Fiber Winding Tensioning Cylinders to Prevent Filament Rupture
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Solution Overview
Problem
Existing methods for tensioning fibers around cylindrical parts, such as flywheels, face challenges with high tensile stress and filament rupture due to high tension, contact pressure, and sliding velocity, especially when using fragile materials like glass fibers, leading to costly and complex multi-cylinder systems.
Innovation Solution
A method involving a series of braked tensioning cylinders where the diameter increases as tension in the fibers increases, synchronized with varying peripheral velocities to manage sliding and contact pressure, allowing for efficient prestressing of concrete flywheels with glass fibers, reducing the risk of filament rupture and material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high tension is applied to fibers during winding to achieve sufficient prestressing, then the tensile strength and energy storage capability of the flywheel is improved, but the risk of filament rupture increases due to high contact pressure and sliding velocity
Solution Approach 1:
The patent applies dynamics by varying the peripheral velocity of tensioning cylinders during the winding process. The peripheral velocity is highest when the fiber tension is lowest (at the beginning of winding) and progressively reduced as the tension increases. This dynamic adjustment optimizes the balance between achieving sufficient prestressing tension and minimizing filament rupture risk from excessive sliding velocity and contact pressure.
2Device complexity
If a single braking system is used to tension fibers, then the device complexity is reduced, but the ability to achieve high tension without filament rupture is compromised
Solution Approach 1:
The patent segments the single braking system into multiple independent braking systems, each associated with a separate tensioning cylinder. This segmentation allows each cylinder to operate with optimized parameters (diameter and peripheral velocity) for different stages of the winding process, achieving high tension with reduced filament rupture risk while managing device complexity through modular design.
Solution Approach 2:
The patent applies dynamics by varying the peripheral velocity of tensioning cylinders during the winding process. The peripheral velocity is highest when the fiber tension is lowest (at the beginning of winding) and progressively reduced as the tension increases. This dynamic adjustment optimizes the balance between achieving sufficient prestressing tension and minimizing filament rupture risk from excessive sliding velocity and contact pressure.
3Ease of operation
If the peripheral velocity of tensioning cylinders is kept constant, then the ease of operation is improved, but the sliding velocity between fibers and cylinders remains high leading to increased filament rupture risk
Solution Approach 1:
The patent applies dynamics by varying the peripheral velocity of tensioning cylinders during the winding process. The peripheral velocity is highest when the fiber tension is lowest (at the beginning of winding) and progressively reduced as the tension increases. This dynamic adjustment optimizes the balance between achieving sufficient prestressing tension and minimizing filament rupture risk from excessive sliding velocity and contact pressure.
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
This method effectively increases the tensile stress in fibers from 1 MPa to 1000 MPa, enabling high-speed rotation and significant energy storage in flywheels with reduced material costs and complexity, achieving a compressive strength of at least 25 MPa in the concrete core.
Implementation Method 1
The theory shows that the tension transmissible to a wire/fibers by adhesion on a braked cylinder is an (exponential) function of the winding angle: T(α)=T(0)·exp(μ·α), where α is the winding angle and μ the coefficient of friction between the wire/fibers and the cylinder.
Implementation Method 2
The centrifugal force undergone by the flywheel causes very high tensile stresses for the material that constitutes its mass.
Data Source
AI summary
A method for binding a cylindrical part by the tensioned winding of fibers, the method including a preliminary step of passing the fibers around at least two braked tensioning cylinders in order to increase the tension in the fibers, wherein the method includes increasing the diameter of the cylinders as the tension in the fibers increases.