Cantilever crane machine, fiber composite material part and production method and production line of fiber composite material part

Abstract

The present invention relates to the field of fiber composite material parts, and discloses a boom machine, a fiber composite material part, and a production method and production line thereof, the production method comprising: a spiral fiber winding step (S10) of spirally winding a resin-infiltrated fiber yarn onto the outer peripheral surface of a part main body expansion core mold (1) to form a spiral fiber layer (4); a circumferential fiber winding step (S11) in which a circumferential fiber (5) is spirally wound on the outer peripheral surface of the spiral fiber layer to form a circumferential fiber wound layer; and a rigid outer mold mounting and heating curing step (S20), in which the rigid outer mold (2) is mounted so as to surround the circumferential fiber winding layer, heat the spiral fiber layer, and extrude the spiral fiber layer toward the rigid outer mold to cure and shape the spiral fiber layer by expanding the workpiece main body expansion core mold. The production method and the production line are beneficial to improving the production efficiency of the fiber composite material part, and can ensure that the fiber composite material part has better surface quality and mechanical property.

Description

Technical Field

[0001] The present invention relates to fiber composite parts, and particularly to a production method of fiber composite parts and a production line of fiber composite parts. On this basis, the present invention further relates to a fiber composite part made by the production method and a boom machine having a boom made of the fiber composite part by the production method. Background Art

[0002] In boom machines such as cranes and aerial work platforms, as an important load-bearing structural member, the performance of the boom greatly affects the overall vehicle technical level and performance. In traditional technologies, the boom is usually made of high-strength steel materials. With the development of new materials and production processes, in order to meet the requirements of lightweight development, fiber composite booms have received increasing attention. Fiber composites have been widely studied for their high specific strength and specific modulus, good fatigue resistance, damage safety, damping and vibration reduction effects, and excellent designability, and have become the mainstream direction of boom lightweight development.

[0003] According to the boom movement form, the booms used in engineering equipment can be divided into folding booms and telescopic booms. Among them, due to its working characteristics, the telescopic boom has high requirements for dimensional accuracy, mechanical properties, and structural adaptability, resulting in the difficulty of existing production methods to meet its actual application requirements, mainly reflected in complex processes, low production efficiency, uneven resin distribution, and difficulty in precisely controlling dimensional accuracy.

[0004] Typically, in the production of fiber composite booms, a vacuum film can be used to tightly wrap the fiber pre-preg coated on the mandrel and extract the air therein, and then it is placed in a autoclave for hot pressing to make the fiber layer cured and formed. This production process requires good sealing during the vacuum pumping and hot pressing processes, and a large autoclave is needed. The process is complex, the cost is high, and the laid fiber pre-preg is discontinuous, affecting the mechanical properties of the boom.

[0005] In response to this, in the prior art such as Chinese Patent Invention CN102729488B, a hot pressing forming method with an inflatable inner mold and a box-shaped mold is provided. After laying the fiber pre-preg on the inflatable inner mold and preliminary shaping, it is placed in the box-shaped mold together with the inflatable inner mold, and the fiber pre-preg is compressed and shaped by further inflating the inflatable inner mold. This method eliminates the use of an autoclave and thus reduces the production cost. However, this production method still has problems such as complex processes, low production efficiency, and difficulty in ensuring good mechanical properties caused by laying the fiber pre-preg.

[0006] In addition, although the above-mentioned and some other production methods can utilize a box-shaped mold (rigid outer mold) to make the produced boom have relatively good outer surface quality, so as to avoid or reduce the problem of fiber cutting caused by post-treatment such as grinding, the pressure application method of inflating the inner mold is difficult to ensure the resin content uniformity and inner surface accuracy of the overall boom, and can only be applied to the production of the last-stage telescopic boom with low requirements for inner surface quality and load-bearing.

[0007] Moreover, during the hot pressing and curing process, the fibers expand and stretch and move relative to the inner and outer molds, resulting in poor outer surface quality of the cured boom body. The outer surface still needs to be post-treated by means such as grinding, resulting in fiber cutting and damaging its mechanical properties. Summary of the Invention

[0008] The object of the present invention is to overcome the problems in the prior art that the production process of fiber composite parts (such as booms) is complex, the production efficiency is low, and it is difficult to ensure good mechanical properties and precise dimensional accuracy. The present invention provides a production method for fiber composite parts and a production line for fiber composite parts. The production method and production line are beneficial to improving the production efficiency of fiber composite parts and can ensure that they have good surface quality and mechanical properties.

[0009] To achieve the above object, on the one hand, the present invention provides a production method for fiber composite parts, including:

[0010] Spiral fiber winding step: spirally winding the fiber yarn infiltrated with resin onto the outer peripheral surface of the expansion core mold of the part main body to form a spiral fiber layer;

[0011] Circumferential fiber winding step: spirally winding circumferential fibers on the outer peripheral surface of the spiral fiber layer to form a circumferential fiber winding layer, and the spiral winding angle of the circumferential fiber is greater than the spiral winding angle of the fiber yarn forming the spiral fiber layer; and,

[0012] Rigid outer mold installation and heating and curing step: installing the rigid outer mold around the outside of the circumferential fiber winding layer, heating the spiral fiber layer, and extruding the spiral fiber layer towards the rigid outer mold by expanding the expansion core mold of the part main body, and at the same time making the spiral fiber layer cured and shaped.

