Autonomous Artificial Muscle Fiber Coiler System and Method of Use

Abstract

The present invention is an autonomous artificial muscle fiber coiler system. The system comprises a motor-driven spool holder for feeding monofilament material under controlled tension, a pulley system to regulate tension dynamically, and a bevel gear assembly with synchronized large bevel gears and a smaller third bevel gear to twist the monofilament into a desired helical structure. Two mirrored or parallel motor drivers, controlled by a power supply unit, vary the speed and direction of the gears to achieve customized twist density. The system is designed to produce consistent and precise coiled fibers for applications in robotics, prosthetics, and advanced materials. The coiler can also produce graded fibers by dynamically adjusting tension and twist density. The system supports multiple materials, including nylon, polyester, Kevlar, and conductive polymers.

Claims

1. An autonomous artificial muscle fiber coiler system comprising: a motor-driven spool holder; a monofilament fiber; a power supply unit; a plurality of controllers; a pulley system; and a bevel gear assembly; wherein said motor-driven spool holder holds said monofilament fiber; wherein said monofilament fiber is fed to said pulley system of the artificial muscle fiber coiler system; wherein said pulley system having a plurality of pulleys for providing dynamic tensioning and twisting movement of said monofilament fiber; wherein said plurality of pulleys rotate synchronously for regulating said monofilament fiber dynamic tension and for controlling a length of said monofilament fiber for forming an artificial muscle fiber; wherein said bevel gear assembly twists said monofilament fiber into a coiled structure; wherein said bevel gear assembly having a first bevel gear and a second bevel gear rotating for the twisting movement of said monofilament fiber; wherein said bevel gear assembly having a third bevel gear disposed between said first bevel gear and said second bevel gear; wherein said first bevel gear and said second bevel gear are larger than said third bevel gear; and further wherein said third bevel gear synchronizes rotation of said first bevel gear and said second bevel gear and controls the twists of said monofilament fiber.

2. The autonomous artificial muscle fiber coiler system of claim 1, wherein said bevel gear assembly having two parallel motor drivers for driving said bevel gear assembly.

3. The autonomous artificial muscle fiber coiler system of claim 2, wherein said two parallel motor drivers vary a speed of driving said third bevel gear.

4. The autonomous artificial muscle fiber coiler system of claim 3, wherein said bevel gear assembly having a material selected from the group consisting of a steel, a brass, an aluminum, and a plastic.

5. The autonomous artificial muscle fiber coiler system of claim 1, wherein a gear ratio of said first bevel gear and said second bevel gear is 1:1 and a gear ratio of said third bevel gear is from 1:1 to 2:1.

6. The autonomous artificial muscle fiber coiler system of claim 5, wherein said first bevel gear and said second bevel gear having from 30 teeth per inch to 40 teeth per inch and said third bevel gear having from 15 teeth per inch to 20 teeth per inch.

7. The autonomous artificial muscle fiber coiler system of claim 6, wherein said monofilament fiber selected from the group consisting of a nylon, a polyester, a Kevlar, a conductive polymer, an elastomer, and a carbon fiber filament.

8. The autonomous artificial muscle fiber coiler system of claim 7, wherein said power supply unit providing electric power to the muscle fiber coiler system.

9. The autonomous artificial muscle fiber coiler system of claim 8, wherein said power supply unit having said plurality of controllers for fine control over a supplied voltage and a current.

10. The autonomous artificial muscle fiber coiler system of claim 6, wherein said first bevel gear and said second bevel gear rotate synchronously.

11. The autonomous artificial muscle fiber coiler system of claim 10, wherein said third bevel gear rotates non-synchronously with said first bevel gear and said second bevel gear.

12. A method of producing an artificial muscle fiber, the method comprising the steps of; providing a motor-driven spool holder, a monofilament fiber, a power supply unit, a plurality of controllers, a pulley system, and a bevel gear assembly, wherein said bevel gear assembly having a first bevel gear and a second bevel gear rotating for a twisting movement of said monofilament fiber, wherein said bevel gear assembly having a third bevel gear disposed between said first bevel gear and said second bevel gear, further wherein said first bevel gear and said second bevel gear are larger than said third bevel gear; holding said monofilament fiber with said motor-driven spool holder; feeding said monofilament fiber to said pulley system of the artificial muscle fiber coiler system; tensioning dynamically said monofilament fiber with said pulley system including a plurality of pulleys; twisting said monofilament fiber; rotating synchronously said plurality of pulleys for regulating said monofilament fiber dynamic tension and for controlling a length of said monofilament fiber for forming an artificial muscle fiber; twisting said monofilament fiber into a coiled structure with said bevel gear assembly; synchronizing rotation of said first bevel gear and said second bevel gear with said third bevel gear; and controlling said twisting of said monofilament fiber with said third bevel gear.

