High-Pressure Tank Liner Joining and Fiber Winding
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Solution Overview
Problem
In high-pressure tank manufacturing, the joining of liner parts often results in level differences due to material shrinkage and misalignment, leading to harmful gaps between the fiber and liner, which compromises strength and makes it difficult to maintain minimum plate thickness.
Innovation Solution
The method involves optimizing the shape of the joined portions by forming cylindrical liner constituents with thicker end portions and tapered joining ends, where the outer diameter at the joined surface is increased to account for expected level differences, and the fiber is wound around the liner using helical winding to minimize gaps while ensuring constant heat input during joining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If parts are joined together to form the liner, then the liner can be manufactured with complex shapes and sizes, but level differences occur at joined portions due to material shrinkage and misalignment
Solution Approach 1:
The liner constituent members are designed with thicker end portions and increased outer diameters at the joined surfaces before joining occurs. This preliminary design compensates for the anticipated level differences that will occur during joining, ensuring that the fiber can be properly wound without gaps even after the joining process introduces dimensional variations.
Solution Approach 2:
The liner constituent members have non-uniform thickness distribution, with thicker end portions specifically at the joined surfaces and thinner portions in the middle sections. This local quality variation allows the structure to accommodate joining-induced level differences at critical locations while maintaining overall design efficiency.
2Reliability
If the outer diameter at joined surface is increased to compensate for level difference, then harmful gaps between fiber and liner are suppressed, but the thickness of the part is thinned after cutting
Solution Approach 1:
The liner constituent members are designed with thicker end portions and increased outer diameters at the joined surfaces before joining occurs. This preliminary design compensates for the anticipated level differences that will occur during joining, ensuring that the fiber can be properly wound without gaps even after the joining process introduces dimensional variations.
Solution Approach 2:
The outer diameter at the joined surface is increased by the estimated level difference amount, which may be more than the actual level difference that occurs. This excessive action ensures that even if the actual level difference is within the estimated range, the fiber can still be properly wound without gaps, and the minimum plate thickness requirement is still met after cutting.
3Strength
If helical winding is used to wind fiber around the liner, then strength is improved through constant fiber tension, but fibers concentrate at end portions causing shape deviation
Solution Approach 1:
The liner has different outer diameters at different locations, with larger outer diameters at the joined surfaces and smaller outer diameters in the middle sections. This local variation in geometry compensates for the fiber concentration effect in helical winding, allowing the fiber layers to maintain more uniform thickness distribution while still achieving constant fiber tension for strength.
Data Source
AI summary
A high-pressure tank in a method of manufacturing a high-pressure tank includes a liner and a fiber. The manufacturing method includes: preparing a dome and a pipe each having a general portion and a joining end portion formed to be thicker than the general portion such that an outer diameter at least at an end face is larger than an outer diameter of the general portion by an estimated level difference amount; joining the joining end portion of the dome and the joining end portion of the pipe together in an axial direction; cutting off portions on the further outer side in a radial direction than a reference plane, with an outer peripheral surface of the general portion of the dome having a large outer diameter at the joined surface as the reference plane; and winding a carbon fiber around the outer peripheral surface of the liner in helical winding.