Radial Offset Needling Head for Annular Fiber Preform Uniformity
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Solution Overview
Problem
Existing needling methods for annular fiber preforms struggle to achieve uniformity of needling and optimal fiber expansion, leading to inconsistent mechanical characteristics in composite materials like carbon/carbon brake disks.
Innovation Solution
A circular needling table with a needling head that moves radially during the needling process, allowing for controlled radial offsets of the needles to ensure uniform needling and enhanced fiber expansion, utilizing a linear stepper motor for precise control and an end-of-stroke sensor for accurate positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a stationary needling head is used on a circular needling table, then the device complexity is reduced, but the uniformity of needling over the entire surface area deteriorates
Solution Approach 1:
The needling head is transformed from a stationary component to a dynamic one capable of radial movement. The patent implements a radial offsetting mechanism that displaces the needling head radially during the needling process, allowing the needles to strike the fiber preform at varying radial positions. This dynamic adjustment enables uniform needling distribution across the entire annular surface area while maintaining reasonable device complexity through controlled mechanical displacement.
2Device complexity
If a stationary needling head is used, then the device structure is simplified, but the fiber expansion optimization deteriorates
Solution Approach 1:
The needling head incorporates a radial offsetting mechanism that dynamically adjusts its position during operation. This dynamic displacement allows the needles to penetrate and separate fibers at multiple radial locations, promoting optimal fiber expansion and fluffiness in the needled textile structure while maintaining a manageable device structure through controlled mechanical movement.
3Device complexity
If the needling head remains fixed radially, then the control system is simpler, but the needling uniformity and fiber expansion deteriorate
Solution Approach 1:
The control system manages the radial offsetting of the needling head through a coordinated movement mechanism. This dynamic control enables the needling head to traverse radial positions that ensure uniform needle distribution across the annular fiber preform surface, achieving consistent needling density and optimal fiber expansion while maintaining a relatively simple control architecture through mechanical coupling with the existing rotational drive system.
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 approach results in more uniform needling and improved fiber expansion, enhancing the infiltration of matrix material into the preform, thereby improving the mechanical properties of the final composite material.
Implementation Method 1
an electric motor mounted on the support and having an outlet shaft coupled to the needling head in order to move it along a direction that is radial relative to the axis of rotation of the fiber preform. Under such circumstances, the motor is, in an embodiment, a linear stepper motor.
Data Source
AI summary
A circular needling table for needling a textile structure made from an annular fiber preform, includes: a horizontal top on which an annular fiber preform is to be placed; a driver system constructed and arranged to drive the fiber preform in rotation about a vertical axis of rotation; and a needling device for needling the fiber preform, the device including a needling head extending over a predetermined angular sector of the table top and to be driven with vertical reciprocating motion relative to the table top, and a mover system constructed and arranged to move the needling head in a direction that is radial relative to the axis of rotation of the fiber preform.