Chopper disc as well as device and method for manufacturing same

Abstract

A chopper disc for a device for the processing of neutron beams is made of carbon fibers and has a concentric, hollow cylindrical recess for receiving a hub for connection to a pivot bearing. The chopper disc also includes a concentric absorber area for absorbing neutrons striking the chopper disc and at least one window in the absorber area through which neutrons of the neutron beam can pass. The carbon fibers extend from the outer periphery of the chopper disc radially in the direction of the recess and contact the recess tangentially.

Claims

1. A chopper disc for a device for the processing of neutron beams, the chopper disc comprising: a concentric, hollow cylindrical recess configured to receive a hub for connection to a pivot bearing; a concentric absorber area configured to absorb neutrons striking the chopper disc; at least one window in the concentric absorber area through which the neutrons of the neutron beam can pass; and a plurality of the carbon fibers extending continuously from an outer periphery of the chopper disc nearly radially in a direction of the concentric, hollow cylindrical recess, wherein the plurality of carbon fibers contact the concentric, hollow cylindrical recess tangentially, wherein each of the plurality of the carbon fibers terminates at the outer periphery; a further plurality of the carbon fibers extending continuously from the at least window of the chopper disc nearly radially in a direction of the concentric, hollow cylindrical recess, wherein the further plurality of carbon fibers contact the concentric, hollow cylindrical recess tangentially, wherein each of the further plurality of the carbon fibers terminates at the at least one window.

2. The chopper disc of claim 1, wherein at least a large portion of the plurality of carbon fibers extends from the outer periphery of the chopper disc nearly radially in the direction of the recess and contact the recess tangentially.

3. The chopper disc of claim 1, wherein all of the plurality of carbon fibers extend from the outer periphery of the chopper disc nearly radially in the direction of the recess and contact the recess tangentially.

4. The chopper disc of claim 1, wherein each first and second end of the plurality of carbon fibers ends at the outer periphery and a section running in a middle between the respective first and second end has a circular arc shape with a profile corresponding substantially to an edge of the recess.

5. The chopper disc of claim 1, wherein each of the plurality of carbon fibers has no, one, two, or more points of intersection with other of the plurality of carbon fibers.

6. The chopper disc of claim 1, wherein, in a cross-section on a plane on which an axis of rotation of the chopper disc lies, a thickness of the chopper disc decreases continuously starting from the axis of rotation in a direction of the outer periphery.

7. The chopper disc of claim 6, wherein the chopper disc has a convex arch in cross-section at least in sections on one side.

8. The chopper disc of claim 1, wherein the plurality of carbon fibers are embedded in a resin system or enclosed by the resin system.

9. The chopper disc of claim 1, wherein a diameter of the chopper disc is between 50 cm and 80 cm.

10. The chopper disc of claim 1, wherein a diameter of a hub is 50 mm to 100 mm.

11. The chopper disc of claim 1, wherein a fiber volume content of the chopper disc is between 50% and 70%.

12. The chopper disc of claim 1, as set forth in any one of the preceding claims, wherein the at least one window is arranged in a section bordering the outer periphery of the chopper disc.

13. The chopper disc of claim 1, wherein the outer periphery is continuous and formed by severed ends of the plurality of the carbon fibers that terminate at the outer periphery.

14. The chopper disc of claim 13, wherein an inner side of the at least one window is continuous and formed by severed ends of the further plurality of the carbon fibers terminating at the at least one window.

Description

BRIEF DESCRIPTION OF THE DRAWING FIGURES

(1) The invention is explained below in further detail on the basis of an exemplary embodiment in the drawing.

(2) FIG. 1 shows a top view of a conventional chopper disc with a number of windows,

(3) FIG. 2 shows a cross-sectional representation of the chopper disc shown in FIG. 1,

(4) FIG. 3 shows a winding mandrel for the manufacture of a chopper disc according to the invention in a cross-sectional representation,

(5) FIG. 4 shows a top view of the winding mandrel shown in FIG. 2 and, for the sake of example, two carbon fiber sections guided over the winding mandrel,

(6) FIG. 5 shows a section through a pressing device according to the invention into which a winding mandrel with an endless carbon fiber wound around it has been introduced.

