Thrust shaft manufacturing method and thrust shaft

Abstract

The present application provides a method for manufacturing a thrust shaft and a thrust shaft. The method includes a winding step, wherein the winding step comprises: spirally winding a first material at a first spiral angle on the outer circumference of a columnar body to form a first material layer; spirally winding a second material at a second spiral angle on the outer circumference of the first material layer to form a second material layer; and spirally winding a third material at a third spiral angle on the outer circumference of the second material layer to form a third material layer; the laminated structure of the first material layer, the second material layer, and the third material layer serves as the main shaft body of the thrust shaft. The present application provides a method for manufacturing a thrust shaft and a thrust shaft, wherein the thrust shaft has high mechanical strength and strong insulation resistance.

Description

Technical Field

[0001] The present application relates to the technical field related to ship transmission, and in particular to a manufacturing method of a thrust shaft and a thrust shaft. Background Art

[0002] When a ship is sailing, it radiates a shaft-frequency electric field into its surroundings, modulated by the propeller. In the time domain, the amplitude of this shaft-frequency electric field signal typically reaches the order of μV / m. In the frequency domain, the shaft-frequency electric field signal is a low-frequency line spectrum with the main shaft rotation as its fundamental frequency. Given these characteristics, shaft-frequency electric field signals are widely used for long-range detection of underwater targets.

[0003] To improve navigation safety, active shaft grounding systems are often used during ship design and manufacturing to reduce shaft-frequency electric field signals, or insulating components are used at the intermediate shaft interface to isolate the shaft-frequency electric field. The former requires the installation of auxiliary equipment within the drive shaft system, increasing space requirements; the latter requires frequent replacement of insulating components, increasing maintenance requirements. Summary of the Invention

[0004] The object of the present application is to provide a method for manufacturing a thrust shaft and a thrust shaft, wherein the thrust shaft has high mechanical strength and strong insulation resistance.

[0005] To achieve the above-mentioned objectives, this application provides the following technical solutions:

[0006] A method for manufacturing a thrust shaft, characterized in that it includes a winding step, wherein the winding step includes:

[0007] Helically winding a first material at a first helical angle on an outer circumference of a columnar body to form a first material layer;

[0008] Helically winding a second material at a second helical angle on the outer circumference of the first material layer to form a second material layer;

[0009] Helically winding a third material at a third helical angle on the outer circumference of the second material layer to form a third material layer;

[0010] The laminated structure of the first material layer, the second material layer and the third material layer serves as the main shaft body of the thrust shaft.

[0011] In some embodiments of the present application, the first helical angle, the second helical angle, and the third helical angle are the same or different in size and in the same or different in direction.

[0012] In some embodiments of the present application, the first helical angle, the second helical angle, and the third helical angle are 15°, 30°, 45°, or a combination of the above angles.

[0013] In some embodiments of the present application, the first material includes glass fiber or aramid fiber; the second material includes carbon fiber; and the third material includes glass fiber or aramid fiber.

[0014] In some embodiments of the present application, a soaking step is further included before the winding step;

[0015] The soaking step includes soaking the first material, the second material, and the third material in resin respectively, so that the resin adheres to outer peripheral surfaces of the first material, the second material, and the third material.

[0016] In some embodiments of the present application, the resin includes epoxy resin, phenolic resin, or a modified resin of one of the above two resins.

[0017] In some embodiments of the present application, a curing step is further included after the winding step;

[0018] The curing step includes placing the main shaft body into a curing furnace to allow the resin to be cured and formed.

[0019] In some embodiments of the present application, a demoulding step is further included after the curing step;

[0020] The demoulding step includes: separating the main shaft body from the columnar body, and the main shaft body is in a hollow tubular shape.

[0021] In some embodiments of the present application, an installation step is also included after the demolding step, and the installation step includes: installing a flange at each end of the main shaft body, the middle protrusion of the flange extends into the hollow position of the main shaft body, the step position where the chassis of the flange is connected to the middle protrusion is abutted against the two end surfaces of the main shaft body, and the abutting parts are coated with adhesive for fixation.

[0022] In some embodiments of the present application, the installation step further includes: before installing the flange, using the first material or the third material, rotating to form a fourth material layer at the step position where the base of the flange connects to the middle protrusion.

[0023] In some embodiments of the present application, a first through hole is provided on the circumference of the free end of the middle protrusion of the flange, and a second through hole is provided at the corresponding position of the main shaft body. The flange is fixed to the main shaft body by matching the first through hole, the second through hole and the corresponding fixing parts.

