Composite Rotor Protection Ring Winding End Delamination Control
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Solution Overview
Problem
Existing rotating electrical machine protection rings delaminate under high-speed operation due to centrifugal force, leading to reduced strength and potential rotor damage.
Innovation Solution
A rotating electrical machine protection ring constructed by winding tape-like or sheet-like reinforcing fibers impregnated with resin, with a widened fiber spread and/or wider area at the winding end to prevent delamination, ensuring the ring maintains structural integrity under high-speed rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a fiber-reinforced composite material is wound in a circular manner to form a protection ring, then the ring provides high strength and lightweight protection, but delamination occurs at the winding end portion under centrifugal force during high-speed rotation
Solution Approach 1:
The fiber tow is pre-cut in a V-shape at the winding end portion before the winding process. This preliminary action ensures that when the fiber tow is wound and subjected to centrifugal force, the V-shaped cut prevents delamination by distributing the stress and preventing the formation of a continuous delamination path at the winding end.
Solution Approach 2:
The fiber tow is cut in a V-shape specifically at the winding end portion, creating a local structural difference. This local quality change addresses the specific problem of delamination at the winding end without affecting the overall structure and properties of the protection ring, allowing the rest of the ring to maintain its high strength characteristics.
2Reliability
If the fiber tow is cut in a V-shape at the winding end to prevent delamination, then delamination is reduced, but stress is concentrated at the distal end portion of the cut
Solution Approach 1:
The V-shaped cut creates a distal end that, while appearing to be a potential stress concentration point, actually serves to redirect and distribute centrifugal forces during rotation. The geometry of the V-cut transforms the potentially harmful stress concentration into a force distribution pattern that prevents delamination while managing stress levels.
Solution Approach 2:
The V-shaped cut introduces a curved geometry at the winding end portion. This curvature helps to distribute stresses more evenly compared to a straight cut, as the angled surfaces of the V-cut allow forces to be distributed along multiple planes rather than concentrating at a single sharp edge.
3Speed
If the rotating electrical machine operates at higher speeds to improve performance, then output and speed are enhanced, but centrifugal force increases causing delamination and potential rotor damage
Solution Approach 1:
The V-shaped cut is prepared in advance at the winding end portion to preemptively counteract the delamination effect that will occur during high-speed rotation. This preliminary structural modification ensures that when centrifugal forces increase with higher rotation speeds, the protection ring is already configured to resist delamination.
Solution Approach 2:
The geometry of the fiber tow end is changed from a straight cut to a V-shaped cut. This parameter change in the structural configuration modifies how the material responds to centrifugal forces, enabling the protection ring to maintain integrity at higher rotation speeds by preventing delamination through the altered end geometry.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively prevents delamination, allowing the rotating electrical machine to operate at higher speeds and maintain structural integrity, enhancing its performance and durability.
Implementation Method 1
when a strong tension is applied to the aforementioned sleeve or rotor sleeve (ring) due to centrifugal force caused by the high-speed rotation of the rotating electrical machine
Data Source
Figure 1~2[B]
AI summary
A rotating electrical machine protection ring constructed by winding a tape-like or sheet-like material made of reinforcing fibers impregnated with resin several times in a circular manner to form a cylindrical laminate and molding the cylindrical laminate, wherein there is formed, in a winding end region of an outermost layer of the laminate, an area in which the reinforcing fibers spread is formed. There is provided a rotating electrical machine protection ring and a manufacturing method of the rotating electrical machine protection ring, the rotating electrical machine protection ring being constructed by molding a fiber-reinforced composite material that has been wound on an outside of a rotor in a rotating electrical machine, wherein the rotating electrical machine protection ring is given improved strength by preventing occurrence of delamination in a winding end portion of the rotating electrical machine protection ring while the rotating electrical machine is operating, thus enabling the rotating electrical machine to rotate at a higher speed.