Description:FIELD OF THE INVENTION
The present invention relates generally to the field of computer-aided design (CAD) technologies and, more specifically, a system and method for generating three-dimensional or 3D computer-aided model of a braided hose assembly.
BACKGROUND OF THE INVENTION
Conventional approaches to modelling flexible braided hose assemblies in computer-aided design (CAD) environments are often limited in scope, fragmented in functionality, and lack the precision necessary for complex engineering applications. Existing tools and plugins—typically offered within general-purpose CAD software such as SolidWorks or AutoCAD—are primarily designed for basic modelling needs and do not offer specialized capabilities for the automated generation of both corrugated hoses and braided wire structures as an integrated assembly.
These traditional systems often require significant manual intervention, such as defining each wire trajectory or mating components separately, which is both time-consuming and error-prone. Moreover, current tools typically lack the mathematical rigor necessary to produce physically accurate and interference free braid geometries, especially when dealing with high-density configurations or non-standard geometries like U-shaped hoses. As a result, engineers are forced to rely on approximations or perform repetitive manual corrections, which reduces efficiency and compromises design integrity.
Furthermore, there is currently no specialized CAD tool capable of generating customized, mathematically defined braid paths using advanced computational methods such as Fourier series, and Heaviside step functions. The lack of this functionality significantly limits the ability to produce precise, simulation-ready models that are compatible with engineering analysis tools such as ANSYS or Abaqus.
Additionally, existing solutions do not offer real-time parametric control or interference-prevention models that dynamically adjust the model to ensure interference-free wire paths during the braid modelling process. As a result, there is a clear gap in the industry for a solution that combines advanced geometric modelling with automated assembly generation in a user-friendly, real-time environment.
Therefore, there is a need in the art for a computer-implemented system and method that provides a comprehensive, automated solution for generating accurate, interference free braid, three-dimensional CAD models of braided hose assemblies. This system should support parametric design, mathematical trajectory modelling, real-time visualization, and seamless export to various industry-standard file formats, enabling both design efficiency and downstream simulation or manufacturing readiness.
OBJECT OF THE INVENTION
An object of the invention is to provide a system for automated generation of three-dimensional CAD models of assembly of the hose and braid components into a single, unified CAD model.
Another object of the invention is to enable the modelling of corrugated hoses with customizable geometric parameters.
A further object of the invention is to allow the modelling of braid wire structures around the hose using computed trajectories.
Yet another object of the invention is to use mathematical modelling techniques to define the spatial paths of braid wires.
Yet another object of the invention is to incorporate mathematical modelling into the braid modelling process to simulate discrete geometric transitions.
Yet another object of the invention is to automate the creation of a three-dimensional CAD model of a U-shaped corrugated hose without the need for manual sketching.
Yet another object of the invention is to enable the automated generation of a three-dimensional CAD model of braid wire solely by inputting design parameters, eliminating manual sketching.
Yet another object of the invention is to automate the creation of a three-dimensional CAD model of the assembly of braided wire and U-shaped corrugated hose by inputting parameter values, without manual intervention.
Yet another object of the invention is to provide system that support output files in various industry-standard formats such as STEP, IGES, DWG, and others.
Yet another object of the invention is to provide a method capable of generating the 3D CAD model of braid wire trajectory and configuration for advanced future modelling, such as tri-axial braiding and 3-in-3 braiding.
SUMMARY OF THE INVENTION
According to one aspect of the invention, there is provided a system for automatically generating a three-dimensional computer-aided model or computer-aided design (CAD) of a braided hose assembly. The system includes a display unit that renders the graphical representation of the CAD model, an input unit that receives one or more parameters related to a corrugated hose and a braided wire structure, and a processing module connected to both the input unit and display unit. The processing module receives the parameters and generates coordinate points for each braid wire based on one or more techniques. These coordinate points are imported into a CAD environment as wire path curves. The system generates three-dimensional solid models of the braid wires by sweeping a circular cross-section along the curves. It groups the wires into clockwise and counterclockwise strands, patterns these strands in a circular structure to form a complete interlaced braid wire mesh structure, generates the 3D CAD model of the corrugated hose based on the input parameters, and assembles both the braid structure and the hose into a unified CAD assembly. The final model is rendered in real time and updates automatically in response to parameter changes.
In accordance with an embodiment of the present invention, the techniques used to generate coordinate points are selected from, but not limited to, non-interference and transition modelling techniques, spatial trajectory generation techniques, or a combination thereof.