(7) FIG. 6 shows a perspective view of a winding mandrel according to the invention with a needle crown arranged on its outer periphery,

(8) FIG. 7 shows another representation of the pressing device shown in FIG. 5, from which the produced structure of two chopper discs according to the invention can be seen, and

(9) FIG. 8 shows the pressing device introduced into an autoclave in order to cure the carbon fiber roving.

DETAILED DESCRIPTION

(10) FIGS. 1 and 2 show a top view and a section along line A-A through a conventional chopper disc 1. The chopper disc 1 has a concentric, hollow cylindrical recess 2 for receiving a hub 3 for connection to a pivot bearing. The pivot bearing can be embodied as a magnetic bearing. The chopper disc 1 is manufactured from a plurality of prepared, trimmed fiber mats.

(11) Typically, the chopper disc is composed of several packages of four fiber mat layers each. The carbon fibers of a respective fiber mat are aligned parallel to each other. The fiber mats of a package are rotated with respect to each other, so that the carbon fibers of a respective layer are arranged in rotated fashion at a predetermined angle with respect to the adjacent layer. After the plurality of fiber mats has been laminated together, trimming is performed, whereby the circular outer periphery 6 (circumference) of the chopper disc 1 is achieved.

(12) An absorber area 4 is provided in a section arranged radially on the outside. The absorber area 4 is provided with a plurality of windows 5. The windows 5 are introduced into the absorber area 4 in the form of grooves, for example by milling or water jet cutting. The absorber area 4 is provided with an absorber material, e.g., boron, and is impermeable to neutrons.

(13) During rotation at a predetermined rotational speed, generally greater than 20,000 revolutions per minute, in order to minimize the forces, which increase as distance from the axis of rotation 7 becomes greater, the thickness of the chopper disc 1 decreases as the distance from the axis of rotation 7 increases. The reduction of the thickness is achieved by means of a material-removing method, e.g., milling or reduction of the number of fiber layers, thus resulting in the concentric, discontinuous transitions (edges) designated by (FIG. 2). A weakening of the material thus occurs in this area, so that the maximum rotational speed of the chopper disc 1 is limited for this reason as well as due to the plurality of fibers, which contribute little or nothing to the strength depending on their angle to the centrifugal force. However, these fibers generate a load due to their weight, thus limiting the overall strength of the chopper disc 1.

(14) In contrast, the manufacture of a chopper disc 1 according to the invention is not performed with the aid of prepared, trimmed fiber mats, but rather a winding process with the aid of a winding mandrel 10 depicted in FIGS. 3 and 4. The winding mandrel 10 has the structure of a disc or of a cylinder 9. i.e., its axial length 16 is substantially shorter than the radius 17 of the winding mandrel or cylinder 9. This can be seen from FIG. 3. The radius 17 of the winding mandrel 10 is slightly greater than the radius to be achieved of the chopper disc to be manufactured. If the radius of the chopper disc is to be between 25 cm and 40 cm, then the radius of the winding mandrel 10 is 2.5 cm to 5 cm greater, for example.

(15) The winding mandrel 10 consists of the cylinder 9 and of a first and second dome top cap 14, 15, which constitute a first and second side surface of the winding mandrel 10. The dome top caps 14, 15 are connected to each other via an axially running circumferential surface 13 cylinder 9. Circumferential surface 13 and dome top caps 14, 15 can be integrally formed. Alternatively, they can also be connected to each other in a positive or nonpositive manner.

(16) As can be seen clearly from the cross-sectional representation of FIG. 3, the dome top caps 14, 15 have concave indentations 18, 19, so that the winding mandrel 10 has a smaller axial length in the area of the axis of rotation 12 than in the area of the periphery. As will become clear from the following description, the concave indentations 18, 19 serve to receive the volume of the carbon fiber to be wound and to enable the smaller thickness of the chopper disc 1 as the distance from the axis of rotation 12 increases.