[0013] Preferably, the production method further includes a preparation and assembly step of the expansion core mold of the part main body performed before the spiral fiber winding step: covering and fixing an expansion core mold layer made of a thermally expandable material on the outer periphery of a rigid core mold layer, and the rigid core mold layer is connected with a rigid core shaft. In the rigid outer mold installation and heating and curing step, the expansion core mold layer is heated to make the expansion core mold layer thermally expand and extrude the spiral fiber layer towards the rigid outer mold.

[0014] Preferably, the expandable core mold layer is made of silicone rubber material, and / or the thickness of the expandable core mold layer at the corner position corresponding to the rigid outer mold is less than that of the remaining part.

[0015] Preferably, the production method further includes: a demolding material coating step performed before the spiral fiber winding step: coating a demolding agent on the outer surface of the expandable core mold of the workpiece body, and / or a demolding step performed after the rigid outer mold installation and heat curing step: removing the rigid outer mold and the expandable core mold of the workpiece body.

[0016] Preferably, the fiber yarn includes at least one of carbon fiber, glass fiber, and aramid fiber, and the resin includes at least one of epoxy resin, unsaturated resin, and phenolic resin.

[0017] Preferably, in the spiral fiber winding step, multiple layers of the fiber yarn are wound respectively at a first spiral winding angle and a second spiral winding angle, wherein the first spiral winding angle is 45° - 90°, the second spiral winding angle is 0 - 45°, and / or the spiral winding angle of the circumferential fiber is not less than 80°.

[0018] Preferably, in the spiral fiber winding step, after at least part of the fiber yarn is spirally wound, the actual profile size of the workpiece body is monitored and compared with the designed profile size, and when they are inconsistent, the tension of the subsequent fiber yarn to be spirally wound is adjusted and / or the part of the workpiece body protruding relative to the designed profile size is compacted.

[0019] Preferably, in the spiral fiber winding step, the actual profile size of the workpiece body is monitored by a manual measuring tool or laser scanning, and / or the tension of the subsequent fiber yarn to be spirally wound is adjusted by an electronic tension system built in the winding machine for winding the fiber yarn, and / or a pressing plate or roller is used to compact the part of the workpiece body protruding relative to the designed profile size.

[0020] Preferably, before the circumferential fiber is spirally wound onto the outer peripheral surface of the spiral fiber layer, the actual profile size of the workpiece body is monitored and compared with the designed profile size.

[0021] If the actual profile size is larger than the designed profile size, the circumferential fiber is spirally wound in an adjacent spiral spaced manner.

[0022] If the actual profile size is smaller than the designed profile size, the circumferential fiber is spirally wound in an adjacent spiral adjacent or overlapping manner.

[0023] Preferably, in the step of installing and heating and curing the rigid outer mold, at least one of curing furnace heating, microwave heating, and self-resistance heating is used to heat the spiral fiber layer.

[0024] The second aspect of the present invention provides a production line for fiber composite parts, including:

[0025] A part main body expansion core mold, which is configured to allow the fiber yarn infiltrated with resin to be spirally wound around its outer periphery to form a spiral fiber layer;

[0026] A fiber winding machine, which is configured to be able to spirally wind circumferential fibers on the outer peripheral surface of the spiral fiber layer to form a circumferential fiber winding layer, and the spiral winding angle of the circumferential fiber is greater than the spiral winding angle of the fiber yarn forming the spiral fiber layer; and,

[0027] A rigid outer mold, which can be installed to surround the outside of the circumferential fiber winding layer and allows the part main body expansion core mold to expand while heating the spiral fiber layer and press the spiral fiber layer toward the rigid outer mold so that the spiral fiber layer is cured and shaped.

[0028] Preferably, the production line further includes:

[0029] A manual measuring tool or a laser scanning device for monitoring the actual contour size of the part main body; and / or

[0030] A pressing plate or a roller for compacting the part that protrudes from the designed contour size on the part main body.

[0031] Preferably, the fiber winding machine is configured to be able to spirally wind the fiber yarn around the outer periphery of the part main body expansion core mold to form the spiral fiber layer, and the fiber winding machine is configured to be able to spirally wind the circumferential fibers on the outer peripheral surface of the spiral fiber layer at a spiral winding angle of not less than 80°, and / or, the fiber winding machine includes a spiral fiber winding machine for spirally winding the fiber yarn around the outer periphery of the part main body expansion core mold to form the spiral fiber layer and a circumferential fiber winding machine arranged downstream of the spiral fiber winding machine, and the circumferential fiber winding machine can spirally wind the circumferential fibers on the outer peripheral surface of the spiral fiber layer at a spiral winding angle of not less than 80°.

