The present application claims priority to and the benefit of German Application No. 102017000467.6, filed on Jan. 19, 2017, which is incorporated herein by reference in its entirety.
The present invention relates to a braiding machine.
The published patent application DE 10 2011 012 166 A1 describes a braiding machine which makes it possible to produce any braiding patterns. Different courses are connected or combined with each other by means of a mechanical switch in order to achieve different braiding patterns. Switching courses takes time. This is directly related to the course length. The shorter the length of the course between two switching points, the faster the switching must be as the clapper movement will otherwise be interrupted until the switching positioning is completed.
It would be desirable to have a braiding machine that may produce any braiding pattern without long set-up times or downtimes. In addition, the braiding machine should be able to perform a braiding operation with high speed and high reliability.
The object of the invention lies in the creation of a braiding machine with high flexibility and high braiding speed while offering, at the same time, high reliability.
This object is solved by the features of the independent claims. Advantageous developments are defined in the dependent claims.
According to a first aspect, a braiding machine is provided comprising at least two impellers for displacing at least one clapper, wherein the clapper is at least partially made of a ferromagnetic material, and each of the impellers has at least one clapper receiver having a plurality of electromagnets, wherein the electromagnets enclose a partial circumference of the clapper from about 50° to about 120°.
Due to the electromagnetic clapper receiver, braiding may be made very flexible because the clappers may be arbitrarily retained or transferred by appropriately activating or deactivating the solenoids to activate or deactivate a magnetic field.
Preferably, a contact surface of the clapper receiver, with which the clapper comes, or may come, into contact, comprises a plurality of flat surfaces corresponding to the number of electromagnets. The flat surfaces, in connection with a cylindrical clapper, have the advantage that adhesion is not so great as to accelerate a transfer of the clapper.
According to another aspect, a braiding machine is provided which comprises at least two impellers for displacing at least one clapper, wherein the clapper is at least partially made of a ferromagnetic material, while each of the impellers comprises at least one clapper receiver comprising an electromagnet, wherein the electromagnet encloses a partial circumference of the clapper of about 50° to about 120°, and has the shape of a letter L with two legs of substantially equal length, while a contact surface with which the clapper comes, or may come, into contact is formed along both legs.
The L-shape of the electromagnets approximates the shape of the clapper receiver in order to reduce the distance to the clapper. As a result, the clapper may be held securely by a very low magnetic field. In addition, the low magnetic field may be activated and deactivated more quickly in order to accelerate the clapper transfer and thus the braiding process.
Preferably, the electromagnets have two coils or coil sections, which are respectively associated with one of the legs of the L-shape, and/or a contact surface of the clapper receiver has an arcuate shape corresponding to an outer contour of the clapper.
Preferably, the electromagnets of an impeller delivering the clapper are turned off prior to a handover point and/or the solenoids of an impeller taking over the clapper are turned on prior to the transfer point and/or the coils or coil sections or individual electromagnets are activated/deactivated by being supplied with a different voltage and/or different power and/or with a time delay.
More preferably, the electromagnets are switched on or off at about 20° to about 80° before the transfer point.
Preferably, a plurality of impellers is arranged on a flat surface above one another and side by side in rows and columns or in a circle.
More preferably, a plurality of impellers is arranged in concentric circles, wherein each of the concentric circles has the same number of impellers.
According to a further preferred embodiment, at least one additional impeller is arranged in a space between at least two of the concentric circles.
More preferably, a plurality of impellers is arranged on the circumference of a cylinder, so that all the clappers are directed towards the axis of the cylinder, or a plurality of impellers is arranged on the surface of a hemisphere, so that all the clappers are at the same distance from the braiding point at the center of the hemisphere.
The invention will now be explained in more detail by means of embodiments with reference to the drawings. Although individual embodiments are described separately, the individual features of the various embodiments may be combined to form other embodiments that are also intended to be covered by the present disclosure.
It should be understood that the invention is not limited to impellers 2 with four clapper receivers 2a, but that the impellers 2 may have any number of clapper receivers 2a, such as one, two, three, five or more clapper receivers 2a. In addition, the clapper receivers 2a need not have the same angular distance from each other on the circumference of the impeller 2, but may also be arranged irregularly on the circumference of the impeller 2.
Each of the clapper receivers 2a in
If the magnetic field is delayed due to the latency after switching off the current, the clapper 1 is released from the clapper receiver 2a and may be, for example, transferred to another impeller (not shown in
The inventors recognized that an angle 4 formed by the vertical lines S of the adjacent adhesive surfaces 8 should lie within a range of about 50° to about 120°. Preferably, the angle 4 should be in the range of about 80° to about 110°, most preferably in the range of about 90° to about 100°. The angle 4 thus encloses a partial circumference T of the cylindrical clapper 1.
The specified angular ranges offer the advantage of good adhesion of the clapper 1 with simultaneous rapid activation and deactivation of the magnetic field of the electromagnets 3 in order to accelerate clapper transfer. Thus, safe and reliable braiding may be performed at high speed.
In addition, a transfer angle, i.e. the angle of the relative position of adjacent impellers 2 with respect to each other during rotation of the impellers 2, is increased when, due to the preferred angular range, a high magnetic attraction force is exerted on the clappers 1. The term “transfer angle” is to be understood as the angle, which is passed during rotation of the impellers 2, starting from the release of the clapper 1 from the adhesive surface 8 of the forwarding impeller 2 to the arrival of the clapper 1 at the adhesive surface 8 of the receiving impeller. 2
A substantially part-circular or arcuate adhesive surface 8 is provided on the legs 7a, 7b of the L-shape, which corresponds to an outer contour of the clapper 1 in order to provide good adhesion of the clapper 1 to the adhesive surface 8.
