INTERIM REPORT

DOM II CEP

Rope Braiding Machine

Group Members:
Hassan Ayub (2018144) Abdul Vasay (2018015)
Farjad Shahid Hassan (2018112) Chaudhary Saadullah (2018095)
M. Areeb (2018242)
 TABLE OF CONTENTS

INTRODUCTION ----------------------------------------------------------------------------- 1
Aims and Objectives------------------------------------------------------------------------1
Description------------------------------------------------------------------------------------ 1
Design Constraints-------------------------------------------------------------------------- 1
Limitations------------------------------------------------------------------------------------ 1
LITERATURE REVIEW 2
PROGRESS TABLE 4

ANALYTICAL SOLUTION---------------------------------------------------------------------------------------- 6
Labelled View of Gears---------------------------------------------------------------------6
Free Body Diagram-------------------------------------------------------------------------- 7
Manual Solution----------------------------------------------------------------------------- 11
CAD MODELS----------------------------------------------------------------------------------------------------- 15
Assembled View----------------------------------------------------------------------------- 15
Exploded View-------------------------------------------------------------------------------- 16
PROBLEMS ENCOUNTERED AND CHANGES IN REQUIREMENTS AND MODIFICATIONS-----18
BIBLIOGRAPHY--------------------------------------------------------------------------------------------------- 19

NOMENCLATURE
N --->Number of Teeth of Gear
m --->Standard Module of
Gear P --->Diametral Pitch
d --->Pitch
Diameter p
--->Circular Pitch
ɸ --->Pressure
Angle a Data Table
--->Addedendum b
Data Table
--->Deddendum
V --->Pitch Line
 DATA TABLE

For Gear Numbers 2,5 and 6:

N2=N5=N6=30
m=2
d2=d5=d6=60
mm

For Gear Numbers 4,3,7,8,9,10:

N4=N3=N7=N8=N9=N10=20
m=1
d4=d3=d7=d8=d9=d10=20 mm

For Both Gears

ɸ= 20°
a= m
b= 1.25m

Note: Further values will be computed from this data

Remaining calculations will be done in Final Report

 Equations and Tables to be used
Course Textbook ‘Shigley’s Mechanical Engineering and Design 10th Edition’ to be
consulted

P=N/d (Eq 13-1)

M=d/N (Eq 13-2)

P=πd/N=πm (Eq 13-3)

pP=π (Eq 13-4)

𝟐𝒌
Np= (𝟏+𝟐𝒎)𝒔𝒊𝒏𝟐 ɸ (𝒎 + √𝒎𝟐 + (𝟏 + 𝟐𝒎)𝒔𝒊𝒏𝟐ɸ (Eq 13-11)

𝐍𝟐
n3=|𝐍𝟑 𝐧𝟐| (Eq 13-29)

𝝅𝒅𝒏
V= 𝟏𝟐 (Eq 13-34)