(17) For the winding process, the winding mandrel 10 is additionally provided on its circumferential surface 13 with a needle crown 25 (cf. FIG. 6) or another slip-resistant surface. The needle crown 25 or the slip-resistant surface enable the winding of the winding mandrel 10 on both sides of the dome top caps 14, 15 beyond the circumferential surface 13 while ensuring that the carbon fiber 20 crossing the circumferential surface 13 does not slip laterally. The needle crown 25 or the slip-resistant surface of the circumferential surface 13 enable the use of an endless carbon fiber.

(18) Merely for the sake of example, the profile of two carbon fiber sections is shown in the top view of the winding mandrel 10 in FIG. 4. Reference symbol 20 designates the endless carbon fiber. In a first winding pass, the profile of the carbon fiber 20, which is designated by the solid line, is achieved with the sections 21, 22, 23. In another winding pass (this need not necessarily be the next one, but can be the hundredth or five-hundredth subsequent winding pass, for example), the profile of the carbon fiber 20 designated by the broken line is achieved with the sections 21, 22, 23. Outer angle 24 is shown between the first and the second sections 21, 22.

(19) The carbon fiber section laid in the first winding pass consists of a first straight section 21 and a second straight section 22 as well as a bent middle section 23 lying therebetween. The straight sections 21, 22 extend from the outer periphery, i.e., the circumferential surface 13, of the winding mandrel 10 radially in the direction of the recess 11, in which a shaft 30 is arranged. The straight sections initially contact the recess 11 or the shaft 30 tangentially. At this point, the straight sections 21, 22 transition into the middle section 23, whose profile corresponds substantially to the edge or the periphery of the recess or shaft. The (external) angle enclosed between the first straight section and the second straight section 21, 22 is preferably between 180 and 225.

(20) After the straight section 22 has reached the outer periphery or circumferential surface 13, it extends in the axial direction of the axis of rotation 12 beyond the circumferential surface 13 and is wound accordingly in a manner as just described on the non-visible side of the winding mandrel 10. After a commensurate winding process has also been carried out on the non-visible back side of the winding mandrel 10, the carbon fiber is guided again in the axial direction over the circumferential surface 13 and the winding process is repeated on the illustrated dome top cap 14, which results, for example, in the profile of the carbon fiber designated by the broken line. The beginning of the first straight section 21 is offset at a predetermined angle 26 with respect to the section designated by the solid line 21. How large the angular offset between the successive carbon fiber sections on a dome top cap is can be determined using optimization calculations or experiments.

(21) It can be seen from the described procedure that the needle crown 25 or the slip-resistant surface on the circumferential surface 13 serves to fix the section of the endless carbon fiber running over the circumferential surface in the axial direction.

(22) The winding process is executed frequently in this way until a predetermined number of superposed layers of carbon fibers have been achieved. A number from 4 to 8 layers (in the axial direction over one another) is sufficient here.

(23) In order to ensure that the middle section of the carbon fiber 20 guided around the shaft is guided in the direction of the winding mandrel 10, the shaft 30 (not shown in FIGS. 3 and 4) is preferably cone-shaped, so that the diameter of the shaft 30 expands away from the recess 11. This cannot be seen in the figures.

(24) The feeding of the carbon fiber can be achieved by means of a carbon fiber feeding device that feeds a carbon fiber (C-fiber roving) saturated in the pass through the resin bath to the winding mandrel. The laying of the carbon fiber on the winding mandrel is done mechanically according to a predetermined deposition plan.

(25) As can readily be seen, laminates are created for two chopper discs; that is, a chopper disc is created on each side of the dome top cap 14, 15. The fiber volume content is set and checked during placement on the basis of a strand weight. During laying of the carbon fiber, it is to be splayed radially from inside to outside. The carbon fiber is laid in a gap-free and uniformly covering manner. When all of the fiber layers have been laid, pressing is performed by means of the pressing device 50 shown schematically in FIG. 5. Pressing discs 51, 52 are applied to the shaft 30 from both sides of the winding mandrel 10 and maintained at a defined distance from one another by spacing sleeves 57. Via holes 58, 59, 60, the pressing discs 51, 52 can be connected each other at the outer periphery through the spacing sleeves 57. The pressing discs 51, 52 are braced by means of clamping sleeves 53, 54. These are guided over the shaft 30 and connected thereto in such a way that the pressing discs 51, 52 are impinged with force.

