Foam-Core Fiber-Reinforced Cable Drum for High Rope Loads
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Solution Overview
Problem
Existing cable drums made of steel or cast materials are heavy, which is disadvantageous in weight-sensitive applications, and alternative materials like honeycomb structures produced by selective laser melting are prone to cracking and distortion, and are expensive.
Innovation Solution
A rope drum with a multi-layered structure comprising fiber-reinforced composite material for the drum shell and end plates, incorporating a foam core and stiffening ribs, which provides lightweight stability and resistance to compressive stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel or cast material is used for the drum shell, then strength and stability are improved, but weight increases
Solution Approach 1:
The drum shell is constructed using composite materials combining a foam core with fiber-reinforced plastic layers (such as carbon fiber or glass fiber). This composite structure provides high strength-to-weight ratio, maintaining the required mechanical strength while significantly reducing the overall weight compared to solid steel construction.
Solution Approach 2:
The drum shell employs varying wall thicknesses and fiber orientations in different regions to optimize strength where needed while minimizing material usage. The fiber reinforcement is concentrated in areas subject to highest stress, allowing weight reduction in less critical areas.
2Weight of moving object
If honeycomb structure is used to reduce weight, then weight is reduced, but manufacturing complexity and cost increase
Solution Approach 1:
A foam core is used instead of a hollow honeycomb structure. The foam provides lightweight properties while being simpler to manufacture through injection molding or foam injection processes, eliminating the complexity of creating and assembling hollow cellular structures.
3Weight of moving object
If foam core is used to reduce weight, then weight is reduced, but resistance to compressive stresses decreases
Solution Approach 1:
The foam core is combined with outer layers of fiber-reinforced plastic that provide the necessary compressive strength. The foam serves as a lightweight core while the fiber-reinforced shells bear the compressive loads from cable winding, creating a composite structure where each material performs its optimal function.
Solution Approach 2:
The fiber reinforcement is strategically oriented and distributed to provide maximum compressive resistance where cable loads are applied, while the foam core provides lightweight bulk. The wall thickness and fiber density are optimized locally to match the stress distribution pattern.
4Stability of the object's composition
If multi-layered structure with foam core is used, then weight is reduced and stability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The multi-layered structure is manufactured as an integrated composite component in a single molding process, where the foam core and fiber-reinforced layers are combined simultaneously. This eliminates the need for separate assembly steps and reduces the accumulation of tolerances that would result from joining multiple pre-manufactured parts.
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 achieves a lightweight, stable, and cost-effective rope drum capable of withstanding high rope loads, reducing weight and manufacturing costs while maintaining structural integrity.
Implementation Method 1
considerable compressive stresses occur on the cable drum due to the cable being wound onto it under load
Implementation Method 2
the drum shell and/or the end plates are made of fiber-reinforced composite material
Implementation Method 3
a multi-layered structure with at least two walls made of fiber-reinforced composite material, which are spaced apart from each other and connected to each other by an intermediate foam core
Data Source
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AI summary
The present invention relates to a cable drum for a cable winch of a cable drive, having a drum shell and two flanged wheels which adjoin the drum shell at the ends, wherein the drum shell and/or the flanged wheels are produced from fiber-reinforced composite material, wherein the drum shell and/or the flanged wheels have a multi-shell structure having at least two walls made of fiber-reinforced composite material, which walls are spaced apart from each other and connected to each other by a foam core.