Magnus Rotor Body Segmented Panel Assembly
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Solution Overview
Problem
Existing methods for manufacturing Magnus-type rotor bodies face challenges in achieving desirable structural properties such as low weight, uniform mass distribution, high stiffness, and cost-effectiveness, often resulting in uneven rotation, wobbling, and deformation during operation.
Innovation Solution
The method involves using at least three arcuate panels with a multilayer structure, each with an arc-length less than the rotor body's circumference, positioned and connected to form a hollow cylindrical loop, which can be stacked to create the rotor body, utilizing composite materials like fiberglass reinforced plastics and balancing members for uniform weight distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If single-piece casting technique is used to manufacture rotor body, then structural integrity is improved, but manufacturing cost and time increase
Solution Approach 1:
The rotor body is divided into multiple segments that can be manufactured separately and then assembled. Each segment is cast individually using smaller molds, which reduces manufacturing time and cost compared to single-piece casting, while the segments are designed to connect in a way that maintains overall structural integrity of the rotor body.
2Device complexity
If half-shell casting method is used to manufacture rotor body, then manufacturing complexity is reduced, but mass distribution uniformity deteriorates
Solution Approach 1:
The rotor body is segmented into multiple sections that are cast separately and then assembled. This segmentation allows for better control of mass distribution in each segment, and the assembly process ensures uniform overall mass distribution, resolving the issue of non-uniform mass distribution that occurs with half-shell casting.
Solution Approach 2:
Different segments of the rotor body can have locally optimized properties including controlled mass distribution. The casting process for each segment can be tailored to achieve specific mass characteristics, and the assembly ensures uniform overall distribution, addressing the uniformity issues with traditional half-shell casting.
3Ease of manufacture
If traditional casting techniques are used, then manufacturing process is simple, but rotor body deformation occurs during operation
Solution Approach 1:
Dividing the rotor body into segments allows each segment to be manufactured with better dimensional control using smaller molds. The assembly process ensures proper alignment and bonding, preventing the deformation issues that occur with traditional large-scale casting while maintaining manufacturing simplicity.
Solution Approach 2:
The segments are pre-manufactured with precise dimensional tolerances and proper alignment features before final assembly. This preliminary preparation ensures that when the segments are assembled, the rotor body maintains consistent shape and avoids deformation during operation, while the overall process remains simple.
4Ease of manufacture
If large molds are used for casting rotor body, then manufacturing capability is achieved, but equipment cost and handling difficulty increase
Solution Approach 1:
The rotor body is divided into segments that can be cast using smaller, more manageable molds. This eliminates the need for large, expensive molding equipment while maintaining the capability to manufacture the complete rotor body through assembly of the segments.
Solution Approach 2:
Instead of manufacturing the complete rotor body in a single large mold (one-dimensional approach), the invention uses multiple smaller molds arranged in a segmented manufacturing approach. This dimensional change in the manufacturing process allows for reduced equipment size and cost while achieving the same final product capability.
Data Source
AI summary
A method is provided for manufacturing a rotor body of a Magnus-type rotor. The method includes providing a plurality of arcuate panels, wherein each of the panels has an arc-length less than a predetermined circumference of the rotor body. The method further includes positioning at least three such arcuate panels in mutual edge-wise abutment to form circumferentially a hollow cylindrical loop, wherein longitudinal edges of adjacent panels are mutually attached to each other. The method further optionally includes co-axially stacking one above another at least two loops of substantially similar diameter. The method further includes connecting edges of adjacent loops to define the rotor body of a predetermined height.