Rapidly configurable braiding machine
A braiding system having a plurality of mobile carrier devices movable under its own power, each mobile carrier including a plurality of wheels, a motor driving the wheels, a power source, a controller, and a pick-up unit having a receiver. Each of the plurality of mobile carriers has a tow carrier positioned in the receiver, and each mobile carrier is simultaneously movable along a virtual track-less path predetermined for each individual carrier, such that the simultaneous movement of the mobile carrier devices along their predetermined paths form a braid.
1. A braiding system comprising:
a braid formation device; and
a plurality of self-powered mobile carrier devices, each of the plurality of self-powered mobile carrier devices including:
a tow carrier adapted for holding tow material;
a plurality of wheels;
a motor driving the wheels;
a power source; and
a controller;
each of the plurality of self-powered mobile carrier devices simultaneously movable along a virtual track-less path predetermined for each mobile carrier device, the simultaneous movement of the plurality of self-powered mobile carrier devices along their predetermined paths forming a braid.
2. The braiding system of claim 1 comprising:
each mobile carrier device being configured to monitor its movement and make directional corrections to maintain its direction along the virtual path.
3. The braiding system of claim 1 comprising:
each mobile carrier device being configured to monitor its movement relative to other mobile carriers and alter course to avoid collision with other carriers.
4. The braiding system of claim 3 comprising:
each mobile carrier device being configured to determine its direction back to the virtual path after altering course to avoid collision.
5. The braiding system of claim 1 wherein the braid formation device comprises a former plate and a take-off device.
6. The braiding system of claim 1 , wherein the controller includes a command module having a microcontroller for controlling each of the plurality of mobile carrier devices.
7. The braiding system of claim 1 , wherein each of the plurality of mobile carrier devices includes:
a dual differential drive system;
an array of sensors;
a communications system; and
a support structure having a tow carrier holder.
8. The braiding system of claim 1 , wherein the tow carrier includes an active tow tensioner.
9. The braiding system of claim 1 , wherein the braid formation device comprises a mandrel and a support structure supporting the mandrel.
10. The braiding system of claim 1 , wherein each of the plurality of self-powered mobile carried devices includes a pick-up unit having a receiver.
11. A braiding system comprising:
a braid formation device; and
at least two groups of self-powered mobile carrier devices, one of the at least two groups of self-powered mobile carrier devices movable along a generally clockwise path around the braid formation device and the other of the at least two groups of self-powered mobile carrier devices movable along a generally counter-clockwise path around the braid formation device, each of the self-powered mobile carrier devices including:
a tow carrier adapted for holding tow material;
a plurality of wheels;
a motor driving the wheels;
a power source;
a controller; and
a pick-up unit having a receiver;
each of the plurality of self-powered mobile carrier devices simultaneously movable along a virtual track-less path predetermined for each mobile carrier device, the simultaneous movement of the plurality of self-powered mobile carrier devices along their predetermined paths forming a braid.
12. The braiding system of claim 11 , wherein the braid formation device is selected from the group consisting of a mandrel, and a former plate and take-off device.
13. A braiding system comprising:
a braid formation device;
a plurality of self-powered mobile carrier devices, each of the plurality of self-powered mobile carrier devices including:
a tow carrier adapted for holding tow material;
a plurality of wheels;
a motor driving the wheels;
a power source;
a controller; and
a pick-up unit having a receiver;
each of the plurality of self-powered mobile carrier devices simultaneously movable along a virtual track-less path predetermined for each mobile carrier device using line-tracking algorithms from the controller, the simultaneous movement of the plurality of self-powered mobile carrier devices along their predetermined paths forming a braid.
14. The braiding system of claim 13 , wherein the braid formation device is selected from the group consisting of a mandrel, and a former plate and take-off device.
15. A braiding system according to claim 13 , wherein the line-tracking algorithm is capable of sensing path tracks and intersections of path tracks and includes timing indicators for maintaining position of each of the plurality of self-powered mobile devices relative to the path tracks and the timing indicators.
16. A braiding system comprising:
a braid formation device; and
a plurality of self-powered mobile carrier devices, each of the plurality of self-powered mobile carrier devices including:
a tow carrier adapted for holding tow material;
a plurality of wheels;
a motor driving the wheels;
a power source;
a controller; and
a pick-up unit having a receiver;
each of the plurality of self-powered mobile carrier devices simultaneously movable along a virtual track-less path predetermined for each mobile carrier device using a grid of lines forming a pattern of bordered cells, the simultaneous movement of the plurality of self-powered mobile carrier devices along their predetermined paths forming a braid.
17. The braiding system of claim 16 , wherein the braid formation device is selected from the group consisting of a mandrel, and a former plate and take-off device.
18. The braiding system of claim 16 , wherein a center of each bordered cell includes a passive RFID tag ID having a code for identifying the location of each bordered cell.
19. The braiding system according to claim 18 , wherein each of the plurality of mobile carrier devices further includes an RFID reader and a pattern of IR sensors.
20. A braiding system according to claim 16 , wherein each of the plurality of mobile carrier devices is preloaded with a series of sets of target navigation numbers, the series of sets of target navigation numbers including an RFID tag ID, a matrix of IR sensor value associated with an orientation and position of the robot in the grid cell associated with the RFID ID tag and a timestamp relative to the beginning of a cycle in the mobile carrier device path.