𝟔𝟎𝟎𝟎𝟎𝑯
Wt = 𝝅𝒅𝒏 (Eq 13-36)
 INTRODUCTION
Aims and Objectives:
The aim and objective of this project is
to design a small scale ‘Automatic
Braiding
Machine’ that fulfills the design criteria
and is efficient and practical.
Description:
A braiding machine is a device that
performs braiding operation; braiding is
a complex structure or a pattern
formatting process by interlacing three
or more strands of yarn or wire. It is
commonly used to form textile
products, braided wire or composite
preform tubes. Various technologies are
available in market to fabricate strings
in a different format. Braiding materials
include natural and synthetic yarns,
metal wires, leather tapes etc. Our
design would consist of a driver shaft
connected with a DC motor, a gear train
attached with the driver shaft to
increase the RPM, four bobbins
mounted to four gears that are in turn
connected to the driver shaft. The wire
strands would be passed through two
vertically adjacent
1
rollers and tightly knot on hook at some
distance from the rollers. The hook will
be fixed on a vertical frame. In this way
initial Tension to the strands will also be
provided. A total of 9 gears would be
used.
Design Constraints/Requirements:
 Minimum 3 braiders are required
 Machine capable of braiding a
rope of 8mm diameter
 CAD modeling should be done in
Solidworks or Creo.
 Mention the Factor of Safety and
speed of braiding in your report
 Doing calculations as per the
failure criteria to be used in
design
 Sustainability analysis required
 Machine should be robust,
lightweight and run smoothly
Limitations:
 Can not be used on large scale
 Slow operation due to small RPM
of motor
 Can not be used for extensive
period as the system may begin
to heat up
 LITERATURE REVIEW
Vincent A. Iannucci: In this rotary braiding machine,
a sleeve having a rounded forward portion is
mounted on a stationary guide cylinder located on the
center axis of the machine. The sleeve is driven in a
reciprocating manner in the axial direction by a push
rod which is coupled through a gear reduction
mechanism to the ring gear of the machine so that the
reciprocation of the sleeve is in timed relation with
the rotation of the machine. The yarn or wire strand is
supplied from two sets of bobbins which are driven
along circular paths in opposing directions. When the
reciprocating sleeve is in its retracted or rearward
position, crossed strands from the bobbins approach
the forward edge of the stationary guide cylinder. As
the crossed strands reach the stationary guide
cylinder, the reciprocating sleeve moves to its
forward position lifting the strands away from the
forward edge of the stationary guide cylinder.
(Iannucci, 1982)
Francis J. Cimprich: This rope braiding machine has
the rear deck interconnected to the front deck which
is composed of three separate elements; the inner
deck plate, the outer deck plate and the quoits. The
respective elements are of a sandwich construction,
wherein a viscoelastic material is bonded to outer
plate members to provide a dampening of the noise.
In addition, the carrier members are similarly
constructed to dampen the noise by a sandwich
construction, wherein the flanges of the carrier have
an inner layer of viscoelastic materials. The carriers
which support the wire spools are driven in a
crisscrossing pattern to provide a braiding action of
the wire as it is layed onto a longitudinally moving
hose. (Cimprich, 1979)
Vincent Alfonso Iannucci’s braiding machine
includes a first rotatable table, stationary sun gear
plus a second rotatable table mounted thereon. The
first table is rotated which includes circular array of
rotatable shafts. The shafts are parallel to the tubular
member with a planetary gear which is aligned with
and causes the sun gear to rotate upon the rotation of
first table. A drive gear is fixed on the first end of
shaft connected to a encircled gear onto the second
table. It causes the second table to rotate in opposite
2
direction to the first one. A circular track is mounted
on the first table between the circular array and the
area of braiding. Every slot enables a aligned strand
arm mounted on the first table which is connected to
the second table via a crank and linkage arrangement.
Each of the plurality of inner strand is fixed onto the
circular path to move along in opposite direction via
pair of alternating drive dogs fixed on the second
table, which prevents contact with outer strands and
inner strands supply bobbin. (Iannucci, 1976)
Donald Richardson patented A maypole type braider
for reinforcement of hose and other tubular products
and for production of ropes and cables. Having the
mechanism for directing strand supply carrier spindle
in serpentine path around the braiding point. This
mechanism includes a circle of carrier spindle
drivers, cooperating means on the driver and carrier
spindles for retaining each carrier spindle in contact
to a driver which is driven for transferring each
spindle from one driver to the next driver of the
circle. Cooperating is eliminating the necessity of
track plate or stationary part fixed on carrier spindles.
The braider is used for maintaining a strand pay-off
point of each carrier on the line drawn via the center
of the spindle and braiding point during the
movement of the carrier spindles in their serpentine
paths around the braiding point. It contributes to the
functioning of the carrier spindle retaining and
transfer means. (Richardson, 1972)
Hayaska Yoshiya :Functioning of braiding machine
is based on rotating a plurality of horn dogs,
respectively in synchronism and alternately each in
reverse directions and running a plurality of carriers
for yarn supply along carrier ways while transferring
said carrier successively to neighboring horn dogs,
and is provided with a belt drive system comprising
plurality of said horn dogs, and a synchro belt for
rotating each synchro pulley in synchronism and
alternatively each in reverse direction by being
passed over between a plurality of said horns.
(Yoshiya, 1988)
Vincent Sokol :Braiding machine comprises of a first
plurality of wire bobbins in an annular array which
dispense yarn to the central axis which array moves
in one direction about the axis and a second plurality
of wire bobbins in a radially more inward annular
 3
array, and each of which dispenses wire to a wire detector controls the advancing of the mechanism and
guide that delivers wire to the central axis; the second controls it if there are any irregularities in the braided
bobbins and the wire guides move together in the harness. (Celani, 1988)
opposite direction around the first bobbins; each wire
Carter Francis Lloyd of Massachusetts, USA,
guide selectively shifts between a position radially
invented a design which was an improvement in
outwardly of the first wire bobbins and radially
internal cam rotary braiding machines where each
inward of the first wire bobbins. (Sokol, 1974)
lower carrier member included many movable, and
Charles Faure-Roux of St-Chamond, France, mounted pulleys used to convey a strand of material
invented a braiding machine in 1930 for applying a from a supply bobbin upward to the upper carrier
sheath of braided material around a core comprising a members, the pulleys were arranged to reduce the
flexible carrier adapted to be put under tension, unwanted stresses which were normally imposed on
means for securing between the ends of said carrier the strand as it was conveyed upward over a deflector
and the said core, pulleys supporting said carrier, member and as it dropped off the trailing edge of the
means for rotating said pulleys alternately in opposite deflector. Further structural improvements were
directions and means for adjusting length of said made with respect to the spindle assembly used for
carrier. Its proposed application was a shock absorber the supply bobbin to reduce the normal movement of
or extensible device e.g. in airplane landing gears. the spindle assembly components during operation
(Faure-Roux, 1930) and to reduce further undesired stresses on the strand.
(Lloyd 1999)
Vincent Sokol of New York, USA, invented a
braiding machine with continuous tension filament
control in 1978. It’s mechanism was that two annular
arrays of bobbins of filaments of wire, yarn, or the
like spin about a common axis and filament from
each of the bobbins is wrapped about this axis, with
the filaments from one array being moved radially
inwardly and outwardly of the filaments from the
inner array as both bobbin arrays are rotating in
opposite directions so as to wind the filament about
the axis. This invention could be used in two
different modes. In the first mode, there is constant
tension on the outer array bobbin filaments, without
the use of a compensator or filament tensioning
means. In the second one, through a minor
substitution of elements, uses deflector means, but
the deflector means of the invention adapt the
braiding machine to rotate in opposite directions.
(Sokol, 1978)

