Extended horn gears in 3D maypole braiding

Abstract

This article presents the theoretical background for the arrangement of horn gears in maypole braiding machines in order to act as equivalent larger gears. The theoretical analysis is verified with numerical simulation and experiments. After review about the state of the art, an analysis of the process for one specific configuration of horn gears is given. This analysis demonstrates how a set of horn gears can be arranged to work as an equivalent to a larger one horn gear. The braiding equation is checked as remaining valid for such extended configurations, too. The theoretical result is verified using numerical simulation for all cases and practical validation for several variants. The theoretical rules give a clear extension of the current braiding knowledge and make the design of complex configurations of braiding machines more systematic and clear.