[0032] The third aspect of the present invention provides a fiber composite part made by the above production method.

[0033] The fourth aspect of the present invention provides a boom machine with a fiber composite boom, and the fiber composite boom is made by the above production method.

[0034] Through the above technical solutions, the production method and production line of the present invention use the expandable core mold of the part body with an expandable core mold layer as the winding basis for fiber yarns, and continuously lay fibers in a helical winding manner, thereby effectively improving the production efficiency of fiber composite parts and making the fibers continuous to ensure the mechanical properties of the parts. Moreover, during the curing and forming process, by expanding the expandable core mold of the part body to apply pressure to the helical fiber layer, an expansion pressure applied to the helical fiber layer can be generated in all directions, playing the role of shape maintenance and pressure holding. As a result, the resin distribution of the whole part is more uniform, the inner surface quality is higher, and it is accurately shaped by the rigid outer mold. The obtained part has high dimensional accuracy and good overall performance. By winding circumferential fibers outside the helical fiber layer at a large helical winding angle, not only can the density of the part be further improved, but also good surface quality can be maintained during the installation of the rigid outer mold and the heating and curing process, thereby avoiding the problem of fiber cutting caused by post-treatment such as grinding and ensuring good mechanical properties. Description of the Drawings

[0035] Figure 1 is a perspective view of the expandable core mold of the part body used in the production method of a fiber composite part according to a preferred embodiment of the present invention;

[0036] Figure 2 is Figure 1 the left view of the expandable core mold of the part body in

[0037] Figure 3 is Figure 1 the perspective view of the rigid core shaft and the rigid core mold layer of the expandable core mold of the part body in

[0038] Figure 4 is Figure 1 the perspective view of the expandable core mold layer of the expandable core mold of the part body in

[0039] Figure 5a is a schematic diagram when fiber yarns are helically wound around the expandable core mold of the part body at the first helical winding angle;

[0040] Figure 5b is a schematic diagram when fiber yarns are helically wound around the expandable core mold of the part body at the second helical winding angle;

[0041] Figure 6 is a schematic diagram of compacting the part of the part body formed by helically winding fiber yarns impregnated with resin that protrudes from the relative design contour size by using a roller;

[0042] Figure 7 is a schematic diagram when circumferential fibers are helically wound around the outer peripheral surface of the part body;

[0043] Figures 8a to 8cRespectively represent enlarged views of helically winding circumferential fibers in a manner of being spaced by adjacent helices, being adjacent, and being overlapped;

[0044] Figure 9 It is a schematic diagram after the circumferential fibers are wound during the production process of the fiber composite part;

[0045] Figure 10 It is Figure 9 The left view after the circumferential fibers are wound during the production process of the fiber composite part in

[0046] Figure 11 It is a schematic diagram when the rigid outer mold is installed on the main body of the part wound with circumferential fibers during the production process of the fiber composite part;

[0047] Figure 12 It is a schematic diagram after the rigid outer mold is installed on the main body of the part wound with circumferential fibers;

[0048] Figure 13 It is Figure 12 The left view after the rigid outer mold is installed on the main body of the part wound with circumferential fibers in

[0049] Figure 14 It is when the rigid outer mold is removed from the main body of the part in the production process of the fiber composite part Figure 12 in

[0050] Figure 15 It is a schematic diagram after the expansion core mold of the main body of the part is removed from the main body of the part in the production process of the fiber composite part Figure 13 in

[0051] Figure 16 It is a flowchart of the production method of the fiber composite boom according to a preferred embodiment of the present invention.

[0052] Explanation of reference numerals

[0053] 1 - Expansion core mold of the main body of the part; 11 - Rigid mandrel; 12 - Rigid core mold layer; 13 - Expansion core mold layer; 2 - Rigid outer mold; 3 - Roller; 4 - Helical fiber layer; 5 - Circumferential fiber. Detailed implementation manners

[0054] The following will explain in detail the specific implementation manners of the present invention with reference to the accompanying drawings. It should be understood that the specific implementation manners described herein are only used to illustrate and explain the present invention and are not used to limit the present invention.

[0055] Refer to Figures 1 to 16As shown, one aspect of the present invention provides a production method for fiber composite parts, which is used to prepare parts such as booms for boom machinery like cranes and aerial work platforms using fiber composites to meet the requirements of lightweight development. Additionally, another aspect of the present invention also provides a production line for fiber composite parts, which can be used to implement the above production method. Generally, the boom of boom machinery can include multiple boom sections that are telescopically or pivotally connected to each other, and are driven by, for example, boom cylinders to enable relative telescopic movement or rotation of adjacent boom sections to achieve functions such as lifting and material transportation. It can be understood from the following detailed description that although the production method and production line of the present invention are described as being used to prepare fiber composite booms, the booms described herein should be understood broadly as the boom sections that make up a complete boom. And although the production method and production line of the present invention will be mainly described in detail with the boom as the preparation object, the production method and production line can also be used for the production of other parts.