In accordance with an embodiment of the present invention, the parameters received include, but are not limited to, hose internal diameter, hose external diameter, hose corrugation thickness, hose corrugation space, hose pitch, length of hose, hose sheet thickness, braid wire diameter, number of wires in braid, number of strands in braid, braid angle, and length of braid.
In accordance with an embodiment of the present invention, the non-interference and transition modelling techniques include, but are not limited to, Heaviside step function, segmented logic transitions, waveform thresholding, and delta modulation.
According to another aspect of the invention, there is provided a method for generating a three-dimensional computer-aided model or computer-aided design of a braided hose assembly. The method includes receiving one or more parameters and generating coordinate points for each braid wire based on one or more techniques, importing the coordinate points into a CAD environment as wire path curves, generating solid models by sweeping a circular cross-section along the curves, grouping the wires into clockwise and counterclockwise strands, combining these to form a complete braid structure, generating the CAD model of the corrugated hose based on the parameters, assembling the hose and braid structure, and rendering the final CAD assembly with automatic real-time updates upon parameter changes.
In accordance with an embodiment of the present invention, the techniques used in the method include, but are not limited to, non-interference and transition modelling methods, spatial trajectory generation techniques, or a combination thereof.
In accordance with an embodiment of the present invention, the non-interference and transition modelling techniques include, but are not limited to, a Heaviside step function, Gaussian step, or a combination thereof.
In accordance with an embodiment of the present invention, the parameters for the method include, but are not limited to, hose internal diameter, hose external diameter, hose corrugation thickness, hose corrugation space, hose pitch, length of hose, hose sheet thickness, braid wire diameter, number of wires in braid, number of strands in braid, braid angle, and length of braid.
According to another aspect of the invention, there is provided a method for automated generation of a corrugated hose model. The method includes receiving hose parameters via the input unit, processing them to generate a periodic corrugation profile along the hose axis, generating the three-dimensional model of the corrugated hose within a CAD environment, and rendering the model on the display unit with real-time updates. The hose parameters include, but are not limited to, hose internal diameter, hose external diameter, hose corrugation thickness, hose corrugation space, hose pitch, length of hose, and hose sheet thickness.
According to another aspect of the invention, there is provided a method for automated generation of a braided wire structure for a hose assembly. The method includes receiving braid parameters via the input unit, generating coordinate points for each braid wire using one or more techniques selected from, but not limited to, spatial trajectory generation and non-interference modelling, importing these points into the CAD environment, generating solid braid wires by sweeping a circular cross-section, grouping wires into clockwise and counterclockwise strands, forming an interlaced braid mesh structure, and rendering it in real time on the display unit with automatic updates. The braid parameters include, but are not limited to, braid wire diameter, number of wires in braid, number of strands in braid, braid angle, and length of braid.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular to the description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, the invention may admit to other equally effective embodiments. These and other features, benefits and advantages of the present invention will become apparent by reference to the following text figure, with like reference numbers referring to like structures across the views, wherein:
Fig. 1 illustrates a system for automated modelling of braided hose assembly, in accordance with an embodiment of the present invention;
Fig. 2A illustrates hose modelling for braided hose assembly, in accordance with an embodiment of the present invention;
Fig. 2B illustrates a plurality of wire of braided wire structure for braided hose assembly, in accordance with an embodiment of the present invention;
Fig. 2C illustrates a braided wire structure forming a mesh around the hose for braided hose assembly, in accordance with an embodiment of the present invention;
Fig. 3 illustrates a braided hose assembly, in accordance with an embodiment of the present invention;
Fig. 4 illustrates user inputs for braided hose assembly, in accordance with an embodiment of the present invention;
Fig. 5 illustrates a method for automated modelling of braided hose assembly, in accordance with an embodiment of the present invention;
Fig. 6A-6G illustrates an information flow diagram for automated modelling of braid wire, in accordance with an embodiment of the present invention; and
Fig. 7 illustrates a braided hose assembly in the generated by the working examples, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE DRAWINGS
The present invention is described hereinafter by various embodiments with reference to the accompanying drawing, wherein reference numerals used in the accompanying drawing correspond to the like elements throughout the description.
