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.

What is claimed is: 
     
         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.