Modeling and analysis of magnetic drive mechanism for 3D braiding machines

Composite materials find applications in both the medical and aerospace industries. As the primary manufacturing equipment for these components, the performance of braiding machines largely determines the final product quality. With the escalating demand in the manufacturing sector for fabrics with variable cross-sections and variable thicknesses, there is an urgent need for a braiding machine capable of flexible trajectory regulation to reduce costs and enhance production efficiency. Addressing technical bottlenecks such as the insufficient flexibility of trajectory control in traditional three-dimensional (3D) braiding machines, this study proposes a magnetic driving mechanism for the electromagnetic assembly of a rotary 3D braiding machine. The specific structural parameters of the mechanism were determined according to the operating conditions and the overall dimensional constraints of the braiding machine. A 3D electromagnetic field finite element (FE) was constructed, incorporating excitations such as ampere-turns a nd boundary conditions like the balloon boundary. The distribution patterns of magnetic field intensity and the force-displacement response characteristics were quantitatively analyzed under varying impeller slot angles and excitation currents. An experimental platform was established to conduct physical tests validating the simulation results. Experimental results demonstrate that the proposed magnetic driving mechanism can stably execute precise actions during the braiding process and supports real-time dynamic regulation of the braiding trajectory.