While the present invention is described herein by way of example using embodiments and illustrative drawings, those skilled in the art will recognize that the invention is not limited to the embodiments of drawing or drawings described and are not intended to represent the scale of the various components. Further, some components that may form a part of the invention may not be illustrated in certain figures, for ease of illustration, and such omissions do not limit the embodiments outlined in any way. It should be understood that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the scope of the present invention as defined by the appended claims. As used throughout this description, the word "may" is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense, (i.e., meaning must). Further, the words "a" or "an" mean "at least one” and the word “plurality” means “one or more” unless otherwise mentioned. Furthermore, the terminology and phraseology used herein is solely used for descriptive purposes and should not be construed as limiting in scope. Language such as "including," "comprising," "having," "containing," or "involving," and variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents, and additional subject matter not recited, and is not intended to exclude other additives, components, integers or steps. Likewise, the term "comprising" is considered synonymous with the terms "including" or "containing" for applicable legal purposes. Any discussion of documents, acts, materials, devices, articles and the like are included in the specification solely for the purpose of providing a context for the present invention. It is not suggested or represented that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention.
The present invention may, however, be embodied in many different forms and should not be construed as limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. In the following detailed description, numeric values and ranges are provided for various aspects of the implementations described. These values and ranges are to be treated as examples only and are not intended to limit the scope of the claims. In addition, a number of materials are identified as suitable for various facets of the implementations. These materials are to be treated as exemplary and are not intended to limit the scope of the invention.
The present invention is described hereinafter by various embodiments. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those skilled in the art. As used throughout this description, the word "may" is used in a permissive sense (i.e. meaning having the potential to), rather than the mandatory sense, (i.e. meaning must). Further, the words "a" or "an" mean "at least one” and the word “plurality” means “one or more” unless otherwise mentioned. Furthermore, the terminology and phraseology used herein is solely used for descriptive purposes and should not be construed as limiting in scope.
The present invention discloses a method for generating accurate and interference free braid CAD models of braided hose assemblies through an automated and mathematically precise approach. Unlike conventional methods that rely on manual modelling or oversimplified helical paths, this invention utilizes advanced equations based on Fourier series, Heaviside step functions, and one or more numerical solvers to define the spatial trajectories of braid wires. This allows for precise modelling of complex geometries, including non-linear and U-shaped hoses, with variable braid angles. A distinguishing feature of the invention is its ability to automatically generate corrected wire overlaps, ensuring interference-free braid structures. Furthermore, the method supports real-time parametric updates, instantly adjusting the model when one or more parameters are modified, significantly improving design efficiency. By addressing both geometric accuracy and process automation, the invention provides a non-obvious and technically superior solution (CAD) modelling of braided hoses, supporting simulation and manufacturing requirements across diverse engineering applications.
Industries such as aerospace, automotive, hydraulics, and robotics increasingly rely on advanced modelling techniques—specifically Fourier series, Heaviside step functions, and \—for the accurate design and simulation of braided hose assemblies. In the aerospace sector, systems are often subject to extreme pressure fluctuations and spatial constraints. Fourier series provide a means to model periodic wire paths accurately, especially for complex geometries. Heaviside step functions are employed to simulate discrete structural transitions, which are critical when modelling interwoven braid patterns or phase shifts along wire paths.
Similarly, the automotive industry demands compact and vibration-resistant hose configurations In hydraulics, the need to maintain structural integrity under high pressure necessitates the use of these techniques to prevent wire overlaps and ensure geometric fidelity in custom hose paths. Finally, in robotics, where flexible hoses or cable sheaths must adapt to dynamic joint movement, these methods enable accurate modelling of flexible paths. Fourier series capture cyclic motion, Together, these techniques enable interference-free, parametric, and simulation-ready CAD models that can be rapidly adapted for manufacturing and real-time system integration.
The invention will now be described wit reference to accompanying drawings:
Figure 1 illustrates a system for automated modelling of braided hose assembly, in accordance with the present invention. As shown in Figure 1, the system (100) includes an input unit (102), an output unit (106), and a processing module (104). The processing module (104) is operably connected with the input unit (102) and output unit (106). In some embodiments, the input unit (102), the output unit (106) and/or the processing module (104) may be included within the same system (100) or distributed across one or more devices.
The input unit (102) may be selected from, but not limited to, keyboards, scanners, cameras, pointing devices, touch-enabled displays, microphones, or combinations thereof. The output unit (106) may be selected from, but not limited to, display screens, touch-enabled displays, 2D printers, 3D printers, plotters, or combinations thereof.
The communication module (1046) may be connected to a communication network, but not limited to, a Local Area Network (LAN) or a Wide Area Network (WAN). The communication network may be implemented using a number of protocols, such as, but not limited to, TCP/IP, 3GPP, 3GPP2, LTE, IEEE 802.x etc. The communication network may be a wireless communication network selected from one of, but not limited to, Bluetooth, radio frequency, internet, or satellite communication networks providing maximum coverage.
