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Centro De Ingeniería Y Desarrollo Industrial Centro de ingeniería y desarrollo industrial Maestría Germano-Mexicana en Mecatrónica Trabajo de tesis de grado: Design and constuction of a robotic thread changer of an industrial braiding machine. Autor: Luis Ricardo Ramirez Martin del Campo Asesores: Dr. Alfonso Gomez Espinoza Dr. Prof. Ing. Jörg Wollert Asesor Externo: Dr. Ing. Fabian Schreiber Fecha de entrega: 12 de Febrero de 2016 Trabajo en colaboración con Gemini Bussiness Solutions GmbH. I hereby confirm that I have written this work independently and no other than the citied sources indicated in the bibliography have been used. The drawings and pictures in this work have been created by myself or been provided with an appropriate list of sources. This work hasn’t been submitted to any other revision board. Luis Ricardo Ramírez Martin del Campo Aachen 18.09.2015 Dedicatory To my Mom, She always has been there for me. To Angie, we almost didn’t make it, but we did, I love you. To my family, even though a small one, we stick together. To my Colleagues at the ITQ, was wonderful being with you guys. I Acknowledgements I would like to express my deepest gratitude to anyone who helped me to achieve this task. Without their support, I wouldn’t be able to get this project to completion. To Dr. Ing. Fabian Schreiber for giving me the opportunity to collaborate in this project, and also to work with a team of colleagues that have become good friends. To Dr. Prof. Ing. Jörg Wollert for helping me with his great experience on the field of automation; I have learned a lot of new things. To Dr. Alfonso Gomez Espinosa that helped me with the thesis process, I appreciate his experience and accurate remarks. To the FH-Aachen, his professors and personnel who enriched my academic formation and professional expectations. To CIDESI that gave me the opportunity to get to this country and be able to participate in the best academic experience of my life. To Prof. Salvador Perez, Ing. Bertha Velazco, Lic. Alicia Marquez and all the personnel of the Master in Mechatronics in the CIDESI for helping me to get this degree. To my family, colleagues and friends in Mexico, because of them I could be able to get to finish this master. To my colleagues and friends in Germany, even though we hadn’t known each other for long time I feel like I know you for a long time. II Abstract The versatility of the braiding technology for the production of customized braids is nowadays still being done with a high manual effort for setting up the braiding machines. An automation of this process promises lower costs, reduced set-up times and consistently high product quality. In the present study a solution for the automated change of material on a conventional braiding machine is designed and constructed. The specifications and pattern of the braid material should be selected by the customer and transmitted through a network to the braiding machine. The development process is based on the proven design methodology of the VDI guideline 2206 which stands for the development of mechatronic systems, where a wide range of methods for the processing of the individual stages of development is applied, ranging from the scenario technique for requirements elicitation to heuristic methods for finding solutions through concept-rating means and utility analysis. III Table of Contents Table of Contents ......................................................................................................................... I List of Figures ............................................................................................................................ VI List of Tables and Formulas ..................................................................................................... VIII Chapter I: Introduction ............................................................................................................. VIII Chapter II: State of the art............................................................................................................ 3 2.1 Braiding Technology........................................................................................................... 3 2.1.1 Conventional braiding machine and its roots ...................................................................... 6 2.2 Industry 4.0 ...................................................................................................................... 11 2.3 Construction Method ........................................................................................................ 16 2.3.1 Design Support on the Micro and Macro levels ................................................................ 16 Chapter III: Problem Discussion................................................................................................. 21 3.1 Project Justification .......................................................................................................... 24 Chapter IV: Development and selection of the solution .............................................................. 26 4.1 Determination of the functional structure .......................................................................... 26 4.2 Determination and systematic development of partial solutions ........................................ 28 4.2.1 Detailed consideration of the partial solutions .................................................................. 28 4.2.2 Controller system selection .............................................................................................. 36 4.2.3 Reduction of the solution variants .................................................................................... 38 4.3 Selection and evaluation of principle combinations .......................................................... 38 4.3.1 Presentation of the chosen alternative for the mechanical part ........................................ 38 4.3.2 Presentation of the chosen alternative for the electronic part ........................................... 40 Chapter V: Project Development................................................................................................ 42 5.1 Electrical construction. ..................................................................................................... 42 5.1.1 Inputs and outputs of the system. ..................................................................................... 43 5.1.2 Stepper motor installation. ................................................................................................ 43 IV 5.1.3 RFID Antennas and analog distance sensors. .................................................................. 47 5.2.4 Electrical installation and safety devices. ......................................................................... 49 5.2 Control design .................................................................................................................. 51 5.2.1 Gripper and ring stepper motor speed control. ................................................................. 54 5.3 Thread change algorithm:................................................................................................. 58 5.4 Application and network development .............................................................................. 62 5.4.1 Programmable logic controller. ......................................................................................... 63 5.4.2 Desktop application development. .................................................................................... 66 5.4.3 Client application development......................................................................................... 69 Chapter VI: Results. ................................................................................................................... 70 6.1 Thread change time and performance. ............................................................................. 70 6.2 Machine assembly and operation. .................................................................................... 71 Chapter VII: Conclusions ........................................................................................................... 76 References ................................................................................................................................ 78 Appendix ................................................................................................................................... 82 V List of Figures Figure 2.1 Differences between Braiding and Weaving [Eng90] .................................................. 4 Figure 2.2 Difference between biaxial and triaxial braids [SCH12] .............................................. 4 Figure 2.3 Curved-, Linear- and 3D-Braid [LAO11] ..................................................................... 5 Figure 2.4: Braided cake (a), lace (b) and idealized representation (c). [KYOY15] ...................... 6 Figure 2.5: Principle of hand braiding [KYOY15] ......................................................................... 7 Figure 2.6 Braiding mechanism example [IHPH14] ..................................................................... 7 Figure 2.7 Thread movement description [IHPH14] .................................................................... 8 Figure 2.8 Industrial Carriers for textile yarns. [KYOY15] ............................................................ 9 Figure 2.9 Track notation for Horn gears [KYOY15] ...................................................................
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