13. The method of producing an artificial muscle fiber of claim 12, wherein a gear ratio of said first bevel gear and said second bevel gear is 1:1 and a gear ratio of said third bevel gear is from 1:1 to 2:1.

14. The method of producing an artificial muscle fiber of claim 13, wherein said first bevel gear and said second bevel gear having from 30 teeth per inch to 40 teeth per inch and said third bevel gear having from 15 teeth per inch to 20 teeth per inch.

15. The method of producing an artificial muscle fiber of claim 14, wherein said monofilament fiber selected from the group consisting of a nylon, a polyester, a Kevlar, a conductive polymer, an elastomer, and a carbon fiber filament.

16. The method of producing an artificial muscle fiber of claim 14, wherein said first bevel gear and said second bevel gear rotate synchronously.

17. The method of producing an artificial muscle fiber of claim 16, wherein said third bevel gear rotates non-synchronously with said first bevel gear and said second bevel gear.

18. A method of producing an artificial muscle fiber, the method comprising the steps of: providing a motor-driven spool holder, a monofilament fiber, a power supply unit, a plurality of controllers, a pulley system, and a bevel gear assembly, wherein said bevel gear assembly having a first bevel gear and a second bevel gear rotating for a twisting movement of said monofilament fiber, wherein said bevel gear assembly having a third bevel gear disposed between said first bevel gear and said second bevel gear, further wherein said first bevel gear and said second bevel gear are larger than said third bevel gear; holding said monofilament fiber with said motor-driven spool holder; unwinding said monofilament fiber from said motor-driven spool holder; transferring said monofilament fiber to said pulley system; feeding said monofilament fiber to said pulley system of an artificial muscle fiber coiler system; tensioning dynamically said monofilament fiber with said pulley system including a plurality of pulleys; rotating said plurality of pulleys for regulating said monofilament fiber dynamic tension; controlling a length of said monofilament fiber for forming an artificial muscle fiber; twisting said monofilament fiber into a helical structure with said bevel gear assembly; synchronizing rotation of said first bevel gear and said second bevel gear with said third bevel gear; and controlling said twisting of said monofilament fiber with said third bevel gear; wherein a gear ratio of said first bevel gear and said second bevel gear is 1:1 and a gear ratio of said third bevel gear is from 1:1 to 2:1, further wherein said first bevel gear and said second bevel gear having from 30 teeth per inch to 40 teeth per inch and said third bevel gear having from 15 teeth per inch to 20 teeth per inch.

19. The method of producing an artificial muscle fiber of claim 18 further comprising the step of: adjusting dynamically a motor speed of said bevel gear assembly to vary a twist density of said monofilament fiber.

20. The method of producing an artificial muscle fiber of claim 18, wherein said first bevel gear and said second bevel gear rotate synchronously, and further wherein said third bevel gear rotates non-synchronously with said first bevel gear and said second bevel gear.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The description refers to provided drawings in which similar reference characters refer to similar parts throughout the different views, and in which:

[0019] FIG. 1 illustrates a perspective view of the artificial muscle fiber coiler system of the present invention in accordance with the disclosed structure;

[0020] FIG. 2 illustrates a perspective view of the bevel gear assembly used in the artificial muscle fiber coiler system of the present invention in accordance with the disclosed structure; and

[0021] FIG. 3 illustrates a flow chart depicting a process of coiling monofilament performed by the artificial muscle fiber coiler system of the present invention.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

[0022] The innovation is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding thereof. It may be evident, however, that the innovation can be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate a description thereof. Various embodiments are discussed hereinafter. It should be noted that the figures are described only to facilitate the description of the embodiments. They are not intended as an exhaustive description of the invention and do not limit the scope of the invention. Additionally, an illustrated embodiment need not have all the aspects or advantages shown. Thus, in other embodiments, any of the features described herein from different embodiments may be combined.