The processing module (104) includes computing capabilities such as a memory unit (1042) configured to store machine-readable instructions. The machine-readable instructions may be loaded into the memory unit (1042) from a non-transitory machine-readable medium such as, but not limited to, CD-ROMs, DVD-ROMs, and Flash Drives. Alternatively, the machine-readable instructions may be loaded in the form of a computer software program into the memory unit (1042). The memory unit (1042) in that manner may be selected from a group comprising EPROM, EEPROM, and Flash memory.
Further, the processing module (104) includes a processor (1044) operably connected with the memory unit (1042). The processing module (104) includes computing capabilities such as the processor (1044) configured to process data. In various embodiments, the processor (1044) is one of, but not limited to, a general-purpose processor, an application-specific integrated circuit (ASIC), and a field-programmable gate array (FPGA).
Figure 2A illustrates hose modelling for braided hose assembly, in accordance with an embodiment of the present invention. As shown in Figure 2A, the corrugated hose (206) may be defined by one or more parameters selected from hose inner diameter (212), hose outer diameter (214), pitch (208), crown diameter (210), corrugation space (206), and sheet thickness (216). The crown diameter (210) is the outer diameter measured at the peak (or crest) of the corrugation. The hose inner diameter (212) is the internal diameter measured at the innermost surface of the hose. The hose outer diameter (214) is the external diameter measured at the outermost surface of the hose. The pitch is the longitudinal distance between successive corrugation peaks. The corrugation space (206) is the gap or distance between adjacent corrugations. The sheet thickness (216) is the uniform thickness of the base hose material.
Figure 2B illustrates a plurality of wire of braided wire structure for braided hose assembly, in accordance with an embodiment of the present invention. As shown in Figure 2B, the braided hose assembly comprises a plurality of wires (1–11) of interwoven wires or wire strand (204) forming a mesh around the hose (206).
Figure 2C illustrates braided wire structure for braided hose assembly, in accordance with an embodiment of the present invention. As shown in Figure 2C, the braided covering (202) forming a mesh around the hose for braided hose assembly.
Figure 3 illustrated an exemplary braided hose assembly (300), in accordance with the present invention. As shown in Figure 3, the braided hose assembly (300) comprises a corrugated hose (206) encased within a braided covering (202), wherein the braided covering (202) consists of multiple interwoven wires or wire strand (204) forming a mesh around the hose (206).
Figure 4 illustrates an input interface for parameter-based CAD model generation, in accordance with an embodiment of the present invention. As shown in Figure 4, the input unit (102) is configured to receive one or more user-defined one or more parameters. The one or more parameters selected from, but not limited to, hose internal diameter, hose external diameter, hose corrugation thickness, hose corrugation space, hose pitch, length of hose, hose sheet thickness, braid wire diameter, number of wires in braid, number of strands in braid, braid angle length of braid or combination thereof.
Figure 5 illustrates a method (500) for automated modelling of braided hose assembly (300), in accordance with the present invention. As shown in Figure 5, the method (500) for the automated modelling of a braided hose assembly (300) includes the following steps:
STEP 502: RECEIVING ONE OR MORE PARAMETERS AND GENERATING ONE OR MORE COORDINATE POINTS FOR EACH BRAID WIRE BASED ON ONE OR MORE TECHNIQUES
The method (500) begins by receiving user-defined one or more parameters. The one or more parameters are inputted through the input unit (102) as shown in the Figure 5. The input unit (102) may include keyboards, touch-enabled displays, or other data entry devices.
In some embodiments, the one or more parameters may be categorized into two sets one or more hose parameters and one or more braid parameters. The one or more hose parameters may be selected from, but not limited to, hose internal diameter, hose external diameter, hose corrugation thickness, hose corrugation space, hose pitch, length of hose, hose sheet thickness or combination thereof. The one or more braid parameters are selected from braid wire diameter, number of wires in braid, number of strands in braid, braid angle length of braid or combination thereof.
Figure 6A-G illustrates an information flow diagram for the automated modelling of the braid wire in accordance with the present invention. As shown in Figure 6A, once the user inputs one or more parameters, they are passed to the processing module (104), which includes a processor (1044) (e.g., general-purpose CPU, ASIC, or FPGA). The processor (1044) uses one or more spatial trajectory generation techniques to compute the X, Y, and Z coordinate points of each braid wire. To model the periodic path of the wire along the hose, a Fourier series may be as:

where H(t−t0) is the Heaviside function that introduces phase shifts at key points, enhancing geometric fidelity.
Dynamic Braid Angle Control: Unlike traditional constant-angle braiding, the equation allows a variable braid angle (θ(z)), improving adaptability for non-uniform hose sections.