[0024] In some embodiments of the present application, the installation step further includes: a fifth material layer is formed in advance by rotating the outer peripheral surface of the fixing member using the first material or the third material.

[0025] To achieve the above objectives, this application also provides a technical solution:

[0026] A thrust shaft obtained by the above-mentioned method for manufacturing a thrust shaft, comprising a main shaft body and flanges provided at both ends of the main shaft body;

[0027] The flange includes a base and a middle protrusion, wherein the base is a disc, the middle protrusion is a cylinder, the axial direction of the middle protrusion is parallel to the normal direction of the base, and an arc connecting portion and a step position are sequentially provided between the base and the middle protrusion, and the step position abuts against the two end surfaces of the main shaft body;

[0028] The main shaft body is a hollow tube, the middle protrusion is inserted into both ends of the main shaft body, the inner diameter of the main shaft body is adapted to the outer diameter of the middle protrusion, and the outer diameter of the main shaft body is adapted to the arc connecting portion.

[0029] In some embodiments of the present application, a first through hole is provided circumferentially on the free end of the middle protrusion of the flange, and a second through hole is provided at a corresponding position of the main shaft body. The first through hole, the second through hole and the corresponding fixing parts cooperate to fix the flange to the main shaft body.

[0030] In some embodiments of the present application, a third through hole is provided on the chassis, and an axial direction of the third through hole is parallel to a normal line of the chassis.

[0031] In some embodiments of the present application, the first through hole, the second through hole, and the third through hole include screw holes or pin holes.

[0032] The beneficial effects of this application are:

[0033] 1. This application provides a method for manufacturing a thrust shaft. The resulting thrust shaft exhibits high mechanical strength and good insulation properties. It can transmit the power of the ship's main engine and withstand thrust while isolating the shaft frequency electric field. This can simplify shaft system installation, reduce maintenance, reduce bearing wear, and reduce vibration and energy absorption.

[0034] 2. This application uses a main shaft made of glass fiber, aramid fiber, and resin, which has the characteristics of insulation, light weight, high strength, and corrosion resistance;

[0035] 3. The spindle body made of carbon fiber and resin in this application is lightweight, high-strength, corrosion-resistant, and has good fatigue performance, and shows good performance in transmitting torque, speed and thrust;

[0036] 4. The main shaft body obtained by the one-piece molding method of the present application has the characteristics of high interlayer strength and strong bearing capacity;

[0037] 5. This application adopts a hybrid connection method of adhesive bonding and mechanical connection, which has the advantages of high strength and good reliability under high load requirements;

[0038] 6. The method of prefabricating a composite material insulation layer on the bolt or pin has the characteristics of insulation and corrosion resistance. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present application. For those skilled in the art, other drawings can be obtained based on these drawings without creative work.

[0040] Figure 1 This is a partial enlarged schematic diagram of the main axis;

[0041] Figure 2 This is a cross-sectional view of the thrust shaft.

[0042] The main reference numerals in the drawings of this application specification are described as follows:

[0043] 101-first material layer; 102-second material layer; 103-third material layer; 2-main shaft body; 3-flange; 301-chassis; 305-middle protrusion; 302-step position; 303-arc connecting part; 304-first through hole; 201-second through hole; 3011-third through hole. DETAILED DESCRIPTION

[0044] The following will clearly and completely describe the technical solutions in the embodiments of this application. Obviously, the embodiments described are only part of the embodiments of this application, not all of them. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without making any creative efforts shall fall within the scope of protection of this application.

[0045] This application provides a method for manufacturing a thrust shaft and a thrust shaft, which are described in detail below. It should be noted that the order in which the following embodiments are described does not limit the preferred order of the embodiments of this application. Furthermore, in the following embodiments, the description of each embodiment has its own emphasis. For portions not described in detail in one embodiment, please refer to the relevant descriptions of other embodiments.

[0046] Example 1

[0047] like Figure 1-2As shown, a method for manufacturing a thrust shaft includes a winding step, wherein the winding step includes: spirally winding a first material at a first spiral angle on the outer circumference of a columnar body to form a first material layer 101; spirally winding a second material at a second spiral angle on the outer circumference of the first material layer 101 to form a second material layer 102; spirally winding a third material at a third spiral angle on the outer circumference of the second material layer 102 to form a third material layer 103; and the stacked structure of the first material layer 101, the second material layer 102 and the third material layer 103 serves as the main shaft body 2 of the thrust shaft.

[0048] In some embodiments of the present application, the first helical angle, the second helical angle, and the third helical angle are the same or different in size and in the same or different in direction.

