Integrated Composite Drive Shaft Flange for Tolerance Loads
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Solution Overview
Problem
Current drive shafts with integrated flanges lack sufficient strength and flexibility to accommodate angular and axial tolerances, leading to potential structural weaknesses and corrosion issues, especially in critical applications like aircraft and spacecraft.
Innovation Solution
A drive shaft with an integrated flange made from composite materials, featuring separate plates branching out at predetermined angles relative to the rotation axis, providing increased flexibility and strength by adjusting fiber lay-up and thickness to accommodate loads, and incorporating reinforcement around mounting holes to reduce part count and prevent galvanic corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metal flanges are attached to composite drive shafts by gluing, clamping, screwing or joining by forming, then the connection can be achieved, but corrosion and earlier stress fractures occur on the connection area
Solution Approach 1:
The flange and drive shaft are merged into a single integral composite structure, eliminating the connection interface that causes corrosion and stress fractures. The flange is manufactured as one piece with the drive shaft using composite material layers, removing the need for separate attachment methods.
Solution Approach 2:
Both the flange and drive shaft are made from composite materials with different fiber orientations and layer configurations optimized for their specific functions. The flange uses layers oriented to handle mounting loads while the shaft uses layers optimized for torsional and bending loads, creating a homogeneous material system that prevents galvanic corrosion.
2Reliability
If flanges are made from composite materials to match composite drive shafts, then galvanic corrosion is prevented, but the strength is relatively low compared to metal flanges
Solution Approach 1:
The flange is constructed with multiple layers of composite material with specific fiber orientations (including 0°, 90°, and ±45° angles) to optimize strength in different directions. The layer configuration and material selection provide torsional strength comparable to metal flanges while maintaining corrosion resistance.
Solution Approach 2:
The flange structure incorporates local reinforcement with additional composite layers and varied fiber orientations in critical areas to increase strength where needed, while maintaining the overall composite construction for corrosion resistance throughout the entire component.
3Adaptability or versatility
If flanges are manufactured separately from drive shafts, then connection flexibility is achieved, but part complexity and production costs increase
Solution Approach 1:
The flange and drive shaft are manufactured as a single integral component, reducing the part count from two separate parts to one. This eliminates assembly steps, reduces quality management complexity, and simplifies inventory management while maintaining the adapted composite structure for mounting flexibility.
Data Source
Figure 1
Figure 2A
Figure 2B~2C
AI summary
The present embodiments are related to a drive shaft 200 made from composite materials 214 that comprises a hollow body 210 and a flange 220 that is integrally formed with the hollow body. The hollow body is adapted to rotating around an associated rotation axis and is made of a first composite material. The flange is made of a second composite material and arranged at an axial end 215 of the hollow body. The flange comprises at least two separate plates that branch out from the hollow body at the axial end. The flange further comprises a mounting section 222 that is configured to be mounted to an external component and comprises a plurality of holes 227 that are adapted to accommodate coupling means.