This makes the software more flexible than existing CAD tools, which typically rely on predefined helical paths.

Automatic Adjustment of Braid Geometry
The software dynamically updates braid pitch (p), wire diameter (d), and braid angle (θ) based on user inputs.
The braid angle is calculated using the equation: where D is the hose diameter, ensuring proper wire coverage without gaps or overlaps.
STEP 504: IMPORTING THE COMPUTED COORDINATE POINTS INTO A CAD ENVIRONMENT AS WIRE PATH CURVES
Once computed, the coordinate points are imported into a CAD environment as 3D path curves as shown Figure 6B. These curves represent the spatial layout of the braid wires and serve as the framework for building solid models.
STEP 506: GENERATING THREE-DIMENSIONAL SOLID MODELS OF THE BRAID WIRES BY SWEEPING A CIRCULAR CROSS-SECTION ALONG THE IMPORTED CURVES
The system proceeds to generate solid wire models by sweeping a circular profile (representing the wire cross-section) along each of the imported curves as shown Figure 6C. This operation converts the wire paths into physical solid bodies, which can be visualized and manipulated in the CAD assembly.
STEP 508: GROUPING THE SOLID WIRES INTO CLOCKWISE AND COUNTERCLOCKWISE STRANDS
The solid wires are analysed and grouped into clockwise and counterclockwise strands, based on their directional orientation as shown Figure 6D. This distinction is essential for representing the true interweaving pattern seen in actual braided hose assemblies.
STEP 510: GENERATING THE PLURALITY OF INTERLACED BRAID STRANDS BY PATTERNING IT IN CIRCULAR STRUCTURE IN ORDER TO OBTAIN COMPLETE INTERLACED BRAID WIRE MESH STRUCTURE
The clockwise and counterclockwise strands are algorithmically interlaced and circularly patterned, as shown in Figure 6E and Figure 6F. This operation generates the plurality of interlaced braid strands, forming a complete braid wire mesh structure enveloping the hose. This step ensures a woven appearance, mimicking real-world braid configurations (e.g., 2-over-2, 3-over-3).
STEP 512: GENERATING THE 3D CAD MODEL OF CORRUGATED HOSE USING THE ONE OR MORE PARAMETERS GIVEN BY THE USER
The three-dimensional CAD model of the corrugated hose (206) is generated using the one or more parameters provided by the user. These hose parameters define a periodic corrugation profile along the hose axis and include, but are not limited to, hose internal diameter, hose external diameter, corrugation thickness, corrugation space, pitch, length, and sheet thickness. The resulting model serves as the structural foundation for subsequent braid assembly.
STEP 514: ASSEMBLING THE 3D CAD MODEL AND THE COMPLETE INTERLACED BRAID WIRE MESH STRUCTURE TO FORM THE BRAIDED HOSE ASSEMBLY
Following the generation of the hose and braid models, the complete interlaced braid wire mesh structure is mated with the corrugated hose (206) to form a unified CAD assembly. This integration ensures proper alignment and manufacturability.
STEP 516: RENDERING THE FINAL CAD ASSEMBLY IN REAL TIME WITH AUTOMATIC UPDATES IN RESPONSE TO CHANGES IN THE ONE OR MORE PARAMETERS
Finally, the complete braided hose assembly is rendered in real time via the output unit (e.g., a display screen or visualization panel), as shown in Figure 6G. The system (100) supports automatic updates — when any design parameter is modified through the input unit, the entire model is recalculated and refreshed instantly, allowing for fast iteration and design optimization. Once the design is finalized, the system allows the complete model to be exported in various industry-standard file formats: .FBX, .OBJ, STEP, IGES, or STL for 3D CAD exchange; DXF or DWG for 2D technical drawings; and XML or JSON for integration into digital workflows like product lifecycle management (PLM) or digital twin systems.
The model to be converted into manufacturing formats such as, but not limited to, STL or 3MF, which can be processed through slicer software to generate layered toolpaths and G-code for 3D printers.
EXAMPLE 1: Consider an example where a mechanical engineer is tasked with designing a U-shaped corrugated hose (206) enclosed within a braided wire mesh, intended for use in a high-pressure hydraulic system. The hose must withstand vibration and pressure fluctuations while fitting within a compact, curved installation space. The system (100) initiates the modelling process through the input unit (102), where the user specifies one or more parameters for the corrugated hose (206) and the braided wire structure. The one or more parameters may include hose internal diameter, hose external diameter, hose corrugation thickness, hose corrugation space, hose pitch, length of hose, hose sheet thickness, braid wire diameter, number of wires in braid, number of strands in braid, braid angle, length of braid, and interlacing pattern such as 2-over-2. These one or more parameters are received by the processing module (104).