[0049] In some embodiments of the present application, the first helical angle, the second helical angle, and the third helical angle are 15°, 30°, 45°, or a combination of the above angles. Specifically, the fiber laying method includes but is not limited to [±15°]n, [±30°]n, [±45°]n, [±15° / ±30°]n, [±15° / ±45°]n, [±30° / ±45°]n, [±15°x / 0° / ±15°y]n, [±30°x / 0° / ±30°y]n, [±45°x / 0° / ±45°y]n, [±45°x / 0° / ±15°y]n, [±45°x / 0° / ±15°y]n. 5°y]n, [±45°x / ±30°m / 0° / ±30°n / ±45°y]n, [±45°x / ±30°m / ±15°a / 0° / ±15°b / ±30°n / ±45°y]n, wherein n is a positive integer and represents the number of times the fibers fill the mold, and when n=1, it represents that the fibers fill the mold once, and x, y, m, n, a, and b are all expressions of the direction and order of the laying method well known to those skilled in the art.

[0050] In some embodiments of the present application, the first material comprises glass fiber or aramid fiber; the second material comprises carbon fiber; and the third material comprises glass fiber or aramid fiber. Specifically, the glass fiber comprises S-glass fiber and E-glass fiber, and the aramid fiber comprises meta-aramid and para-aramid. During the winding step, the same type of fiber may be wound alone, or different types of fibers may be mixed and wound.

[0051] In some embodiments of the present application, a soaking step is further included before the winding step; the soaking step includes: soaking the first material, the second material and the third material in resin respectively, so that the resin is adhered to the outer peripheral surfaces of the first material, the second material and the third material, and the parameters such as the bath ratio of the fiber and the resin, the soaking temperature and time are common knowledge in the art.

[0052] In some embodiments of the present application, the resin includes epoxy resin, phenolic resin, or a modified resin of one of the above two resins. Specifically, the first material layer 101 and the third material layer 103 can only use the glass fiber or the aramid fiber; the second material layer 102 can only use carbon fiber; the first material layer 101, the second material layer 102, and the third material layer 103 can only use the epoxy resin or one of its modified resins, or only use the phenolic resin or one of its modified resins, or other types of resins, and the resin system used by the second material layer 102 must be the same or compatible with the resin system used by the first material layer 101 and the third material layer 103. If two adjacent layers use different resin systems, it is required that the resin systems of the two adjacent layers must not inhibit polymerization or produce harmful substances. The modification methods of the above resins and / or the types and ratios of the components are common knowledge in the field.

[0053] In some embodiments of the present application, a curing step is further included after the winding step; the curing step includes placing the main shaft body 2 into a curing furnace to allow the resin to be cured and formed.

[0054] In some embodiments of the present application, the resin is cured and formed using a rotational curing method, with a linear speed of no more than 0.5 m / s. In some embodiments of the present application, after curing, the resin has a water absorption rate of no more than 0.35% after being immersed in a constant temperature water bath at 23°C for 10 days. The curing temperature is determined by reaction heat analysis of the resin system used.

[0055] In some embodiments of the present application, a demolding step is further included after the curing step; the demolding step includes: separating the main shaft body 2 from the columnar body, and the main shaft body 2 is in a hollow tubular shape.

[0056] In some embodiments of the present application, an installation step is also included after the demolding step, and the installation step includes: installing a flange 3 at each end of the main shaft body 2, the middle protrusion 305 of the flange 3 extends into the hollow position of the main shaft body 2, and the step position 302 where the chassis 301 of the flange 3 is connected to the middle protrusion 305 is abutted against the two end surfaces of the main shaft body 2, and the abutting parts are coated with adhesive for fixation.

[0057] The flange 3 is made of metal, specifically stainless steel, aluminum alloy, copper alloy and other metals, or a polymer material.

[0058] In some embodiments of the present application, the installation step further includes: before installing the flange 3, using the first material or the third material, rotating to form a fourth material layer at the step position 302 where the base 301 of the flange 3 is connected to the middle protrusion 305.

[0059] In some embodiments of the present application, a first through hole 304 is provided circumferentially at the free end of the middle protrusion 305 of the flange 3, and a second through hole 201 is provided at a corresponding position of the main shaft body 2. The flange 3 is fixed to the main shaft body 2 by matching the first through hole 304, the second through hole 201 and the corresponding fixing parts (not shown).

[0060] In some embodiments of the present application, the installation step further includes: a fifth material layer (not shown) is pre-formed on the outer peripheral surface of the fixing member by rotating the first material or the third material.