[0056] As Figures 1 to 4 and Figures 11 to 13 shown, the production line for fiber composite parts provided by the present invention includes a part main body expansion core mold 1 and a rigid outer mold 2. Among them, the part main body expansion core mold 1 can have an expansion core mold layer 13 that at least partially covers its outer peripheral surface, to allow the fiber yarn infiltrated with resin to be helically wound around the outer periphery of the expansion core mold layer 13 to form a helical fiber layer 4, as Figures 5a to 6 shown; furthermore, the circumferential fiber 5 can be helically wound around the outer peripheral surface of the helical fiber layer 4 by a fiber winding machine to form a circumferential fiber winding layer, as Figures 7 to 9 shown, and the helical winding angle of the circumferential fiber 5 is greater than the helical winding angle of the fiber yarn forming the helical fiber layer 4; the rigid outer mold 2 can be installed to surround the outside of the circumferential fiber winding layer, to allow the helical fiber layer 4 wound helically to be heated, and to extrude the helical fiber layer 4 towards the rigid outer mold 2 by expanding the part main body expansion core mold 1 (such as by heating the expansion core mold layer 13 made of a thermally expandable material), while causing the helical fiber layer 4 to be cured and shaped, as Figures 11 to 13 shown.

[0057] Combined with Figure 16, the production method of the fiber composite part provided by the present invention at least includes a spiral fiber winding step S10, a circumferential fiber winding step S11, and a rigid outer mold installation and heating and curing step S20. In the spiral fiber winding step S10, the fiber yarn infiltrated with resin is spirally wound onto the outer peripheral surface of the part main body expansion core mold 1 to form a spiral fiber layer 4. In the circumferential fiber winding step S11, the circumferential fiber 5 is spirally wound onto the outer peripheral surface of the spiral fiber layer 4 to form a circumferential fiber winding layer, and the spiral winding angle of the circumferential fiber 5 is greater than the spiral winding angle of the fiber yarn forming the spiral fiber layer 4. In the rigid outer mold installation and heating and curing step S20, the rigid outer mold 2 is installed to surround the outside of the circumferential fiber winding layer, then the spiral fiber layer 4 is heated, and the spiral fiber layer 4 is extruded toward the rigid outer mold 2 by expanding the part main body expansion core mold 1, and at the same time, the spiral fiber layer 4 is cured and shaped.

[0058] Different from the existing production method that uses an inflatable inner mold or a box-shaped mold as the laying basis of the fiber prepreg and cures and shapes the fiber prepreg by inflatable hot pressing, the above production method and production line provided by the present invention use the part main body expansion core mold 1 as the winding basis of the fiber yarn, and use the spiral winding method (such as through a winding machine) to continuously lay the fiber on the part main body expansion core mold 1, so as to effectively improve the production efficiency of the fiber composite part and make the fiber continuous, ensuring the mechanical properties of the part. In particular, in the preferred embodiment using the part main body expansion core mold 1 with the expansion core mold layer 13 as the winding basis, during the curing and forming process, by making the expansion core mold layer 13 thermally expand to apply pressure to the spiral fiber layer, an expansion pressure applied to the spiral fiber layer 4 can be generated in all directions, playing the role of maintaining the shape and pressure, thereby making the resin distribution of the whole part such as the boom more uniform, the inner surface quality higher, and accurately shaped by the rigid outer mold 2, and the manufactured part has higher dimensional accuracy and better overall performance.

[0059] In the production method of the present invention, by winding the circumferential fiber 5 outside the spiral fiber layer 4 with a larger spiral winding angle, not only can the density of the part be further improved, but also good surface quality can be maintained during the installation of the rigid outer mold 2 and the heating and curing process, thereby avoiding the problem of fiber cutting caused by post-treatment such as grinding and processing, and ensuring that the part has good mechanical properties. The production method of the present invention combines the advantages of the hot pressing process and the winding process, applies the expansion core mold and the rigid outer mold to the winding process, the expansion core mold maintains the shape and pressure, the circumferential fiber self-locks, and the rigid outer mold accurately shapes. The boom has the advantages of high dimensional accuracy and dense fibers in the hot pressing process, improves the production efficiency, reduces the cost, and the fibers are continuously laid, improving the overall mechanical properties.

[0060] According to the above, the production method and production line of the preferred embodiment of the present invention can thermally press and form the spiral fiber layer 4 by using the workpiece body expansion mandrel 1 with the expansion mandrel layer 13. The expansion mandrel layer 13 is heated and expanded to extrude the spiral fiber layer 4, which can effectively ensure the fiber compactness and the resin distribution uniformity. The produced workpiece has a high inner surface quality and good mechanical properties, which is beneficial to ensuring the dimensional accuracy of the workpiece and is particularly suitable for the preparation of telescopic boom or non-rotating body boom with high requirements for dimensional accuracy, mechanical properties and structural adaptability. Although the traditional production method can basically meet the relatively low performance requirements for the folding boom, it does not exclude the use of the production method and production line of the present invention for the preparation of the folding boom. In other embodiments, the workpiece body expansion mandrel 1 can also be expanded and extrude the spiral fiber layer by other means. For example, it can be made of a material that can be vacuum compressed, and is deformed by shrinking by wrapping it in a pressure bag and sucking out the air therein to serve as the winding basis for the fiber, and gas is introduced into the pressure bag during heating and curing to expand it, thereby extruding the spiral fiber layer.