The processing module (104) then generates (502) one or more coordinate points for each braid wire based on one or more techniques. The one or more techniques are selected from spatial trajectory generation techniques, non-interference and transition modelling techniques, or a combination thereof. In one embodiment, the spatial trajectory generation techniques include the application of Fourier series to model the periodic motion of braid wires as they wrap helically around the corrugated hose (206). Each coordinate point is derived using parametric functions where the X(t), Y(t), and Z(t) positions are expressed in terms of sine and cosine functions—X(t) representing side-to-side motion, Y(t) representing vertical oscillations, and Z(t) representing axial progression of the braid wire. The variable t is a parametric variable, while the frequency component ω is derived based on the braid pitch and braid angle.
To simulate inter-layer transitions and ensure non-overlapping geometry in high-density braid structures, the processing module (104) applies non-interference and transition modelling techniques, which may include the use of Heaviside step functions to implement discrete phase shifts or vertical displacements in the braid wire path. These transitions occur, for example, after each full helical turn or when a braid wire switches between layers. These methods collectively ensure the spatial integrity of the braid even in dense interlaced configurations.
Let’s, say a user inputs the following design specifications into the system:

Assembly Input
Hose Input Braid Input
ID 22 Wire Dia 0.3
OD 32 No of wire/Strand 12
Thickness 0.2 No of Strand 46
Root Dia 2 Braid Angle 49
Crown Dia 2.5 Length 1000
Pitch 7 Material SS304L
Length 1000
Material SS321
In some embodiments, the material may be selected from, but not limited to, Inconel 625, Monel 500, PTFE (Polytetrafluoroethylene) lined stainless steel braids, 316L stainless steel, Kevlar® (aramid fibre) or combination thereof.
Once the one or more coordinate points are generated, the processing module (104) imports (504) the one or more coordinate points into a CAD environment as wire path curves. These curves define the spatial paths of individual braid wires. The system then generates (506) three-dimensional solid models of the braid wires by sweeping a circular cross-section (equal to the braid wire diameter) along each of the imported curves. The solid wires are then grouped (508) into one set of clockwise strand and counter clockwise strand to form the unit structure of the entire braid mesh. This grouping replicates the actual configuration used in braid-weaving machinery and is essential to create interlaced, balanced mesh structures.
The processing module (104) then generates (510) the plurality of interlaced braid strands by patterning the grouped braid wires in a circular structure around the hose, thereby forming a complete interlaced braid wire mesh structure. The system applies a logical strand pairing routine to sequence the wires so they alternately pass over and under each other around the hose circumference. This pattern is circularly duplicated and axially distributed along the hose length. During this operation, the processing module (104) ensures accurate alignment of strand entry and exit points with the hose’s curvature and endpoint locations. Angular and axial spacing is preserved to maintain braid density and uniformity, even in curved portions such as U-bends.
In parallel, the processing module (104) generates (512) the 3D CAD model of the corrugated hose (206) using the one or more parameters given as the parametric input. The hose corrugation is modelled as a sinusoidal, U-shaped, or angular waveform along the axis of the hose. The corrugation profile is generated based on the input values for pitch, crown/root diameter, wall thickness, and length, ensuring compatibility with the overlaying braid structure.
The system then assembles (514) the 3D CAD model and the complete interlaced braid wire mesh structure to form the braided hose assembly. The braid mesh is automatically aligned and mated to the external surface of the corrugated hose (206), with each wire path conforming precisely to the outer contours. The processing module (104) checks for endpoint alignment to ensure that the braid does not overshoot or fall short of the hose length. Geometric validation routines are applied to confirm that all interwoven wires correctly follow the hose curvature, including complex shapes such as bends or transitions. Adjustments are made where necessary to prevent floating mesh, overlaps, or misalignments.
The system then renders (516) the final CAD assembly in real time with automatic updates in response to changes in the one or more parameters. The display unit (106) is configured to present the rendered CAD model graphically, which may include a high-resolution display or 3D visualization environment. Any change to the one or more parameters—such as braid angle, wire diameter, strand count, hose length, or corrugation pitch—triggers the processing module (104) to reapply the one or more techniques, regenerate coordinate points, update the solid braid wires and corrugated hose geometry, and recompute the complete assembly. The regenerated CAD model is displayed in real time on the display unit (106), supporting rapid design iteration, early error detection, and optimization.
