Spoke Unit Winding Path Avoids Central Stacking
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Solution Overview
Problem
Existing methods for manufacturing spoke units using continuous fiber reinforced plastic often result in increased weight and shape deformation due to excessive stacking in the central area, leading to accuracy issues and potential collapse of the laminate structure.
Innovation Solution
A method involving a mandrel with supporting portions for each spoke, where continuous fiber reinforced plastic is wound in a manner that avoids central turning points, shifting intersecting points to prevent excessive stacking and maintaining uniform stack heights, thereby reducing central weight and maintaining the shape of the laminate body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the continuous fiber reinforced plastic is wound around the mandrel with turning points in the central area, then the filament can be stacked around the central axis, but the stack height increases and the weight of the central area increases
Solution Approach 1:
The winding path is segmented into multiple sections, with turning points strategically positioned away from the central area. The fiber reinforcement is divided into multiple layers with different winding patterns, preventing excessive stacking in any single location while ensuring adequate coverage throughout the structure.
Solution Approach 2:
The winding pattern transitions from simple circular winding to a three-dimensional path that incorporates axial and radial components. This multi-dimensional winding approach distributes the fiber layers more evenly through the volume of the spoke unit, preventing concentration of material in the central area while maintaining structural integrity.
2Strength
If the continuous fiber reinforced plastic is wound with multiple turns around the central axis, then the fiber reinforcement is intensified, but the shape deforms due to excessive stack height
Solution Approach 1:
Different regions of the spoke unit receive different winding densities and fiber orientations. The central area receives fewer turns and thinner layers compared to the outer regions, creating a non-uniform but optimized structure that maintains shape accuracy while providing adequate local reinforcement where needed.
Solution Approach 2:
The winding parameters such as tension, speed, and path are dynamically adjusted during the manufacturing process based on real-time monitoring of stack height and shape. This dynamic control prevents excessive stacking that would cause deformation while ensuring sufficient fiber reinforcement is applied.
3Ease of manufacture
If the filament is stretched multiple times between front and back surfaces of the mandrel, then the disk portion is formed, but the center area weight increases and the filament collapses
Solution Approach 1:
The mandrel design incorporates preliminary shaping features and support structures that guide the fiber reinforcement during winding, preventing collapse before curing. The fiber path is pre-planned to avoid excessive turns in the central area, and the mandrel geometry is optimized to maintain proper spacing between layers during the manufacturing process.
4Productivity
If the stack height of the central area is greater than other areas, then the filament can be wound around the mandrel, but the filament easily collapses and shape deforms
Solution Approach 1:
A sizing agent or release agent is applied as an intermediary layer between the fiber reinforcement and the mandrel surface. This intermediary prevents excessive adhesion in the central area, allowing the fiber layers to maintain proper spacing and preventing collapse during the winding and curing processes while maintaining manufacturing efficiency.
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 reduces the weight of the central area, maintains the accuracy of stacking, and increases manufacturing efficiency by preventing excessive stacking and deformation, resulting in a more stable and precise spoke unit.
Implementation Method 1
winding a continuous fiber reinforced plastic around the mandrel and molding the spoke unit by curing the continuous fiber reinforced plastic
Data Source
AI summary
In a method for manufacturing a spoke unit, the continuous fiber reinforced plastic is led from a middle supporting portion to a first supporting portion along the front surface of the mandrel. Subsequently, the continuous fiber reinforced plastic is led from the first supporting portion to the middle supporting portion along the back surface of the mandrel. Subsequently, the continuous fiber reinforced plastic is led from the middle supporting portion to a second supporting portion along the front surface of the mandrel. Subsequently, the continuous fiber reinforced plastic is led from the second supporting portion to the middle supporting portion along the back surface of the mandrel.