(26) As can readily be seen from the cross-sectional representation of FIG. 5, both the first and the second pressing disc 51, 52 have a concave indentation 55, 56, which respectively correspond to the concave indentations 18, 19 of the winding mandrel. This ensures the symmetrical structure of the corresponding chopper discs 40, 41 (cf. FIG. 7).

(27) If the carbon fibers were not already saturated with a resin system during the winding process, this can also be done before the pressing step or simultaneously with pressing.

(28) During pressing, the laminated carbon fiber composite is severed along the periphery of the winding mandrel 10. The severing can be done by milling, cutting or water jet cutting, for example. During severing, the chopper discs 40, 41 whose shape has already been established are already braced slightly in the laminating device 50.

(29) Next, curing is performed in the autoclave, which is shown for the sake of example in FIG. 8. The autoclave 70 comprises a bottom plate 71 as well as a cover 72. A circumferential seal 73 is arranged between these. In the autoclave 70, curing is performed according to a predetermined pressure, temperature and time profile. Upon completion of curing, demolding is performed, with both chopper discs 40, 41 then being tempered in the exposed state. The tempering is performed in a predefined manner according to a temporally predetermined temperature profile.

(30) Subsequently, the edge and the edge cutouts (windows) are worked using a material-removing method. Water jet cutting can be used for this purpose, for example, whereby the outer contour of the chopper disc is established, that is, the radius of the chopper disc is established and the number and shape of the required windows are introduced into the absorber area. In addition, the absorber area is coated in a known manner with an absorber material, e.g., boron.

(31) As a result, two chopper discs are made available in which all of the now individual carbon fibers have a nearly radial profile. Due to the method of manufacture, it turns out that the thickness of the chopper disc decreases continuously starting from the axis of rotation in the direction of the outer periphery. The chopper discs have a convex arch on each side. As a result, chopper discs having nearly the same strength are made available which have an optimized ratio of disc thickness to stress. Consequently, it is possible to use the chopper discs at higher rotational speeds.

(32) Although the chopper discs are manufactured from a single, endless plastic fiber, upon completion of the manufacturing process, each of the chopper discs consists of many individual carbon threads which extend from the outer periphery of the chopper disc radially in the direction of the recess in order to receive the hub and contact the recess tangentially.

(33) The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.

LIST OF REFERENCE SYMBOLS

(34) 1 chopper disc 2 recess 3 hub 4 absorber area 5 window 6 outer periphery 7 axis of rotation 8 discontinuous transition (edge) 9 cylinder 10 winding mandrel 11 recess for receiving a shaft 12 axis of rotation 13 cylinder circumferential surface 14 dome top cap and first side surface of the winding mandrel 15 dome top cap and second side surface of the winding mandrel 16 axial length of the winding mandrel or cylinder 17 radius of the winding mandrel or cylinder 18 concave indentation 19 concave indentation 20 carbon fiber 21 first straight section of the carbon fiber 20 22 second straight section of the carbon fiber 20 23 bent middle section of the carbon fiber 20 21 first straight section of the carbon fiber 20 22 second straight section of the carbon fiber 20 23 bent middle section of the carbon fiber 20 24 (outer) angle between the first and the second section 21, 22 25 needle crown 26 angle 30 shaft 40 first chopper disc 41 second chopper disc 50 pressing device 51 first pressing disc 52 second pressing disc 53 first clamping sleeve 54 second clamping sleeve 55 concave indentation der first pressing disc 51 56 concave indentation der second pressing disc 52 57 spacing sleeve 58 hole 59 hole 60 hole 70 autoclave 71 bottom plate 72 cover 73 seal