraid form assembly as it moves though a
braiding operation.
[0012] Also attached is an Appendix with drawings showing related
subject matter.
DETAILED DESCRIPTION
[0013] With reference to FIGS. 1-N, an apparatus usable in a method
to manufacture braided articles may be referred to herein as a
braiding apparatus 100. A braiding apparatus 100 may comprise a
braiding machine 120, a lower guide mechanism 140, and an upper
guide mechanism 160. The lower guide mechanism 140 may comprise
either a multiple-axis robot 142 or another multiple axis
mechanism. The upper guide mechanism 160 may comprise either a
multiple-axis robot 162 or another multiple axis mechanism. The
lower guide mechanism 140 and the upper guide mechanism 160 may
have coordinated control by a controller 104. In certain
embodiments, and without limitation, the braiding machine 120 may
be a maypole braider.
[0014] The braiding apparatus 100 may further comprise a cutting
mechanism 172. The cutting mechanism 172 may be affixed to the
upper guide mechanism 160 or may be part of a separate mechanism
170. Mechanism 170 may be a multiple-axis robot 174 or another
multiple axis mechanism.
[0015] The braiding apparatus 100 may be adapted for operational
engagement with an overbraid form assembly 180. An overbraid form
assembly 180 may comprise an overbraid form 182 having a leading
form edge 181, a lead guide tool 184 affixed to the leading form
edge 181, and a trailing guide tool 186. The overbraid form 182
comprises an overbraid form surface 182a which is adapted for
forming a braid 118 thereon. Operational engagement of the braiding
apparatus 100 with the overbraid form assembly 180 may comprise
forming of a braid 118 over the overbraid form 182 by the braiding
machine 100 and either 1) engagement of the trailing guide tool 186
by the lower guide mechanism 140, or 2) engagement of the lead
guide tool 184 by the upper guide mechanism 160.
[0016] The lead guide tool 184 may comprise a lead grasp feature
185 adapted for being grasped by a grasping component 164 of the
upper guide mechanism 160. By grasping the lead grasp feature 185,
the upper guide mechanism 160 may guide the lead guide tool 184
through a braid formation region 124. The braid formation region
124 is the general area of the braiding machine 120 where the
braided structure 110 begins to form. As the braided structure 110
is laid down on the overbraid form 182 the upper guide mechanism
160 is engaged to the lead guide tool 184 by lead grasp feature 185
through the braid 118. That is, the braid 118 is trapped between
the grasping component 164 of the upper guide mechanism 160 and the
lead guide tool 184.
[0017] The lead guide tool 184 may comprise a lead interlocking
feature 188. A lead interlocking feature 188 may be adapted for
selectable engagement with a counterpart feature such as the
trailing interlocking feature 189 or the start interlocking tool
136 described herebelow. A lead interlocking feature 188 may be
male or female or of other form chosen with good engineering
judgment. A lead guide tool 184 may comprise a cutting facilitation
feature 183. A cutting facilitation feature 183 may facilitate the
cutting of the braid 118 and may be, without limitation a cutting
groove.
[0018] The trailing guide tool 186 may comprise a trailing grasp
feature 187 adapted for being grasped by a grasping component 144
of the lower guide mechanism 140. The trailing guide tool 186 may
comprise a trailing interlocking feature 189. A trailing
interlocking feature 189 may be adapted for selectable engagement
with a counterpart feature such as a lead interlocking feature 188.
A trailing interlocking feature 189 may be male or female or of
other form chosen with good engineering judgment. A trailing guide
tool 186 may comprise a cutting facilitation feature 183. A cutting
facilitation feature 183 may facilitate the cutting of the braid
118 and may be, without limitation a cutting groove.
[0019] The braiding apparatus 100 may be adapted for operational
engagement with a start assembly 130. A start assembly 130 may
comprise an elongated mandrel 132, a start guide tool 134 having a
leading start edge 131, and a start interlocking tool 136.
[0020] The elongated mandrel 132 comprises an elongated mandrel
surface 132a which is adapted for forming a braid 118 thereon. In
some embodiments the elongated mandrel 132 is substantially
cylindrical. Operational engagement of the braiding apparatus 100
with the start assembly 130 may comprise forming of a braid 118
over the elongated mandrel 132 by the braiding machine 100 and
either 1) engagement of the start interlocking tool 136 by the
lower guide mechanism 140, or 2) engagement of the start guide tool
134 by the upper guide mechanism 160.