Upon finalization, the CAD model is exportable in industry-standard formats including STEP and IGES for CAD interoperability, STL and 3MF for 3D printing, DXF or DWG for 2D drawings, and XML or JSON for integration with product lifecycle management (PLM) and digital twin systems. The model can be converted for additive manufacturing using slicer software to generate toolpaths and G-code for 3D printers. For subtractive manufacturing, the geometry can be imported into CAM software to create CNC machining operations. In advanced applications, the individual wire trajectories may be extracted to directly control automated braiding machines or robotic arms, enabling real-world manufacturing of the designed braided hose assembly.
This complete and automated pipeline—from design specification to digital export to fabrication—makes the system (100) a powerful tool across industries such as aerospace, automotive, robotics, and fluid-handling. In some embodiments, the system (100) may be used for only automated braid generation, or only automated generation of a corrugated hose (206), or for complete automated generation of a braided hose assembly. The present invention thus offers a system (100) and a method (500) for the automated generation of braid, the automated generation of corrugated hose (206), and the automated generation of braided hose assemblies.
The present invention offers several advantages, some of which are listed below:
1. Automated Generation of Braided Hose Assemblies: Eliminates manual CAD modelling of complex braided wire structures by enabling automated creation of full assemblies using parametric inputs. This significantly reduces design time and eliminates human error.
2. Parametric Control Over Design Variables: Allows real-time modification of key one or more parameters. This flexibility enables rapid prototyping and iterative refinement without reconstructing the model manually.
3. Use of Mathematical Techniques for Spatial Accuracy: By employing spatial modelling techniques such as Fourier series, and Heaviside transitions, the invention ensures mathematically precise, interference free braid, and geometrically realistic wire trajectories, enhancing manufacturability and simulation compatibility.
4. Integrated Interference Prevention and Transition Modelling: Prevents wire intersections or overlaps in high-density braid configurations using embedded logic for interlacing phase shifts. This ensures physical feasibility and structural reliability in real-world applications.
5. Unified Assembly Modelling in a Single CAD Environment: Seamlessly combines the hose and braid models into one coherent, exportable 3D CAD assembly. This supports direct use in engineering workflows, reducing the need for external merging tools or post-processing steps. Although separate hose and braid models may also be generated.
6. Real-Time Visualization and Regeneration: Enables instant rendering and updating of the full hose-braid assembly upon parameter changes. This provides immediate design feedback and ensures high responsiveness in interactive modelling environments.
7. Direct Export for Manufacturing Integration: Supports export in multiple file formats (STEP, STL, XML, G-code, etc.), enabling direct transition from digital design to 3D printing, CNC machining, or braid-guiding systems. This facilitates end-to-end digital manufacturing, especially important for aerospace, automotive, and robotics applications.
In general, the word "module," as used herein, refers to logic embodied in hardware or firmware, or to a collection of software instructions written in a programming language, such as, for example, Java, C, or assembly. One or more software instructions in the modules may be embedded in firmware, such as an EPROM. It will be appreciated that modules may comprise connected logic units, such as gates and flip-flops, and may comprise programmable units, such as programmable gate arrays or processors. The modules described herein may be implemented as either software and/or hardware modules and may be stored in any type of computer-readable medium or other computer storage device.
Further, while one or more operations have been described as being performed by or otherwise related to certain modules, devices, or entities, the operations may be performed by or otherwise related to any module, device, or entity. As such, any function or operation that has been described as being performed by a module could alternatively be performed by a different server, by a cloud computing platform, or a combination thereof.
It should be understood that the techniques of the present disclosure might be implemented using a variety of technologies. For example, the methods described herein may be implemented by a series of computer-executable instructions residing on a suitable computer-readable medium. Suitable computer-readable media may include volatile (e.g., RAM) and/or non-volatile (e.g., ROM, disk) memory, carrier waves, and transmission media.
Various modifications to these embodiments are apparent to those skilled in the art from the description and the accompanying drawings. The principles associated with the various embodiments described herein may be applied to other embodiments. Therefore, the description is not intended to be limited to the embodiments shown along with the accompanying drawings but is to be providing broadest scope of consistent with the principles and the novel and inventive features disclosed or suggested herein. Accordingly, the invention is anticipated to hold on to all other such alternatives, modifications, and variations that fall within the scope of the present invention and the appended claims.