[0061] For better understanding of the production method and production line provided by the present invention, the following will describe each step and the devices / equipment used in the preferred embodiment according to Figure 16 the technological process shown:

[0062] S00. Preparation and Assembly Steps of the Expanding Core Mould for the Workpiece Main Body

[0063] Figures 1 to 4 Shown is the workpiece body expansion mandrel 1 and its components such as the expansion mandrel layer 13 that can be used in the above production method. Among them, the workpiece body expansion mandrel 1 can have a rigid mandrel 11, a rigid mandrel layer 12 and an expansion mandrel layer 13. The rigid mandrel 11 and the rigid mandrel layer 12 can be made of metal materials and can be connected to the rotary drive device through the rigid mandrel 11 so as to be driven to rotate around its central axis, so that the fiber yarn infiltrated with resin and the circumferential fiber are respectively spirally wound on the outer peripheral surface of the workpiece body expansion mandrel 1 in the spiral fiber winding step S10 and the circumferential fiber winding step S11 described in detail later.

[0064] For different design and manufacturing requirements, an expansion mandrel layer 13 with an appropriate material can be selected and made to have an appropriate thickness. Among them, the expansion mandrel layer 13 can be made of a material with a large thermal expansion coefficient such as silicone rubber and is coated and fixed on the outer periphery of the rigid mandrel layer 12. In the production of different booms, the forming pressure required for spiral fiber winding and hot pressing may vary, and for this, the expansion mandrel layer 13 can be made to have an appropriate thickness.

[0065] In addition, for non-rotary boom, after winding the fiber composite material around the main body expansion core mold 1 of the workpiece, there are differences in the tension and resin content at the corner positions of the corresponding boom compared with other corresponding positions (plane parts), which will lead to the defect that the cured boom is thinner at the corner positions and thicker at the plane parts, thereby affecting the overall mechanical properties of the boom and even not meeting the dimensional accuracy requirements of the telescopic boom. In this regard, the main body expansion core mold 1 of the workpiece can be set such that the thickness of the expansion core mold layer 13 at the corner positions corresponding to the rigid outer mold 2 is less than the thickness of the remaining parts, so that the expansion core mold layer 13 has a relatively smaller expansion amount at the corner positions compared with the remaining parts during hot pressing, which is beneficial to forming a boom with uniform wall thickness and ensuring that the overall boom has high mechanical properties and dimensional accuracy.

[0066] S01. Coating Step of the Demoulding Material

[0067] After the preparation and assembly of the main body expansion core mold of the workpiece are completed, a release agent can be coated on the outer surface of the main body expansion core mold 1 of the workpiece (especially the outer surface of the expansion core mold layer 13) to facilitate the separation of the main body expansion core mold 1 from the obtained workpiece main body after the workpiece is cured and formed, and complete the demolding.

[0068] S10. Spiral Fiber Winding Step

[0069] As Figure 5a and Figure 5b shown, in the spiral fiber winding step, the fiber yarn can be spirally wound around the outer surface of the main body expansion core mold 1 of the workpiece at different spiral winding angles. Among them, Figure 5a shown is the winding of the fiber yarn at the first spiral winding angle, and the first spiral winding angle can be, for example, 45° - 90°, preferably 45° - 60°; Figure 5b shown is the winding of the fiber yarn at the second spiral winding angle, and the second spiral winding angle can be, for example, 30° - 45°. The spiral winding angle described here refers to the angle between the extension direction of the fiber yarn and the length direction of the workpiece (or the main body expansion core mold 1 of the workpiece). Among them, in the boom prepared by this production method, the fiber yarn wound at the larger first spiral winding angle can better bear the bending moment generated by the self-weight of the boom and the torque generated by the load of the boom, while the fiber yarn wound at the smaller second spiral winding angle can effectively improve the performance of the boom in bearing the bending moment generated by its self-weight and load. The thickness and layer laying order of each fiber layer wound at different spiral winding angles can be determined according to the boom design requirements.

[0070] The above-mentioned spirally wound fiber composite can select various suitable types of fiber materials and resin components. For example, the fiber material can be selected from carbon fiber, glass fiber or aramid fiber, etc., preferably carbon fiber; the resin can be epoxy resin, unsaturated resin or phenolic resin, etc., preferably epoxy resin. The fiber yarn can be released by the winding machine, and after being impregnated with resin in the glue tank, it is spirally wound on the outer surface of the expansion core mold 1 of the main body of the workpiece with appropriate tension to form a spiral fiber layer 4, or the spirally wound fiber composite can directly use fiber prepreg. Among them, the fiber yarn is impregnated with resin in the glue tank before being wound, which can not only ensure good interlayer shear performance, but also facilitates to ensure that the size of the workpiece meets the design requirements by dynamically adjusting the fiber winding tension and fiber compaction.