[0023] As noted above, there exists a long-felt need in the art for an autonomous system that can efficiently and consistently produce artificial muscle fibers. There is also a long-felt need in the art for a system that eliminates the labor-intensive and error-prone process of manually coiling artificial muscle fibers. Additionally, there is a long-felt need in the art for a system that provides uniformity and precision in coiled fibers. Moreover, there is a long-felt need in the art for a solution that can dynamically control tension and twist density to produce artificial muscle fibers. Further, there is a long-felt need in the art for a system that can handle a wide range of monofilament materials, including nylon, polyester, Kevlar, and conductive polymers, to support diverse applications. Furthermore, there is a long-felt need in the art for a robust, scalable system capable of producing artificial muscle fibers in continuous lengths without frequent interruptions for adjustments or repairs. Finally, there is a long-felt need in the art for an autonomous artificial muscle fiber coiler system that enhances efficiency, precision, and versatility in fiber production while minimizing material waste and manual intervention.

[0024] The present invention, in one exemplary embodiment, is an artificial muscle fiber coiler system. The system includes a motor-driven spool holder adapted to hold a monofilament material and feed the monofilament steadily and under controlled tension, a pulley system comprises a plurality of pulleys configured to provide dynamic tension and regulate the length of the monofilament where coiling occurs, a bevel gear assembly comprises a first large bevel gear and a second large bevel gear rotating synchronously, and a smaller third bevel gear disposed between the first and second large bevel gears, is configured to synchronize the rotation of the large bevel gears and control the twisting process of the monofilament. Two mirrored or parallel motor drivers are configured to drive the bevel gear assembly and vary the speed and direction of the smaller third bevel gear to twist the monofilament into a desired coiled structure.

[0025] Reference will now be made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals are used in the drawings and the description to refer to the same or like parts.

[0026] Referring initially to the drawings, FIG. 1 illustrates a perspective view of the artificial muscle fiber coiler system of the present invention in accordance with the disclosed structure. The autonomous artificial muscle fiber coiler system 100 of the present invention is designed to automate the process of coiling artificial muscle fibers for various applications like robotics and prosthetics. More specifically, the system 100 employs a robotic or autonomous system to perform the coiling process, eliminating the need for manual labor. Further, the system 100 provides consistent and precise coiling, minimizing irregularities and fiber breakage. The system 100 includes a motor-driven spool holder 102. The motor-driven spool holder 102 is adapted to hold the raw monofilament material/fiber 104 for the coiling process and feeds the monofilament steadily and under controlled tension into the next stages of the system 100. The motor-driven spool holder 102 also minimizes slack and prevents irregularities in the fiber. Monofilament including but not limited to nylon, polyester, Kevlar, conductive polymers, elastomers, carbon fiber filaments, and more can be used in the system 100.

[0027] A power supply unit 106 provides electric power to different electronic components of the system 100. The unit 106 includes a plurality of controllers 108 for fine control over the supplied voltage and suppled current. The power supply unit 106 may include batteries or can also be connected to conventional AC power supply for providing electrical supply to the artificial muscle fiber manufacturing system 100. The power supply unit 106 preferably provides direct current compatibility with different motors used in the system 100.

[0028] The monofilament 104 is fed to a pulley system 110 of the artificial muscle fiber coiler system 100. The pulley system 110 includes a plurality of pulleys 112 for providing dynamic tensioning and movement for the monofilament. The pulleys 112 rotate synchronously for regulating the fiber's tension and controlling the length of the fiber where the coiling occurs. The pulley system 110 also eliminates issues with uneven coils or fiber breaks, ensuring uniformity and reliability in the artificial muscle fibers.

[0029] A bevel gear assembly 114 is designed to twist the monofilament into the desired coiled structure. The bevel gear assembly 114 includes a first large bevel gear 115 and a second large bevel gear 116. The large bevel gears 115, 116 rotates for twisting the monofilament and a smaller third bevel gear 118 is disposed between the two large bevel gears 115, 116. The smaller third bevel gear 118 is configured to synchronize rotation of the large bevel gears 115, 116 and control the twisting process of the monofilament.

[0030] Two mirrored or parallel motor drivers 120a, 120b are disposed in the artificial muscle fiber manufacturing system 100 and are used for driving the motors used for the bevel gear assembly 114. The motor drivers 120 (i.e., 120a, 120b) are coupled to the power supply unit 106 and regulates the power supply for fine control over motor speed and direction. The motor drivers 120 (i.e., 120a, 120b) may include a plurality of electronic components such as resistors, capacitors, and more. The motor drivers 120 (i.e., 120a, 120b) vary the speed of driving of the smaller gear 118, thereby twisting the monofilament fiber. Preferably, the system 100 is portable and can be placed on a platform 124 which can be positioned on any surface for easy placement and portability. The platform 124 can be made of glass, metal, wood, or any other durable and lightweight material.

