Composite Transmission Shaft
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Composite Transmission Shaft
Introduction of the composite transmission shaft
With the wide application of carbon fiber materials, laying of carbon fiber composites on metal axis makes it possible for a one-part transmission shaft. Compared with the traditional two-part metal transmission shaft, the composite transmission shaft can effectively reduce the noise and vibration, improve the power and fuel economy of the automobile and reduce the emission of the pollutants.
The transmission shaft of carbon fiber is generally a thin-walled circular tube structure, which is mainly subjected to torque load during work, so it can be made by molding technology such as pressure injection resin in fiber tube or filament winding. Among them, the filament winding is the preferred molding process because of the advantages of equal strong structure, integral molding and easy operation.
The composite transmission shaft is designed according to the use conditions and performance requirements. By adjusting the winding angle, the order of the layer, the geometric size of the product and the material selection, the requirements of the strength, the critical speed (natural frequency) and the torsional buckling performance are met. The composite transmission shaft is composed of the straight tube of carbon fiber, the composite flange, the diaphragm, the wheel fastener, fastener and other components. Usually, the straight tube of carbon fiber is formed by carbon fiber / epoxy composite through winding process, the composite flange is made of glass fiber composite through molding process, and the two part is connected with the bonding and pin. The structure is characterized by the light weight and the high reliability.
The straight tube of carbon fiber is formed by carbon fiber / epoxy composite, the composite flange of both ends is made of glass fiber cloth/epoxy resin. The composite layer structure of the straight tube section adopts an alternating layer structure of ±45 degrees, ±7 degrees and 90 degrees, and the layer of ±45 degrees can increase the effect of the torsion load supported by the cylinder body, and the layer of ±7 degrees can increase the effect of the axial stiffness, and the layer of ±90 degrees meets the requirements of the circumferential stiffness and strength.
The straight tube of the composite transmission shaft is wound by the four - six degree of freedom numerical control winding machine with high precision, and the internal solidification heating of the domestic leading electromagnetic induction heating technology is used . The four - six degree of freedom NC winding machine is equipped with the tension control device and the automatic yarn returning device, which can realize precise winding of the composite transmission shaft. For the composite transmission shaft, the winding machine uses our own developed fiber winding software, compared with the leading CADWIND software in the international winding field, our software has an absolute price advantage, which can reduce the cost of the carbon fiber shaft. In addition, we have independently developed the pipe reinforced core mold heated by the electromagnetic induction and applied it to the curing process of the composite transmission shaft. The core mold has the characteristics of uniform temperature, small temperature difference and high energy utilization, which can fully guarantee the consistency of the product, especially for the products with the high requirement for curing quality, such as the composite transmission shaft. The pipe reinforced core mold heated by the electromagnetic induction improves the heating and curing efficiency and enhances the molding quality of the composite transmission shaft.
The competitiveness of the composite transmission shaft
The development of the material of the transmission shaft has gone through the propulsion process of wood material to metal material, metal material to polymer material, and polymer material to inorganic material and composite material. Nowadays industry has been looking for ways to reduce the weight of the material itself and increase its payload, so the resin composite drive shaft of the high - strength, high modulus, hardness plays a more and more important role. The composite transmission shaft has the following main advantages:
The lightweight technology adapted to China's national conditions: compared with the hard steel shaft, the weight of the composite transmission shaft is obviously reduced, which includes the necessary metal parts at the end of the composite tube, but the weight of the carbon fiber tube itself is very light. In general, the longer the shaft is, the greater the weight loss is, the more obvious the effect of weight reduction is. Lightweight technology is the fundamental way to improve fuel efficiency. First, each weight loss of the car is 10%, the fuel consumption can be reduced by 6%-8%, and the emissions are reduced by 5%-6%, while the fuel consumption is reduced by 1L, and the emission of CO2 is reduced by 2.45K. Second, the lightweight technology improves the fuel efficiency, while there are obvious improvements in the functional indicators of safety, shock proof, sound insulation, thermal insulation and so on. Third, the lightweight technology makes vehicle design more flexible.
Greater ground drive: the composite transmission shaft has smaller inertia during rotation because of the light weight of the shaft when applied to a car drive shaft, which reduces the loss of rotational energy. A lighter drive shaft makes your engine has more dynamic on the ground.
High critical speed: when applied to a ship, as the speed is given, the advantages of using the composite transmission shaft are embodied in the long propulsion shafting. The long propulsion shafting usually does not need to be arranged bearings, or the number of bearings is reduced. This reduces the cost, lightens the shafting, reduces the parts, saves the cost of bearing support, and lightens the weight.
Good damping resistance: all drive shafts will be distorted after exerting torque to a certain degree. The distortion of the impedance elasticity is expressed by elastic distortion. The torsion ratio of the composite transmission shaft is smaller than that of aluminum, only about half of the steel. The advantage of low elasticity is lower vibration of power transmission system, less force on other parts of the power transmission system, and increasing traction. The vibration of carbon fibers is twice as fast as that of the metal. When suddenly started and accelerated, the resulting rapid vibration is reduced and translated into a backward jump and a vibration at the other end of the wheel.