Process planning of hexagonal 3D braiding using an equivalent virtual braiding machine model

At present, the braiding process is heavily dependent on technicians’ experience for the second-generation hexagonal braiding machine. Meanwhile, the Maypole braiding principle, as a widely adopted tubular braiding process, cannot be directly applied to this braiding machine. These situations restrict the flexibility of the second-generation hexagonal braiding machine and make it difficult to fully develop the diversity of fabric structures. To address this issue, this paper proposes a process design method based on equivalent virtual braiding machine model. It conducts theoretical analysis and algorithmic research around two core aspects of the braiding process: the initial arrangement of carriers and motion trajectory planning. Firstly, different equivalent horn gears are constructed. The mathematical model of the equivalent virtual braiding machine is further established. Based on this model, the hexagonal braiding machine can not only apply the Maypole principle but also realize complex trajectory planning of carriers. Secondly, according to the structural characteristics of the fabric and the Maypole principle, the initial arrangement of carriers is determined. The position information of carriers at each step is calculated and recorded. Then, by setting the interweaving centerline, the positions of effective slots are determined and the motion mode of carriers is judged, thereby deriving the motion trajectory of carriers and its solution algorithm. Finally, the mapping relationship is inversely deduced between the virtual model and the actual braiding machine, so a process conversion algorithm linking the two systems is established. This study enables the standardized design and rapid development for the hexagonal braiding process.