高速永磁电机护套热塑性预浸带张力缠绕预紧与松弛机制研究

The technology of thermoplastic prepreg tape winding with tension is an effective method to solve the preload problem of hi-speed permanent magnet machine(HSPMM) sleeve, which can satisfy the manufacture of prestressed composites (≮ 1000MPa).The resin matrix presents complex phase change and viscoelastic rheological behavior under laser heating and tension winding. Meanwhile the temperature field and the prestress field are coupled with each other, which leads the pretension and relaxation mechanism is unclear, and seriously restricts the application of this technology. This project focuses on the thermo-mechanical phenomenon of in-situ consolidation process with tension winding and laser heating.The evolution law of viscoelastic constitutive relation is accurately described considering the resin matrix thermo-mechanical phase change. The analytical method of pre-stress dynamic performance under the transient thermo-mechanical condition is proposed. Then the models from material behavior to mechanical behavior are established. The law of pre-stress dynamic performance during filament winding with tension is theoretically revealed, and the effect of preload and relaxation is evaluated quantitatively, which provides theoretical support for the development of composite sleeve of HSPMM.

热塑性预浸带张力缠绕技术可以实现复合材料含预应力（≮1000MPa）制造，是解决MW级大容量高速永磁电机转子复合材料护套预紧问题的有效方法。在激光加热和张力缠绕作用下树脂基体呈现复杂的相变和粘弹性流变行为，温度场和预应力场相互耦合，导致其预紧和松弛机制不明，严重制约了该技术的应用。本课题拟围绕热塑性预浸带张力缠绕成型工艺中的热-力学现象展开研究，准确描述考虑树脂基体热-力学相变的复合材料粘弹性本构关系演化规律，提出瞬态热-力条件下粘弹性缠绕层预应力场动态分析方法，建立从材料行为到力学行为的成型全过程数学模型，从理论上揭示预浸带张力缠绕预应力场动态变化规律，并定量评估其预紧与松弛效果，为高速永磁电机转子复合材料护套的研制提供理论支撑。

高速永磁电机具有高功率密度、高效率和高功率因素等特点，以及便于实现高速直驱等优势，非常适合并满足高端装备的特殊需求，但是高速转子含预应力复合材料护套的设计与制造技术一直是瓶颈。热塑性预浸带张力缠绕技术可以实现复合材料含预应力（≮1000MPa）制造，是解决MW级大容量高速永磁电机转子复合材料护套预紧问题的有效方法。. 本课题围绕热塑性预浸带张力缠绕激光加热原位固结成型工艺中的热力学现象展开研究，准确描述考虑树脂基体热力学相变的复合材料粘弹性本构关系演化规律，提出瞬态热-力条件下粘弹性缠绕层预应力场动态分析方法，建立从材料行为到力学行为的成型全过程数学模型，从理论上揭示预浸带张力缠绕预应力场动态变化规律，并定量评估其预紧与松弛效果，为高速永磁电机转子复合材料护套的研制提供理论支撑。. 该技术覆盖高速永磁发电机功率几kW至数MW，转子护套预应力水平不低于1000MPa，长期耐温性不低于180℃，表面线速度不低于200m/s。采用该技术制造的15MJ/1MW复合材料飞轮在青岛地铁3号线进行了示范应用，制备的22kW氢燃料电池用高速永磁空压机已完成性能测试。