[0071] In the process of winding to form the spiral fiber layer 4, the actual outline size of the workpiece body can also be monitored in real time, and then adjusted according to the difference between the actual outline size and the design outline size of the corresponding stage to ensure the molding accuracy of the workpiece body. Specifically, after a portion of the fiber yarn is spirally wound, the actual outline size of the workpiece body can be monitored by manual measuring tools or laser scanning. If the actual outline size is inconsistent with the design outline size of the corresponding stage, the tension of the subsequent spirally wound fiber yarn and / or the protruding portion of the workpiece body relative to the design outline size can be adjusted in time to dynamically adjust the fiber winding tension and fiber compaction. As mentioned above, the fiber yarn can be released by the winding machine (spiral fiber winding machine), and the tension of the subsequent spirally wound fiber yarn can be adjusted by the electronic tension system on the winding machine. For the relatively protruding portion on the plane of the workpiece body, a pressing plate or roller can be used for compaction to squeeze out excess resin. Figure 6 The schematic diagram shows the operation of using the roller 3 to compact the portion of the workpiece body that protrudes relative to the designed contour size.

[0072] Therefore, during the spiral winding process, if the actual outline size is too small, the fiber tension is reduced, or resin is applied to the corresponding position; if the actual outline size is too large, the fiber tension is increased, or a pressing plate or roller is used to compact the protruding position to squeeze out excess resin. By controlling the resin content of the spiral fiber layer 4, it is convenient to use a rigid external mold to accurately shape according to the designed outline size.

[0073] The above-mentioned winding, monitoring, tension control and compaction operations are repeated alternately until the spiral fiber layer 4 reaches the designed thickness, at which point the spiral fiber winding is completed.

[0074] S11. Circumferential Fiber Winding Step

[0075] like Figures 7 to 10As shown, after the spiral fiber winding is completed, the circumferential fiber 5 can also be spirally wound around the outer peripheral surface of the workpiece body. The spiral winding angle of the circumferential fiber 5 is significantly larger than that of the above-mentioned spiral fiber, and even close to 90°. Generally, the spiral winding angle of the circumferential fiber 5 is not less than 80°. Thus, the circumferential fiber 5 can wrap the fiber yarns with relatively small spiral winding angles in the spiral fiber layer 4, which is beneficial to improving the density of the workpiece body and facilitating maintaining good surface quality of the workpiece body during the subsequent installation of the rigid outer mold and the heating and curing process.

[0076] The tension and coverage of the circumferential fiber 5 being spirally wound can be determined according to the difference between the actual contour size and the designed contour size of the spiral fiber layer 4. If the actual contour size is on the larger side, the circumferential fiber 5 is spirally wound in a way that adjacent spirals are spaced apart, as Figure 8a shown, and the winding tension of the circumferential fiber 5 can be set relatively large, which is beneficial to extruding the excess resin in the spiral fiber layer 4; if the actual contour size is on the smaller side, the circumferential fiber 5 is spirally wound in a way that adjacent spirals are adjacent or overlapped, as shown in Figure 8b and Figure 8c respectively, and the winding tension of the circumferential fiber 5 can be set relatively small. Similar to the winding method of the above-mentioned spiral fiber layer, the circumferential fiber 5 can be wound around the outer peripheral surface of the workpiece body by a circumferential fiber winding machine. Or, the circumferential fiber 5 can also be released and wound around the outer peripheral surface of the workpiece body by the above-mentioned spiral fiber winding machine, thereby saving equipment costs and improving production efficiency when preparing large-sized boom frames.

[0077] So far, the spiral fiber layer 4 and the circumferential fiber 5 are wound around the outside of the expansion core mold layer 13 of the workpiece body expansion core mold 1 from the inside out, as Figure 10 shown.

[0078] S20. Installation and Heating Curing Step of the Rigid Outer Mould

[0079] As Figures 11 to 13 shown, the rigid outer mold 2 can include an upper half mold and a lower half mold, and can be connected into one body by fasteners after mold closing. Among them, the rigid outer mold 2 can be made of a rigid wave-transparent material, so as to heat the fiber composite layer including the spiral fiber layer by means such as microwave heating and infrared heating, and make it cured and formed under the extrusion action of the expansion core mold layer 13. Or, the fiber composite layer can be heated by self-resistance heating. Compared with traditional heating methods such as curing furnace heating, microwave heating, self-resistance heating or composite heating methods are beneficial to the overall uniform heating of the workpiece to ensure the forming quality. In addition, the expansion core mold layer 13 undergoes thermal expansion under the action of heat, so as to extrude the spiral fiber layer 4 towards the rigid outer mold 2, so that the fibers are densely distributed.