, C , Claims:We Claim:
1. A system (100) for automatically generating three-dimensional computer-aided model or computer-aided design (CAD) of a braided hose assembly, the system (100) comprising:a display unit (106) configured to render a graphical representation of a CAD model;an input unit (102) configured to receive one or more parameters for a corrugated hose (206) and a braided wire structure;a processing module (104), operably connected to the input unit (102) and the display unit (106), wherein the processing module (104) is configured to:receive one or more parameters and generate one or more coordinate points for each braid wire based on one or more techniques; import the one or more coordinate points into a CAD environment as wire path curves;generate three-dimensional solid models of the braid wires by sweeping a circular cross-section along the imported curves;
group one set of clockwise strand and counter clockwise strand to form unit structure of entire braid mesh;
generate the plurality of interlaced braid strands by patterning it in circular structure in order to obtain complete interlaced braid wire mesh structure;
generate the 3D CAD model of corrugated hose using the one or more parameters given as the parameters as input;
assemble the 3D CAD model and the complete interlaced braid wire mesh structure to form the braided hose assembly; and
render the final CAD assembly in real time with automatic updates in response to changes in the one or more parameters.
2. The system (100) as claimed in claim 1, wherein the one or more techniques are selected from non-interference and transition modelling techniques, spatial trajectory generation techniques or a combination thereof.
3. The system (100) as claimed in claim 1, wherein the one or more parameters are selected from hose parameters including hose internal diameter, hose external diameter (214), hose corrugation thickness, hose corrugation space, hose pitch, length of hose, and hose sheet thickness, and braid parameters including braid wire diameter, number of wires in braid, number of strands in braid, braid angle, length of braid or wire diameter.
4. The system (100) as claimed in claim 1, wherein the non-interference and transition modelling techniques configured to simulate the wire paths, are selected from Heaviside step function, segmented logic transitions, waveform thresholding, and delta modulation.
5. A method (500) for generating three-dimensional computer-aided model or computer-aided design (CAD) of a braided hose assembly, the method comprising:
receiving one or more parameters and generating (502) one or more coordinate points for each braid wire based on one or more techniques;
importing (504) the one or more coordinate points into a CAD environment as wire path curves;
generating (506) three-dimensional solid models of the braid wires by sweeping a circular cross-section along the imported curves;
grouping (508) one set of clockwise strand and counter clockwise strand to form unit structure of entire braid mesh;
generating (510) the plurality of interlaced braid strands by patterning it in circular structure in order to obtain complete interlaced braid wire mesh structure;
generating (512) the 3D CAD model of corrugated hose using the one or more parameters given as the parametric input;
assembling (514) the 3D CAD model and the complete interlaced braid wire mesh structure to form the braided hose assembly; and
rendering (516) the final CAD assembly in real time with automatic updates in response to changes in the one or more parameters.
6. The method (500) as claimed in claim 5, wherein the one or more techniques are selected from non-interference and transition modelling techniques methods, spatial trajectory generation techniques, or a combination thereof.

7. The method (500) as claimed in claim 6, wherein the non-interference and transition modelling techniques are selected from a Heaviside step function, Gaussian step, or a combination thereof.
8. The method (500) as claimed in claim 5, wherein the one or more parameters are selected from hose internal diameter, hose external diameter, hose corrugation thickness, hose corrugation space, hose pitch, length of hose, hose sheet thickness, braid wire diameter, number of wires in braid, number of strands in braid, braid angle length of braid or combination thereof.
9. A method for automated generation of a corrugated hose model, the method comprising:
receiving, via the input unit (102), one or more hose parameters;
processing, by the processing module (104), the received the one or more hose parameters to generate a periodic corrugation profile along the hose axis;
generating, within the CAD environment, a three-dimensional model of the corrugated hose (206) using parametric surface modelling techniques to define the crest or crown and root geometries;
rendering the corrugated hose model on the display unit (106) and updating the model in real time in response to changes in the hose parameters;
wherein the one or more hose parameters are selected from hose internal diameter, hose external diameter, hose corrugation thickness, hose corrugation space, hose pitch, length of hose, hose sheet thickness, or combination thereof.
10. A method for automated generation of a braided wire structure for a hose assembly, the method comprising: receiving, via the input unit (102), one or more braid parameters; generating, by the processing module (104), one or more coordinate points for each braid wire based on one or more techniques selected from spatial trajectory generation techniques, non-interference modelling techniques, or a combination thereof;importing the coordinate points into the CAD environment as wire path curves and generating three-dimensional solid braid wires by sweeping a circular cross-section along each path; grouping the braid wires into clockwise and counterclockwise strands, and combining them in a circular pattern to form an interlaced braid wire mesh structure around the hose; rendering the braided structure in real time on the display unit (106), with automatic updates in response to changes in the braid parameters;
wherein the one or more braid parameters are selected from braid wire diameter, number of wires in braid, number of strands in braid, braid angle length of braid, or combination thereof.