[0021] The start guide tool 134 may comprise a start grasp feature
135 adapted for being grasped by a grasping component 164 of the
upper guide mechanism 160. By grasping the start grasp feature 135,
the upper guide mechanism 160 may guide the start assembly 130
through the braid formation region 124. As the braided structure
110 is laid down on the elongated mandrel 132 the upper guide
mechanism 160 is engaged to the start guide tool 134 by start grasp
feature 135 through the braid 118. That is, the braid 118 is
trapped between the grasping component 164 of the upper guide
mechanism 160 and the start guide tool 134. The start guide tool
134 may comprise a cutting facilitation feature 133. A cutting
facilitation feature 133 may facilitate the cutting of the braid
118 and may be, without limitation a cutting groove. The start
guide tool 134 may optionally comprise conventional features for
ting or gripping fibers 112, axial bias or otherwise, at the
beginning of the braiding operation.
[0022] The start interlocking tool 136 may be graspable by the
grasping component 144 of the lower guide mechanism 140. By
grasping the start interlocking tool 136, the lower guide mechanism
140 may guide the start assembly 130 into or through the braid
formation region 124. The start interlocking tool 136 may be
adapted for selectable engagement with a counterpart feature such
as a lead interlocking feature 188. A start interlocking tool 136
may be male or female or of other form chosen with good engineering
judgment.
[0023] The leading form edge 181 may be the first portion of the
overbraid form 182 to enter the shed 122 during a braiding
operation.
[0024] Without limitation, one method for using the braiding
apparatus 100 to manufacture braided articles is as follows.
[0025] Lower guide mechanism 140 engages start assembly 130 by
grasping the start interlocking tool 136 with the grasping
component 144 and guides the start assembly 130 so that the leading
edge 131 of the start guide tool 134 is located at a predetermined
position in the braid formation region 124. Fibers 112 are pulled
off of bias carriers 114 and/or axial spools 116 and brought to the
axis 126 of the braiding machine 120 and up along the start
assembly 130. Braiding machine 120 is operated at some operating
speed to generate braid 118 over start guide tool 134 and start
assembly 130 is moved along axis 126 by the lower guide mechanism
140 at some predetermined ratio with respect to the operating speed
of braiding machine 120. Once the braid 118 has formed over the
start guide tool 134, the upper guide mechanism 160 may engage the
start grasp feature 135, trapping the braid 118 between the
grasping component 164 of the upper guide mechanism 160 and the
start guide tool 134, to guide the start assembly 130. The lower
guide mechanism 140 disengages from the start assembly 130. The
lower guide mechanism 140 picks up an overbraid form assembly 180
by engaging with its trailing guide tool 186 and engages the lead
guide tool 184 of the overbraid form assembly 180 with the start
interlocking tool 136 on the start assembly 130. Operation of the
braiding machine 120 to continue braiding resumes until lead guide
tool 184 of overbraid form assembly 180 is in position to be
engaged by the upper guide mechanism 160. At this point a
repetitive operational loop may be initiated. The upper guide
mechanism 160 engages the lead guide tool 184 of the overbraid form
assembly 180 to guide the overbraid form assembly 180. The cutting
mechanism 172 is activated to trim the braid 118 at some desired
location above the region at which the upper guide mechanism 160
engages the lead guide tool 184. Operation of the braiding machine
120 to continue braiding resumes with the upper guide mechanism 160
and the lower guide mechanism 140 coordinating motion through
controller 104 so that the axial fibers follow desired
predetermined paths along the overbraid form assembly 180. When the
overbraid form 182 and a desired portion of the trailing guide tool
186 have been braided, braiding stops. The lower guide mechanism
140 disengages from the trailing guide tool 186. At this point
braiding may stop entirely or if further braiding is desired,
continued. If continuation is desired, the lower guide mechanism
140 picks up a new overbraid form assembly 180 and engages the lead
guide tool 184 of this new overbraid form assembly 180 with the
trailing guide tool 186 of the old overbraid form assembly 180.
Operation of the braiding machine 120 to continue braiding resumes
until the lead guide tool 184 of the new overbraid form assembly
180 in in position to be engaged by the upper guide mechanism 160.
At this point the repetitive operational loop terminates and
operation continues by repeating the steps beginning at the point
of initiation of the repetitive operational loop.