[0080] By precisely shaping the outer surface of the workpiece with the rigid outer mold 2 and combining the thermal expansion extrusion (profile holding pressure) of the expansion core mold 1 of the workpiece body, the manufactured workpiece can have high dimensional accuracy and good overall performance, and reduce or avoid the problem of fiber cutting caused by post-treatment such as grinding.

[0081] S21. Demoulding Step

[0082] After the workpiece body is cured and shaped, such as Figure 14 and Figure 15 shown, the rigid outer mold 2 and the expansion core mold 1 of the workpiece body can be sequentially removed to complete demolding, and the workpiece body shown in Figure 15 is obtained, which has good inner and outer surface quality and high dimensional accuracy.

[0083] The production method of the present invention combines the advantages of the hot pressing process and the winding process, applies the expansion core mold and the rigid outer mold to the winding process, the expansion core mold performs profile holding pressure, the circumferential fibers are self-locked, and the rigid outer mold performs precise shaping. The workpiece has the advantages of high dimensional accuracy and dense fibers in the hot pressing process, improves production efficiency, reduces costs, and the fibers are continuously laid, improving the overall mechanical properties. For the problem of large dimensional fluctuations in the winding process, the present invention proposes to adopt a profile monitoring method combined with dynamic winding tension and compaction control method to control the resin content of the workpiece, so that the dimensions of the workpiece always basically match the designed dimensions, and then use the rigid outer mold to perform high-precision shaping according to the designed dimensions.

[0084] To implement the above production method, the production line of the present invention may include: a manual measuring tool or a laser scanning device for monitoring the actual profile dimensions of the workpiece body; a spiral fiber winding machine for spirally winding the fiber yarn impregnated with resin around the outer periphery of the expansion core mold layer, and the spiral fiber winding machine is set to be able to adjust the tension of the fiber yarn to be spirally wound; a pressing plate or a roller for compacting the protruding part of the workpiece body relative to the designed profile dimensions. And / or, the production line may further include a circumferential fiber winding machine arranged downstream of the spiral fiber winding machine, and the circumferential fiber winding machine can spirally wind circumferential fibers on the outer peripheral surface of the workpiece body at a spiral winding angle not less than 80°. As a preferred embodiment, the circumferential fibers 5 can also be released and wound on the outer peripheral surface of the workpiece body by the above-mentioned spiral fiber winding machine, thereby saving equipment costs and improving production efficiency when manufacturing large-sized boom frames.

[0085] Furthermore, the present invention also provides a fiber composite workpiece and a boom machine with a fiber composite boom, such as a crane. Wherein, the fiber composite workpiece and the fiber composite boom are manufactured by the above production method.

[0086] The preferred embodiments of the present invention have been described in detail above in conjunction with the accompanying drawings. However, the present invention is not limited thereto. Within the scope of the technical concept of the present invention, various simple modifications can be made to the technical solution of the present invention, including any suitable combination of each specific technical feature. To avoid unnecessary repetition, the present invention will not separately describe various possible combination methods. However, these simple modifications and combinations should also be regarded as the content disclosed by the present invention and all fall within the protection scope of the present invention.

Claims

1. A method for producing a fiber composite material product, characterized in that: include: Spiral fiber winding step (S10): spirally winding the fiber yarn impregnated with resin onto the outer peripheral surface of the expansion core mold (1) of the workpiece body to form a spiral fiber layer (4); A hoop fiber winding step (S11): helically winding a hoop fiber (5) on the outer peripheral surface of the spiral fiber layer (4) to form a hoop fiber winding layer, wherein the helical winding angle of the hoop fiber (5) is greater than the helical winding angle of the fiber yarn forming the spiral fiber layer (4); and Rigid outer mold installation and heating and curing step (S20): install the rigid outer mold (2) to surround the outer side of the annular fiber winding layer, heat the spiral fiber layer (4), and extrude the spiral fiber layer (4) toward the rigid outer mold (2) by expanding the expansion core mold (1) of the workpiece body, and at the same time cure the spiral fiber layer (4) to shape.

2. The method for producing a fiber composite material product according to claim 1, characterized in that: It also includes a workpiece main body expansion core mold preparation and assembly step (S00) performed before the spiral fiber winding step (S10): an expansion core mold layer (13) made of heat expansion material is coated and fixed on the periphery of the rigid core mold layer (12), and the rigid core mold layer (12) is connected to a rigid core shaft (11); in the rigid outer mold installation and heating and curing step (S20), the expansion core mold layer (13) is heated to allow the expansion core mold layer (13) to thermally expand and squeeze the spiral fiber layer (4) toward the rigid outer mold (2).

3. The method for producing a fiber composite material product according to claim 2, characterized in that: The expansion core mold layer (13) is made of silicone rubber material, and / or the thickness of the expansion core mold layer (13) at the corner position corresponding to the rigid outer mold (2) is smaller than the thickness of the remaining part.