[0061] Example 2

[0062] like Figure 2 As shown, a thrust shaft is obtained by the above-mentioned thrust shaft manufacturing method, comprising a main shaft body 2 and flanges 3 provided at both ends of the main shaft body 2; the flange 3 comprises a base 301 and a middle protrusion 305, wherein the base 301 is a disk, the middle protrusion 305 is a cylinder, the axial direction of the middle protrusion 305 is parallel to the normal direction of the base 301, and an arc connecting portion 303 and a step position 302 are sequentially provided between the base 301 and the middle protrusion 305, wherein the step position 302 abuts against the end surfaces of the main shaft body 2;

[0063] The main shaft body 2 is a hollow tube, the middle protrusion 305 is inserted into both ends of the main shaft body 2 , the inner diameter of the main shaft body 2 is adapted to the outer diameter of the middle protrusion 305 , and the outer diameter of the main shaft body 2 is adapted to the arc connecting portion 303 .

[0064] The material of the main shaft body 2 is obtained by the manufacturing method of the thrust shaft described in Example 1; the main shaft body 2 provided by this application has the characteristics of high interlayer strength, strong load-bearing capacity, and insulation and corrosion resistance. The first material layer 101 and the third material layer 103 are made of one of glass fiber or aramid fiber and resin, and have the characteristics of good insulation, corrosion resistance, light weight, and high strength. Carbon fiber has the characteristics of light weight, high strength, corrosion resistance, and fatigue resistance. The second material layer 102 is braided and wound with carbon fiber adhered with the resin, and bears the majority of the mechanical load of the thrust shaft, transmitting torque, speed, and thrust.

[0065] In some embodiments of the present application, the two oppositely disposed middle protrusions 305 may be connected within the main shaft body 2, or they may be separated and non-contact to form a cylindrical cavity (not numbered), the diameter of which corresponds to the outer diameter of the middle protrusion 305. When the length of the cylindrical cavity is sufficiently long, it can be considered that the present application utilizes carbon fiber reinforced resin, i.e., the second material layer 102, to replace a traditional metal shaft body, thereby significantly reducing the deadweight of the thrust shaft while achieving high load bearing capacity.

[0066] In some embodiments of the present application, a first through hole 304 is provided circumferentially at the free end of the middle protrusion 305 of the flange 3, and a second through hole 201 is provided at a corresponding position of the main shaft body 2. The first through hole 304, the second through hole 201 and the corresponding fixing parts cooperate to fix the flange 3 to the main shaft body 2.

[0067] In some embodiments of the present application, a third through hole 3011 is provided on the chassis 301 , and the axial direction of the third through hole 3011 is parallel to the normal line of the chassis 301 .

[0068] In some embodiments of the present application, the first through hole 304 , the second through hole 201 , and the third through hole 3011 include screw holes or pin holes.

[0069] Example 3

[0070] like Figure 2 As shown, a thrust shaft is obtained by the manufacturing method of the thrust shaft described in Example 1, and its structure is the same as the thrust shaft described in Example 2.

[0071] like Figure 1 As shown, specifically, the first material layer 101 is made of E glass fiber and epoxy resin, the plying method is [±45°]3, and the ply thickness is 2mm; the second material layer 102 is made of T700 grade carbon fiber and epoxy resin, the plying method is [±45°] 56, the layer thickness is 34mm; the third material layer 103 is made of E glass epoxy resin, the layer method is [±45°]3, and the layer thickness is 2mm; the material of the flange 3 is 45 steel and the fourth material layer as described in Example 1 is prefabricated on the middle protrusion 305, and its thickness is 2mm; the flange 3 and the main shaft body 2 are correspondingly bored, namely the first through hole 304 and the second through hole 201, and the fixing member provided with the fifth material layer with a thickness of 2mm is inserted into the first through hole 304 and the second through hole 201.

[0072] Compared with an all-metal shaft of the same size and shape made entirely of 42CrMo, the thrust shaft provided in this application has a weight reduction of 34%, reduces the load on the thrust bearing and the intermediate bearing, and improves the power density. The maximum torque of the thrust shaft reaches 720kNm, the maximum tension reaches 1200kN, and the maximum thrust reaches 1500kN; not only that, the three-layer composite material used in the thrust shaft isolates the shaft frequency electric field, and its insulation resistance reaches 75MΩ.

[0073] The above is only a specific embodiment of the present application, but the scope of protection of the present application is not limited thereto. Any person skilled in the art can easily think of changes or replacements within the technical scope disclosed in the present application, which should be included in the scope of protection of the present application. Therefore, the scope of protection of the present application should be based on the scope of protection of the claims. In addition, the specification uses specific examples to illustrate the principles and implementation methods of the present application. The description of the above embodiments is only used to help understand the method and core ideas of the present application. The content of this specification should not be understood as limiting the present application.

