Composite Barrel Shape Control via Modular End Rings and Spoke Supports
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Solution Overview
Problem
The challenge lies in maintaining the geometric shape of large, frameless composite barrel sections during transport and assembly, as existing methods fail to control the shape within desired tolerances, leading to increased labor costs and rework.
Innovation Solution
A system comprising end rings and internal support rings with adjustable spokes that attach to the composite barrel sections to maintain shape, combined with a moveable cart that supports the barrel's outer surface, ensuring geometric control during transport and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional transport methods are used for composite barrel sections, then the barrel sections can be moved, but the shape cannot be maintained within geometric tolerances
Solution Approach 1:
The support system is divided into multiple independent components: end rings positioned at the ends of the barrel and mid supports positioned along the length. Each segment independently contributes to maintaining the barrel's shape, allowing the system to effectively support large, frameless composite barrel sections while maintaining geometric tolerances during transport and assembly.
Solution Approach 2:
End rings and mid supports are introduced as intermediary elements between the barrel and the transport cart. These intermediaries directly contact and support the barrel's outer surface, distributing loads and preventing deformation, thereby maintaining the barrel's shape within geometric tolerances during movement and storage.
2Manufacturing precision
If rigid support structures are used to maintain barrel shape, then geometric tolerance is improved, but the system becomes complex and difficult to install/remove
Solution Approach 1:
The support system is divided into multiple independent, modular components (end rings and mid supports) that can be easily installed and removed. Each component is relatively simple in design but collectively they provide comprehensive shape control, reducing overall system complexity while maintaining geometric tolerances.
Solution Approach 2:
The support system is designed to be dynamically configurable - end rings and mid supports can be positioned at different locations along the barrel and adjusted as needed. This flexibility allows the system to adapt to different barrel sizes and support requirements without requiring a complex fixed structure.
3Manufacturing precision
If multiple support points are used to maintain shape, then geometric tolerance is improved, but the device complexity increases
Solution Approach 1:
End rings and mid supports are designed as universal components that can be used in multiple positions and configurations. Each component serves multiple functions: providing structural support, maintaining geometric shape, and distributing loads. This multi-functionality reduces the need for specialized components, thereby reducing overall device complexity while achieving precise shape control through multiple support points.
Data Source
AI summary
A barrel assembly for a composite structure includes a barrel of composite material, a first end ring, and a mid support. The barrel of composite material has a first end, an interior surface and an outer surface, and the first end ring is removably attached to the first end. The first end ring has a perimeter that is substantially congruent with the first end, and is configured to maintain a shape of the barrel. The mid support is removably disposed within the barrel, and has a plurality of spokes extending outwardly from a central hub to contact the interior surface, to maintain a shape of the barrel.