Jeffrey A. Celani of California, USA, made a design

that was to be an improvement of mechanical
braiding machines. Bobbins supporting the thread
were arranged circumferentially. His design was
focused on making possible the continuous motion of
the machine by utilizing a sensor, a detector, and
actuator arms. The sensor was actuated to control the
operation of a mechanism for advancing the braided
harness out from the zone of braiding operation to
allow the unrestricted motion of the harness. The
 PROGRESS TABLE 4

Task Progress Due Date

 Design Discussion 1 -
Search for research
Done 10-10-2020
papers and patents
regarding
braiding machine
 Procurement Operation 1 -
Search for prices of
components from the Done 12-10-2020
market of
Islamabad/Rawalpindi

 Literature Review drafting -

Compiling relevant
educational documents Done 10-10-2020
found online or in different
books

 Design Discussion 2 –
Finalize possible idea which
Done 1-11-2020
can be integrated in our
design

 Distribution of work
1. CAD Modelling
and FEA Team –
Hassan Ayub and
Done 10-10-2020
Farjad Shahid
2. Manual
Calculation

Team –
 Chaudhary 5
Saadullah, M.
Areeb and
Abdul Vasay
3. Verification of
calculation –
Hassan Ayub
and Farjad
Shahid
4. Data
Management
Team – M.
Areeb and
Abdul Vasay
5. Report
Writing Team

– Hassan
Ayub and
Chaudhary
Saadullah

 Manual Calculations Partially Done 25-11-2020

 CAD Modelling Done 5-11-2020

 Sustainability Analysis Pending 25-11-2020

 FEA and Engineering

Pending 25-11-2020
Drawing

 Material Selection Pending 20-11-2020

NOTE: Fabrication part is excluded due to the current pandemic situation.

 Analytical Solution 6

Labelled View of Gears:

11 7

8 4
3
2

10

5
Free Body Diagrams: 7
8
9
10
11
12
13
14
 15
CAD MODELS (modelled in Fusion 360)
Assembled View:(Design maybe subjected to minor changes in Final Report)

Fig 1

Fig 2
 16

Exploded View:

Fig 3

Fig 4
Fig 5
PROBLEMS ENCOUNTERED AND CHANGES IN
REQUIREMENTS AND MODIFICATION:
 Due to pandemic situation, the a simple DC motor was chosen in
procurement of fabrication the final design.
material and fabrication itself

couldn’t be initiated. So, the

project will be theoretical based
but the design proposed is
entirely practical and can easily
be fabricated.
 In order to obtain a lightweight,
robust and sustainable machine,
the appropriate work material
needs to be chosen, such that
the

different components don’t fail,

have a suitable strength to
weight ratio and the machine
has a greater life.
 Our initial design suggested the
use of infinity motion for the
wire bobbins. But due to time
constraints, cost and complexity,
a much straight forward
approach was adopted as
mentioned earlier.
 Our initial design suggested the
use of Arduino Uno along with a
stepper motor for generating
motion. But due to time
constraints, cost and complexity,
 19

BIBLIOGRAPHY  BRADING MACHINE

[Patent] / invent.
Iannucci Vincent
Alfonso. - United States,
Sept 27, 1976.
 BRADING MACHINE
WITH SYNCHRO BELT
SYSTEM [Patent] /
invent. Yoshiya
Hayasaka. - Japan, Nov
17, 1988.
 BRAIDDING MACHINE
[Patent] / invent. Faure-
Roux Charles. - United
States, Nov 21, 1930.
 BRAIDING MACHINE
[Patent] / invent.
Cimprich Francis J.. -
United States, Jul 26,
1979.
 BRAIDING MACHINE
[Patent] / invent.
Richardson Donald. -
United States, Aug 14,
1972.
 BRAIDING MACHINE
WIRE CONTROL
[Patent] / invent. Sokol
 Vincent. - United States, June 6, 1974.
 BRAIDING MACHINE WITH CONTINUOUS
TENSION FILAMENT CONTROL [Patent]
/ invent. Sokol Vincent. - United States, Feb
15, 1978.
 ROTARY BRAIDING MACHINE [Patent] /
invent. Iannucci Vincent A.. - United
States, Mar 12, 1982.