[0031] FIG. 2 illustrates a perspective view of the bevel gear assembly used in the artificial muscle fiber coiler system of the present invention in accordance with the disclosed structure. The bevel gear assembly 114 is disposed on a frame 202 which includes a power connector 204 for connecting to at least one motor driver. The large bevel gears 115, 116 preferably rotate synchronously and the smaller third bevel gear 118 twists the monofilament. The smaller third bevel gear 118 rotates non-synchronously with the large bevel gears 115, 116. Referring again to FIG. 1, the bevel gear assembly 114 includes a supporting member 122 for supporting the assembly 114 and preventing lateral movement of the bevel gears.

[0032] FIG. 3 illustrates a flow chart depicting a process of coiling monofilament performed by the autonomous artificial muscle fiber coiler system of the present invention. Initially, the spool holder 102 rotates and unwinds the monofilament therefrom (Step 302). The monofilament is continuously transferred to the pulley system 110 where the plurality of pulleys 112 provides a consistent tension in the monofilament (Step 304). Then, the bevel gear assembly 114 twists the monofilament into the desired helical structure (Step 306), and the coiled filament is wound onto a take-up spool for storage (Step 308).

[0033] In some embodiments, the pulley system 110 dynamically adjusts the tension of the monofilament based on a pre-set profile and the bevel gear system 114 twists the monofilament while maintaining the desired tension variation. The system 100 of the present invention can produce artificial muscle fibers with uniform mechanical properties or graded mechanical properties such as stronger at one end and more elastic at the other. For graded mechanical properties, the motor speeds in the bevel gear system are adjusted dynamically to vary the twist density of the monofilament.

[0034] In some embodiments of the present invention, two or more spools of monofilament are used in the autonomous artificial muscle fiber coiler system 100 wherein different sets of pulleys maintain synchronized tension for all materials and the bevel gear assembly 114 twists the materials together into a composite artificial muscle fiber.

[0035] The bevel gear assembly 114 can be made of steel, brass, aluminum, plastic, or any other similar material. The preferable gear ratio for the different gears of the assembly 114 is 1:1 and the smaller gear may have gear ratio from 1:1 to 2:1. The larger bevel gears 115, 116 may have 30-40 teeth per inch and the smaller third bevel gear 118 may have 15-20 teeth per inch.

[0036] Certain terms are used throughout the following description and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not structure or function. As used herein autonomous artificial muscle fiber coiler system, artificial muscle fiber coiler system, artificial muscle fiber manufacturing system, and system are interchangeable and refer to the autonomous artificial muscle fiber coiler system 100 of the present invention.

[0037] Notwithstanding the forgoing, the autonomous artificial muscle fiber coiler system 100 of the present invention can be of any suitable size and configuration as is known in the art without affecting the overall concept of the invention, provided that it accomplishes the above stated objectives. One of ordinary skill in the art will appreciate that the autonomous artificial muscle fiber coiler system 100 as shown in the FIGS. are for illustrative purposes only, and that many other sizes and shapes of the autonomous artificial muscle fiber coiler system 100 are well within the scope of the present disclosure. Although the dimensions of the autonomous artificial muscle fiber coiler system 100 are important design parameters for user convenience, the autonomous artificial muscle fiber coiler system 100 may be of any size that ensures optimal performance during use and/or that suits the user's needs and/or preferences.

[0038] Various modifications and additions can be made to the exemplary embodiments discussed without departing from the scope of the present invention. While the embodiments described above refer to particular features, the scope of this invention also includes embodiments having different combinations of features and embodiments that do not include all of the described features. Accordingly, the scope of the present invention is intended to embrace all such alternatives, modifications, and variations as fall within the scope of the claims, together with all equivalents thereof.

[0039] What has been described above includes examples of the claimed subject matter. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the claimed subject matter, but one of ordinary skill in the art may recognize that many further combinations and permutations of the claimed subject matter are possible. Accordingly, the claimed subject matter is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term includes is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term comprising as comprising is interpreted when employed as a transitional word in a claim.