Mandrel Fortification for Wound Tank Transition Segments
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Solution Overview
Problem
The manufacturing of large wound tank containers using existing mandrels is hindered by high manufacturing costs, material inefficiencies, and structural integrity issues, particularly at transition segments between cylindrical and end segments, due to uneven pressure distribution and deformation during the winding process.
Innovation Solution
A mandrel with a surface structure and fortification at transition segments to support elongate elements, preventing deformation and ensuring a continuous, uninterrupted structure, combined with inflatable or dissolvable materials for ease of removal, and optional rigid bodies for enhanced support and thermal control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If existing mandrels are used for manufacturing large wound tank containers, then the manufacturing process can be completed, but high manufacturing costs and material inefficiencies occur
Solution Approach 1:
The mandrel is divided into multiple modular segments that can be assembled and disassembled. This segmentation allows the mandrel to be optimized for specific production runs and easily removed from the finished product, reducing material waste and manufacturing costs associated with traditional single-piece mandrels.
Solution Approach 2:
The mandrel utilizes inflatable elements that can change their physical state (inflated/deflated) to facilitate removal from the finished wound tank container. This parameter change allows the mandrel to be easily extracted without damaging the composite structure, eliminating the need for expensive manual removal processes and reducing material loss.
2Reliability
If existing mandrels are used for manufacturing large wound tank containers, then the manufacturing process can be completed, but structural integrity issues occur at transition segments
Solution Approach 1:
The mandrel incorporates rigid reinforcement elements specifically at transition segments where structural integrity is most critical. This local quality enhancement provides additional support during the winding process, ensuring precise fiber placement and maintaining structural integrity at the most vulnerable areas of the tank container.
Solution Approach 2:
The mandrel design includes pre-positioned rigid bodies and reinforcement structures at transition zones before the winding process begins. These elements provide beforehand cushioning and support to prevent deformation and ensure manufacturing precision during the application of composite layers at critical transition segments.
3Productivity
If conventional mandrels are used, then the winding process can proceed, but uneven pressure distribution and deformation occur during wrapping
Solution Approach 1:
The mandrel incorporates inflatable elements that can dynamically adjust their pressure and volume during the winding process. This dynamic capability allows the mandrel to maintain uniform pressure distribution across different sections of the tank, preventing deformation and ensuring manufacturing precision while maintaining productivity.
Solution Approach 2:
The mandrel utilizes pneumatic inflation systems to control the pressure distribution across its surface during the winding process. This pneumatic mechanism allows for precise control of pressure uniformity, preventing deformation of the composite structure while maintaining efficient winding operations.
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 allows for the production of accurately shaped, robust, and efficiently manufactured wound objects with improved structural integrity and increased storage volume, reducing delamination and breakage risks, while enabling cost-effective and environmentally friendly manufacturing processes.
Implementation Method 1
The mandrel comprises an inflatable portion
Implementation Method 2
the forces associated with winding fixing the tank container walls can be counteracted
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A method is provided of manufacturing a wrapped object, comprising a first segment and a second segment connected to each other by a curved transition segment having a common tangent with the first segment and a common tangent with the second segment, respectively. The method comprises the step of providing a mandrel with a surface structure to define at least part of the shape of the first segment, of the shape of the second segment and of the shape of the transition segment in between, and the step of wrapping, one or more elongate elements over the mandrel and bonding the one or more elongate elements to itself and/or each other so as to provide the first segment, the second segment and the transition segment as a continuous structure. The mandrel is provided with a fortification at least at the position of the transition segment, the fortification being configured to support the one or more elongate elements forming the transition segment against inward-directed forces, with respect to the direction of curvature of the transition segment, while wrapping and/or bonding the one or more elongate elements to form the transition segment.