4. The method for producing a fiber composite material product according to claim 1, characterized in that: Also includes: A demoulding material coating step (S01) is performed before the spiral fiber winding step (S10): a demoulding agent is coated on the outer surface of the expansion core mold (1) of the workpiece body, and / or a demoulding step (S21) is performed after the rigid outer mold installation and heating and curing step (S20): the rigid outer mold (2) and the expansion core mold (1) of the workpiece body are removed.

5. The method for producing a fiber composite material product according to claim 1, characterized in that: The fiber yarn includes at least one of carbon fiber, glass fiber, and aramid fiber, and the resin includes at least one of epoxy resin, unsaturated resin, and phenolic resin.

6. The method for producing a fiber composite material product according to claim 1, characterized in that: In the spiral fiber winding step (S10), multiple layers of the spiral yarn are wound at a first spiral winding angle and a second spiral winding angle, respectively, wherein the first spiral winding angle is 45°-90°, the second spiral winding angle is 0-45°, and / or the spiral winding angle of the circumferential fiber (5) is not less than 80°.

7. The method for producing a fiber composite material product according to any one of claims 1 to 6, characterized in that: In the spiral fiber winding step (S10), after spirally winding at least a portion of the fiber yarn, the actual contour dimensions of the workpiece body are monitored and compared to see if the actual contour dimensions are consistent with the designed contour dimensions. If they are inconsistent, the tension of the subsequently spirally wound fiber yarn is adjusted and / or the portion of the workpiece body that protrudes relative to the designed contour dimensions is compacted.

8. The method for producing a fiber composite material product according to claim 7, characterized in that: In the spiral fiber winding step (S10), the actual contour size of the workpiece body is monitored by manual measuring tools or laser scanning, and / or the tension of the fiber yarn subsequently spirally wound is adjusted by an electronic tension system of a winding machine used to wind the fiber yarn, and / or a pressing plate or roller (3) is used to compact the portion of the workpiece body that protrudes relative to the designed contour size.

9. The method for producing a fiber composite material product according to any one of claims 1 to 6, characterized in that: Before the hoop fibers (5) are spirally wound onto the outer circumference of the spiral fiber layer (4), the actual contour size of the workpiece body is monitored and compared with the designed contour size. If the actual outline size is larger than the designed outline size, the annular fiber (5) is spirally wound in a manner that adjacent spirals are spaced apart; If the actual outline size is smaller than the designed outline size, the annular fiber (5) is spirally wound in a manner where adjacent spirals are adjacent to each other or overlap each other.

10. The method for producing a fiber composite material product according to any one of claims 1 to 6, characterized in that: In the rigid outer mold installation and heating and curing step (S20), the spiral fiber layer (4) is heated by at least one of curing furnace heating, microwave heating and self-resistance heating.

11. A production line for fiber composite material parts, characterized in that: include: A component body expansion mandrel (1), the component body expansion mandrel (1) being configured to allow fiber yarns impregnated with resin to be spirally wound around its periphery to form a spiral fiber layer (4); A fiber winding machine, wherein the fiber winding machine is configured to be able to helically wind circumferential fibers (5) on the outer peripheral surface of the spiral fiber layer (4) to form a circumferential fiber winding layer, wherein the helical winding angle of the circumferential fibers (5) is greater than the helical winding angle of the fiber yarn forming the spiral fiber layer (4); and A rigid outer mold (2) can be installed to surround the outer side of the annular fiber winding layer and allow the expansion core mold (1) of the workpiece body to expand and press the spiral fiber layer (4) toward the rigid outer mold (2) while heating the spiral fiber layer (4) so ​​that the spiral fiber layer (4) is cured and shaped.

12. The production line for fiber composite parts according to claim 11, characterized in that: Also includes: Manual measuring tools or laser scanning equipment for monitoring the actual contour dimensions of the body of the part; and / or A pressing plate or roller (3) is used to compact the portion of the workpiece body that is protruding relative to the designed outline size.

13. The production line for fiber composite parts according to claim 11, characterized in that: The fiber winding machine is configured to be capable of spirally winding the fiber yarn onto the outer periphery of the component body expansion core mold (1) to form the spiral fiber layer (4), and the fiber winding machine is configured to be capable of spirally winding the annular fibers (5) on the outer periphery of the spiral fiber layer (4) at a spiral winding angle of not less than 80°, and / or the fiber winding machine includes a spiral fiber winding machine for spirally winding the fiber yarn onto the outer periphery of the component body expansion core mold (1) to form the spiral fiber layer (4) and an annular fiber winding machine arranged downstream of the spiral fiber winding machine, the annular fiber winding machine being capable of spirally winding the annular fibers (5) on the outer periphery of the spiral fiber layer (4) at a spiral winding angle of not less than 80°.

14. A fiber composite material product, characterized in that: The fiber composite material product is manufactured by the production method according to any one of claims 1 to 10.

15. A boom machine, characterized in that: The boom machine has a fiber composite boom manufactured according to the production method according to any one of claims 1 to 10.

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