Claims

1. A method for manufacturing a thrust shaft, characterized in that: The method comprises a winding step, wherein the winding step comprises: Helically winding a first material at a first helical angle on an outer circumference of a columnar body to form a first material layer; Helically winding a second material at a second helical angle on the outer circumference of the first material layer to form a second material layer; Helically winding a third material at a third helical angle on the outer circumference of the second material layer to form a third material layer; The laminated structure of the first material layer, the second material layer and the third material layer serves as the main shaft body of the thrust shaft; Wherein, the first material includes glass fiber or aramid fiber; the second material includes carbon fiber; the third material includes glass fiber or aramid fiber; The invention also includes an installation step, wherein the installation step comprises: installing a flange at each end of the main shaft body, wherein the middle protrusion of the flange extends into the hollow position of the main shaft body, and the step position where the bottom plate of the flange connects to the middle protrusion abuts against the end surfaces of the main shaft body; The installation step further includes: before installing the flange, using the first material or the third material, rotating to form a fourth material layer at a step position where the bottom plate of the flange connects to the middle protrusion.

2. The method for manufacturing a thrust shaft according to claim 1, characterized in that: The first helical angle, the second helical angle and the third helical angle are of the same or different sizes and of the same or different directions.

3. The method for manufacturing a thrust shaft according to claim 2, wherein: The first helical angle, the second helical angle and the third helical angle are 15°, 30°, 45° or a combination of the above angles.

4. The method for manufacturing a thrust shaft according to claim 1, wherein: The method further comprises a soaking step before the winding step; The soaking step includes soaking the first material, the second material, and the third material in resin respectively, so that the resin adheres to outer peripheral surfaces of the first material, the second material, and the third material.

5. The method for manufacturing a thrust shaft according to claim 4, characterized in that: The resin includes epoxy resin, phenolic resin, or a modified resin of one of the two resins.

6. The method for manufacturing a thrust shaft according to claim 4, characterized in that: The method further comprises a curing step after the winding step; The curing step includes placing the main shaft body into a curing furnace to allow the resin to be cured and formed.

7. The method for manufacturing a thrust shaft according to claim 6, characterized in that: The method further comprises a demoulding step after the curing step; The demoulding step includes: separating the main shaft body from the columnar body, and the main shaft body is in a hollow tubular shape.

8. The method for manufacturing a thrust shaft according to claim 7, wherein: The installation step is further included after the demoulding step, and the installation step further includes: the abutting portion between the flange and the main shaft body is coated with adhesive for fixing.

9. The method for manufacturing a thrust shaft according to claim 8, characterized in that: A first through hole is provided on the circumference of the free end of the middle protrusion of the flange, and a second through hole is provided at the corresponding position of the main shaft body. The flange is fixed to the main shaft body through the cooperation of the first through hole, the second through hole and the corresponding fixing parts.

10. The method for manufacturing a thrust shaft according to claim 9, wherein: The installation step further includes: a fifth material layer is formed on the outer peripheral surface of the fixing piece by rotating the first material or the third material in advance.

11. A thrust shaft, characterized in that: A thrust shaft manufactured by the method according to any one of claims 1 to 10, comprising a main shaft body and flanges provided at both ends of the main shaft body; The flange includes a base and a middle protrusion, wherein the base is a disc, the middle protrusion is a cylinder, the axial direction of the middle protrusion is parallel to the normal direction of the base, and an arc connecting portion and a step position are sequentially provided between the base and the middle protrusion, and the step position abuts against the two end surfaces of the main shaft body; The main shaft body is a hollow tube, the middle protrusion is inserted into both ends of the main shaft body, the inner diameter of the main shaft body is adapted to the outer diameter of the middle protrusion, and the outer diameter of the main shaft body is adapted to the arc connecting portion.

12. The thrust shaft according to claim 11, characterized in that: A first through hole is provided on the circumference of the free end of the middle protrusion of the flange, and a second through hole is provided at a corresponding position of the main shaft body. The first through hole, the second through hole and the corresponding fixing member cooperate to fix the flange to the main shaft body.

13. The thrust shaft according to claim 12, characterized in that: The chassis is provided with a third through hole, and the axial direction of the third through hole is parallel to the normal line of the chassis.

14. The thrust shaft according to claim 13, characterized in that: The first through hole, the second through hole and the third through hole include screw holes or pin holes.

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