[0026] It should be understood that the braided articles to be
formed may comprise any of a variety of desired shapes. In some
non-limiting embodiments, the braided articles to be formed may be
preforms for use in braided shoes or components of braided shoes,
braided preforms for aircraft seat frames, braided preforms for
vehicle fuselage frames and families of braided structures of
similar geometry but varying dimensions.
[0027] For families of braided structures of similar geometry but
varying overall or other dimensions, the lead guide tool 184 and
the trailing guide tool 186 of the overbraid form assemblies 180
may have varying extents such that the grasp features, lead grasp
feature 185 and trailing grasp feature 187, are located at a fixed
position relative to a common point within the family of braided
structures, thereby enabling the upper guide mechanism 160 and the
lower guide mechanism 140 to grip the lead guide tool 184 and the
trailing guide tool 186 at the same fixed position in the braiding
space as each overbraid form assembly 180 is braided. This
eliminates the need for a hunting mechanism to locate the grasp
features.
[0028] For braided structures comprised of more than one overbraid
layer, the above-described method and apparatus may be employed to
overbraid a first layer on the overbraid form assembly 180, and
subsequent overbraid layers may be laid over the first layer by
feeding the same overbraid form assembly 180, with the first layer
thereon, back through the braiding apparatus 100 and using the
apparatus and method as described to overbraid a second layer on
the braided overbraid form assembly 180. In this manner two or more
layers of braid may be layered as required.
[0029] In some embodiments, multiple apparatus may be used for
layers of varying fiber content, fiber density, etc.
[0030] To facilitate tracking an quality control of preforms some
of the overbraid forms, such as overbraid form assembly 180, may
employ an identification means 192 such as, without limitation,
non-contact, non-line-of-sight means like an embedded RFID tag. By
using such identification means ID and other designation data can
be sensed through any braid layers thereon. Such identification
means 192 may be detectable by detectors 194 in other components in
the apparatus.
[0031] The overbraid forms, such as overbraid form assembly 180,
may be constant geometry forms selected as required for the
production sequence or, may be comprised of customized or
customizable geometric features to facilitate production of
preforms within the range of parts comprising the family of parts
to be produced.
[0032] The overbraid forms, such as overbraid form assembly 180,
may be produced on demand by 3D printing, building up customized
geometric features on a standards form by 3D printing, machining
customized 3D forms on demand from a standard master with overall
dimensions greater than or equal to the maximum dimensions
encompassed by the family of parts, or may be comprised of flexible
forms with internal mechanical, pneumatic, or other internal
adjustment means to change the outer geometric form of the
overbraid form, or the dimensions of a standard master form may be
altered by selective dipping of the form into a hardenable or
semi-hardenable medium chosen with good engineering judgment.
[0033] The braided structure 110 produced on said apparatus 100 and
by said method may be comprised of conventional triaxial braided
structures with dry fibers wherein the axial fibers 112 laid into
the regular, or plain, braid lock the overall geometry of the
braided structure 110 once the overbraid is fully formed over the
entire overbraid form 182.
[0034] Alternatively, hot melt fibers may be co-wound with the
axial fibers 112 with heat then applied to the fully-formed braid
118 continuously or periodically in the region below the lead grasp
feature 185 through to the trailing grasp feature 187 or portions
of said region thereby further assisting the retention of the
fully-formed overbraid braided structure 110.
[0035] Alternatively, elastic axial fibers may be substituted for
some or all generally inelastic fibers to facilitate making
preforms of a braided structure 110 that can be stretched to remove
them from the overbraid form 182 and then return to the original
overbraid shape or, once remove, to permit the braided structure
110 to be stretched over other forms to facilitate subsequent
processing.
[0036] It should be noted that the engagement of the above noted
interlocking components, start interlocking tool 136, lead
interlocking feature 188, and trailing interlocking feature 189 may
be rotatable engagement whereby the engaged components are free to
rotate with respect to one another about multiple dimensions
simultaneously. Such engagement may be chosen with good engineering
judgment. Such engagement may include various kinds of ball
joints.
[0037] While the subject matter has been described with reference
to certain embodiments, it will be understood by those skilled in
the art that various changes may be made and equivalents may be
substituted without departing from the scope of the subject matter.
In addition, many modifications may be made to adapt a particular
situation or material to the teachings of the subject matter
without departing from its scope. Therefore, it is intended that
the subject matter not be limited to the particular embodiment
disclosed, but that the subject matter will include all embodiments
falling within the scope of the appended claims.
* * * * *