Composite Transmission Shaft RTM Flange for Torsional Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional transmission shafts in aircraft are heavy due to metallic flanged end fittings, which increase weight and complexity when replaced with composite materials, while maintaining mechanical properties.
Innovation Solution
A composite transmission shaft formed entirely of composite material, with a flanged end fitting comprising a flared sleeve and reinforcement portions, resin transfer moulded together with the shaft portion, optimizing torsional load transmission and reducing weight and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic flanged end fittings are used, then mechanical strength and structural integrity are ensured, but weight increases
Solution Approach 1:
The patent changes the material parameter from metallic to composite material for the flanged end fitting, transforming it from a homogeneous metal structure to a layered composite structure with fibres and resin, thereby reducing weight while maintaining mechanical properties
Solution Approach 2:
The flanged end fitting is constructed using composite materials consisting of fibres embedded in a resin matrix, replacing traditional metallic materials to achieve weight reduction while preserving structural integrity and mechanical strength
2Weight of moving object
If composite material is used for flanged portion, then weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent merges the flanged end fitting and shaft portion into a single integrated composite structure manufactured in one resin transfer moulding process, eliminating the need for separate manufacturing and assembly steps, thereby reducing manufacturing complexity
Solution Approach 2:
The flanged end fitting is pre-formed with embedded fibres and resin in the desired final configuration before being integrated with the shaft portion through resin transfer moulding, simplifying the overall manufacturing process
3Weight of moving object
If composite material is used for flanged portion, then weight is reduced, but manufacturing process becomes more complex
Solution Approach 1:
The manufacturing process merges the formation of the flanged end fitting and shaft portion into a single resin transfer moulding operation, where both components are manufactured and integrated simultaneously, thereby simplifying the manufacturing process despite using composite materials
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 all-composite transmission shaft achieves weight reduction, improved mechanical properties, and simplified manufacturing by integrating the flanged end fitting with the shaft portion using resin transfer moulding, enhancing torsional load transmission and structural integrity.
Implementation Method 1
The flanged end fitting and shaft portion have been resin transfer moulded together to form the transmission shaft
Data Source
AI summary
A composite transmission shaft includes a shaft portion, and a flanged end fitting. The flanged end fitting comprises a flared sleeve comprising a tubular portion and a flared portion, and a reinforcement portion fixed to the flared portion of the sleeve. The flanged end fitting and shaft portion have been resin transfer moulded together to form the transmission shaft.