Preferably, each coil or each coil section 5a, 5b may be controlled separately or may create a different high magnetic field. This may be achieved, for example, by the coils or coil sections 5a, 5b being supplied with power at different times, or the coils or coil sections 5a, 5b being supplied with a different high voltage and/or different high current. Another possibility for creating a different magnetic field is that the number of windings of one coil 5a may be different from the number of windings of the other coil 5b.
The advantage of the two coils or coil sections 5a, 5b having a different high magnetic field is that the transfer of the clapper 1 may be further optimized or accelerated, for example, when one of the legs 7a behind the other leg 7b in the direction of rotation of the impeller 2, has a stronger or weaker magnetic field and/or a magnetic field that is activated or deactivated with a delay with respect to the other leg 7b.
It should be understood per se that the creation of different high magnetic fields and/or delayed activation is not limited to the embodiment of
Preferably, moreover, the clapper 1 has a sliding element 11 (in particular circular or wheel-shaped) at one axial end of the cylindrical shape in order to be mechanically guided by a corresponding mechanical guide element 10 of the braiding machine.
Just before the transfer point 14, i.e. just before the clapper receivers 2a of the adjacent impellers 2 lie directly opposite as shown in
The greater a transfer angle, the more the remaining time for the transfer of the clapper 1. A high value is therefore desirable. Based on the descriptions and figures, it is already clear that the transfer angle when using a part-circular clapper receiver 2a and the application of only one electromagnet 3, is significantly lower than when using a plurality of electromagnets 3 in a mutual angular arrangement. To substantiate this statement, corresponding calculations have been made, the results of which are shown in
Based on the fact that a magnet of a suitable size can no longer exert an attracting force when the distance to the clapper 1 is too long, distance values between 0 and 1 mm are of interest. Impeller designs with clapper receivers 2a always achieve a higher transfer angular range with constant cylinder spacing. At a maximum distance of about 1 mm and an angular opening of about 60°, this corresponds to a transfer angular gain of about 170%. For the further determination of the system parameters, therefore, only angular impeller openings are considered.
The investigation of the change in the transfer angle as a function of the impeller opening angle requires, first of all, that both the impeller radius and the impeller clearance remain constant for the calculation. The calculated values are based on the following assumptions and largely reflect realistic properties:
The impeller opening angle corresponds to the angle which is formed by the two adhesive surfaces 8.8 of the clapper receivers 2a.
By “impeller wheel radius” is meant the radius from the center or pivot point of the impeller 2 to the circle outer line of the impeller 2.
By “impeller distance” is meant the distance from the circular outer lines to the two adjacent impellers.
As the impeller opening angle increases, the transfer angle values will decrease exponentially.
At opening angles between 110° and 170°, the value of the transfer angle changes by just 1° between 30° and 110°, wherein the difference between the maximum and minimum transfer angle is approximately 7°. If the geometrical properties of the electromagnets 3, such as size and shape, are ignored, smaller impeller opening angles are advantageous since a larger range of the transfer angle may be ensured. Useful opening angles lie between about 30° and about 110°, since at values above this range, the change in the transfer angle is minimal.
The impingement of the clapper 1 on the impeller opening results in different loads and torques on the respective motor axis. Depending on the distance of the point of impingement from the clapper 1 and the impeller 2 to the central axis, different leverage ratios may be achieved as shown in
A 100% leverage corresponds to an impingement of the clapper 1 at the extreme point of the impeller opening, which is approximately equal to the diameter value. The course of the curve may be described essentially by a parabolic drop as shown in
In the stated useful range of the impeller opening angle between about 30° and about 170°, the lever length ratio varies between 97% and 9%, which represents a significant drop. Due to the attracting force of the electromagnet 3, the clapper 1 is accelerated beyond its current path speed and may impinge on an opening edge of the adjacent impeller 2. The larger the resulting torque, the more advantageous it is that the electric motor in question compensates for this shock from the impingement of the clapper 1 on an edge of the impeller 2. It is therefore advantageous to compensate with a motor-side compensation of these shocks upon impingement in order to prevent an increase in load on the braided material used, and thus on the entire braiding to be produced. Thus, braid fractures may be advantageously prevented, which could otherwise lead to an interruption of the braiding process. As a result, the inventors recognized that larger opening angles with respect to the lower leverage are beneficial and may be advantageously taken into account in determining a suitable region for the cylinder transfer.
It should be understood that the invention is not limited to the arrangement of two substantially concentric circles of the impellers 2, but a plurality of three, four, five or even more substantially concentric circles of impellers 2 may be arranged. Furthermore, the invention is not limited to impellers 2 with four clapper receivers 2a, but may also relate to any number of clapper receivers 2a arranged on the impeller 2, or on a plurality of impellers 2, or impellers 2 may be combined with a different number of clapper receivers 2a.
A further possible embodiment relates to the arrangement of a single impeller 2 between two substantially concentric circles of a plurality of impellers 2, as shown in
However, the invention is not limited to the arrangement of concentric circles of impellers 2. Rather, the impellers 2 may also be arranged according to a rectangle or a special (i.e. predetermined) pattern or matrix (i.e. arranged in rows and columns in particular), as shown for example in
Furthermore, it is possible to arrange the impellers substantially along the surface of a hemisphere, as shown in
The invention is not limited to an arrangement of impellers 2 according to
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