Die Vorteile des Systems „Horn“ gegenüber dem Gangbahn-Flügelrad System liegen in der faserschonenden und lageparallelen Flechtfadenverlegung sowie in der gesteigerten Flechtgeschwindigkeit. Die Herausforderung um das Potential des Systems „Horn“ zur Herstellung von Preforms durch Überflechten zu erschließen, bestand in der Integration eines dritten Fadensystems in eine antriebstechnisch umsetzbare Verlegetechnik zur Fertigung einer triaxialen Flechtstruktur. Für die Synthese dieser Antriebstechnik zur kinematisch optimalen Verlegung der Flechtfäden wurde eine prozessorientierte Synthesemethodik, auf Basis einer Technologiesynthese, erarbeitet. / Advantages of the system “Horn” versus the horn gear motion system lie in a gentle and parallel processing of the braiding materials as well as in an increased speed of braiding. The challenge in extrapolating the potential of the system “Horn” for the production of preforms by over-braiding was to integrate a third yarn system into a laying technique that is technically feasible for processing a triaxial braided structure. For the synthesis of this drive technology and to guarantee an optimal kinematic transfer of threads, a process-oriented synthesizing method, based on a technology synthesis, was elaborated.

In this project the objective is to understand how to design a braiding machine capable of automated production of Omnifibre in a research environment. Automated production of Omnifibre is the key issue for the researchers as they want to increase the weaveabilty of the fibers and make it more suitable for use in active textiles. To achieve the necessary knowledge when designing a braiding machine, an extensive literature study was performed which focused on braids, braiding machines, and CNC manufacturing. An Interview with a researcher and with a manufacturing expert was conducted. Simulations of different braiding machine configurations were performed in TexMind braiding machine configurator. Solidworks was used to estimate the size of the braiding machine. A large amount of the machine’s parts were manufactured on a CNC mill and lathe to test manufacturability and to aid in designing optimal subsystems. The result is a proposed design for a braiding machine in the form of a 3-D model and a partially completed prototype used for testing and design evaluation. The conclusion is that Omnifibre is much like other ultra-fine braided threads, and the research on its applicability has a big impact on the braiding machine’s design, especially on flexibility in thread material and braiding patterns.

Die Vorteile des Systems „Horn“ gegenüber dem Gangbahn-Flügelrad System liegen in der faserschonenden und lageparallelen Flechtfadenverlegung sowie in der gesteigerten Flechtgeschwindigkeit. Die Herausforderung um das Potential des Systems „Horn“ zur Herstellung von Preforms durch Überflechten zu erschließen, bestand in der Integration eines dritten Fadensystems in eine antriebstechnisch umsetzbare Verlegetechnik zur Fertigung einer triaxialen Flechtstruktur. Für die Synthese dieser Antriebstechnik zur kinematisch optimalen Verlegung der Flechtfäden wurde eine prozessorientierte Synthesemethodik, auf Basis einer Technologiesynthese, erarbeitet. / Advantages of the system “Horn” versus the horn gear motion system lie in a gentle and parallel processing of the braiding materials as well as in an increased speed of braiding. The challenge in extrapolating the potential of the system “Horn” for the production of preforms by over-braiding was to integrate a third yarn system into a laying technique that is technically feasible for processing a triaxial braided structure. For the synthesis of this drive technology and to guarantee an optimal kinematic transfer of threads, a process-oriented synthesizing method, based on a technology synthesis, was elaborated.

Recent research and development has resulted in a working prototype of an automated process for manufacturing IsoTruss® and other innovative open lattice composite structures which yields faster, and more predictable and consistent parts, while automatically consolidating individual members. This machine is sufficiently versatile to manufacture any type of open lattice structure fabricated from filamentary composite materials. The objectives of the research in this thesis were two-fold: (1) to validate this new process for making IsoTruss structures; and (2) to measure the compression strength and stiffness of specimens produced on the machine. In order to accomplish the first purpose, various parts were manufactured on this prototype machine, including: a six-node IsoTruss structure with single outer longitudinal members, a three-longitudinal member section of an inner longitudinal IsoTruss structure with consolidated members, and a two-bay IsoTruss panel structure. By creating and running patterns to make these parts, the hypothesis that the machine will make any geometry of IsoTruss structure was validated. The second objective of this research was accomplished by testing the compression strength and stiffness of specimens manufactured with this automated process. Buckling versus compression failure of members was examined by varying member aspect ratios. The effect of intersecting helical members was also explored, as was the effect of changing the number of braiding bobbins used to consolidate members. Testing showed that increasing the number of braiders increases consistency of the braided sleeves and reduces scatter in the results. The ratio of helical to longitudinal tows at a joint is directly related to the percent decrease in member strength at the joint. Compression failure of individual members is the preferred method of failure, because this type of failure absorbs significantly more energy. This research proves that the manufacturing process will produce even the most complex IsoTruss geometries, with the necessary consolidation of individual members. Findings also indicate that a few modifications -- such as improved bobbins, more reliable switches, more accurate pulling system, etc. -- will enable this automated process to produce composite lattice structures with superior mechanical properties.