Design optimization of a three-dimensional hexagonal braiding technique

The three-dimensional hexagonal braiding technique, utilizing an individually controllable horn gear mechanism, enables the automatic generation of a wide range of intricate fabric preforms for structural composites. However, the limited yarn-carrying capacity and the potential risk of collisions between horn gears hinder the development of this type of braiding machine. This study proposes an optimized hexagonal braiding technique to enhance the machinery and control system, aiming to improve the yarn-carrying capacity and prevent collisions. Specifically, the optimization includes modifying the switch device, developing a new algorithm for controlling each horn gear, and designing a control panel to facilitate human–computer interaction. Additionally, simulations of various fabric structures demonstrate improved braiding capability compared to traditional hexagonal braiders. Moreover, a prototype braider is assembled, capable of automatically braiding diverse fabrics using the control system, thereby demonstrating its potential to manufacture complex composite preforms.