Variable Cone Angle Braiding for Composite Connecting Rods
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Solution Overview
Problem
Existing methods for manufacturing composite material connecting rods are inadequate in producing components with varying mechanical qualities, as they require complex and expensive processes to add material locally, especially at ends subjected to higher stresses, and existing braiding machines are not compatible with large mechanical components.
Innovation Solution
A braiding method that includes a reconfiguration step to modify the angle of the cone formed by reinforcing fibers and adjust the mandrel feed rate and reel rotation speed, allowing for different fiber inclinations and mechanical properties in various regions of the connecting rod.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If material is added locally at the ends to increase mechanical strength and fatigue resistance, then the mechanical qualities of the connecting rod are improved, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent applies local quality by varying the fiber inclination angle along the length of the connecting rod. The ends (yokes) have a first inclination angle optimized for multidirectional stresses, while the main body has a second inclination angle optimized for longitudinal stresses. This allows different mechanical properties in different regions without adding material or using complex manufacturing processes.
Solution Approach 2:
The patent changes the parameter of fiber inclination angle along the longitudinal axis of the connecting rod. By controlling the angle of the cones formed by fibers during braiding, the mechanical properties are optimized for different regions: higher inclination at ends for multidirectional strength, lower inclination in the body for longitudinal strength, eliminating the need for additional material.
2Adaptability or versatility
If a braiding machine with programmable parameters is used to vary fiber density along the tube, then the mechanical qualities can be varied along the component, but the machine cost and complexity increase and it is incompatible with large mechanical components
Solution Approach 1:
The patent segments the connecting rod into distinct regions (ends/yokes and main body) with different mechanical requirements. Each region is braided with fibers at different inclination angles achieved through different cone angles during the braiding process, allowing region-specific optimization without requiring a complex programmable braiding machine.
Solution Approach 2:
The patent uses dynamic adjustment of the cone angle during the braiding process to vary fiber inclination along the length of the connecting rod. By changing the angle at which fibers converge on the mandrel, the system dynamically adapts fiber orientation to match the mechanical requirements of different regions, achieving versatility with a simple braiding machine.
Data Source
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Figure 4A~5C
Figure 6A~7C
AI summary
A method of braiding reinforcing fibers on a mandrel (8) with a machine having a ring (9) carrying at least two series of reels of fibers, by moving the mandrel at a predetermined forward speed while moving the two series of reels along the ring (9) so that they cross while rotating in opposite directions and at a predetermined speed of rotation about an axis (AX) of the ring. The braid is formed on the mandrel (8) in the vicinity of a region of convergence (R) of the fibers that together define a conical shape (C). The method comprises: a step of reconfiguring the machine in which the angle (a2) at the apex of the cone (C) defined by the fibers takes on a new value (a2); and a step of restarting braiding in which the movement of the reels along the ring (9) and the forward movement of the mandrel (8) are re-established with a new speed of rotation and a new speed of advance.