Carbon Fiber Drive Shaft, A Superior Alternative to Traditional Steel Sheet

Introduction

ENCON Group:

A pioneering force in the Cooling Tower industry since 1987, specializing in Axial Flow EFRP Fans. From our base in India, we've grown to become a premier manufacturer and exporter, serving loyal clients across 45 nations.
Our commitment to excellence is further underscored by our corporate membership in the Cooling Technology Institute and our engagement with talent from leading institutions like IIT Bombay and IISc.
With an impressive track record of over 558,000 installations and a robust manufacturing infrastructure unit in Sinner, Nashik - Maharashtra, ENCON delivers best quality and reliability worldwide.

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Cross Sectional Of Cooling Tower

Problems with Steel Shafts:

Extremely heavy (100–200kg)

Corrosion prone (chlorine exposure)

Rubber bushings degrade quickly

High vibration and frequent misalignment

Complex installation/removal process

Short lifespan: 5–7 years

Higher cost due to frequent maintenance

Problem with traditional Steel Shaft

Corrosion Prone

Effects of Corrosion
1) Loss of Material cause Imbalance - Vibration
2) Entire assembly has to be replaced. Assembly Balance is done - Part (hub) replacement not possible.
3) Service Life is 5-7 years. Results in RECURRING CAPITAL COSTS

Degraded Rubber Bush

Multiple Parts	16 sets of Pin & Bush
Rubber bush degraded by Chlorine	Misalignment capacity gone - Vibration Frequent Replacement

Flexible Joint Difference

8 sets of Pin & Bush per End	Unitized (1 piece) Flexible Disc per End
Low service life rubber	Min 5 years - Composite
Minimized misalignment tolerance has led to performance loss due to material hardening.	The misalignment capacity is three times the standard threshold.

Why ENCON CARBON Composite Shafts?

Weight:

Experience unparalleled ease of handling with an ultra-lightweight design, ranging from just 09 to 70 kilograms. This significantly reduces strain during installation and maintenance.

Material Properties:

Built with SS316 stainless steel and advanced CARBON composite, this system delivers exceptional corrosion resistance for reliable performance in any environment. Hub (SS 316) Flexible Element (Composite) Spacer (Composite)

Operational Benefit:

Minimize wear and tear on your valuable equipment. The design inherently produces minimal vibration, contributing to a significantly longer lifespan for Gearbox and connected rotary machinery.

Usability:

Installation and removal are designed to be swift and secure. This efficiency saves valuable time and resources during setup and any necessary maintenance.

Carbon Composite Materials: A Comprehensive Overview

These high-performance materials, known as advanced carbon composites, usually comprise a polymer base strengthened by continuous fibers aligned in a predetermined way.

Types of Fiber Used:

• Fiberglass
• Carbon/Graphite*

Technical Advantages

Key Benifits:

• Flexible Joints
• Misalignment Tolerance
• Thermal Expansion
• High Strength-to-Weight Ratio

cfrp The composite disc joint boasts a longer minimum service life (5 years), three times the standard misalignment capacity, and avoids hardening issues associated with the low service life rubber used in the pin and bush design.

Carbon composite materials: A graphical perspective

Density Comparision

Lightweight design facilitates easier handling, minimizes stress on bearings, and reduces vibration.

Carbon composite materials: A graphical perspective

SPECIFIC STIFFNESS
x 1000000 INCHES
(MODULUS / DENSITY)

Specific stiffness, calculated as modulus divided by density, highlights material stiffness relative to its weight. Carbon composite's superior specific stiffness (demonstrated by less sag in a rod comparison) allows Encon couplings to achieve longer spans compared to steel and aluminum.

Carbon composite materials: A graphical perspective

SPECIFIC STIFFNESS
x 1000000 INCHES
(Tensil Strength / DENSITY)

Carbon fiber boasts a specific strength six times greater than comparable industry materials when considering tensile strength relative to density. Ultimately, carbon composites offer a superior combination of being lighter, stiffer, and stronger than both aluminum and stainless steel.

Steel vs. Carbon Fiber Driveshafts: A Comparison

	STEEL	ENCON CARBON FIBRE COMPOSITE	BENEFITS
WEIGHT	HEAVY (100-200 KG)	ULTRA LIGHT (09-70 KG)	• Faster Installation & Alignment • Easy Maintenance
VIBRATION	HIGHER (> 10 MM/SEC)	MINIMAL (< 2 MM/SEC)	• Longer Bearing and End Equip life. • Lesser Down Time
CORROSION	HIGH	NO CORROSION	• Min Ownership cost during for life of Cooling Tower
FLEXIBLE JOINT	PIN & BUSH (8 SETS)	UNITIZED (1 PIECE)	• Simple Replacement • Reduced Maintenance cost & time
SERVICE LIFE	5-7 YEARS	CT LIFE TIME	• No Recurring Capital Cost
DOWNTIME TIME & COST	HIGHER	MINIMUM	• Trouble free operation