Composite material mesh processing and forming method
By combining sensor monitoring and automated cutting devices with synchronous transmission of the lead wire device, the problem of winding accuracy and consistency in composite fiber winding molding equipment has been solved, achieving high-precision fiber winding, weaving and curing, and improving finished product quality and production efficiency.
Patent Information
- Application Number
- CN202511729695.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-24
- Publication Date
- 2026-02-10
AI Technical Summary
Existing composite fiber winding molding equipment suffers from problems such as poor winding accuracy and product consistency due to transmission gaps and cumulative errors. Furthermore, traditional winding equipment is difficult to effectively adjust the yarn spacing, and the synchronous control system is complex and costly.
Sensors are used to monitor the position of the composite material wire harness, and automated winding and weaving are achieved using a lead wire device and a cutting device. Heating and curing are controlled by a curing temperature strategy, and synchronous transmission of a single linkage drive shaft and an active gear kit is combined to ensure the consistency of fiber segment length and the adjustment of yarn spacing.
It improves the precision and stability of winding and weaving, enhances the quality of finished products and production flexibility, reduces manufacturing costs and maintenance difficulty, and ensures the uniformity and accuracy of fiber arrangement.
Smart Images
Figure CN121496660A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the technical field of composite material processing, and particularly relates to a composite material mesh processing and forming method. BACKGROUND
[0002] In the manufacture of composite materials, the production of cable reinforcing cores or similar processes, fiber winding forming is a key technology. The process generally involves precisely and uniformly winding a plurality of resin-impregnated fibers (or dry-wound yarns) onto a core mold, followed by heating and curing to form a product with specific physical properties.
[0003] The winding device in the prior art often uses gear sets, belts, chains or multiple independent servo motors as transmission modes when driving multiple winding spindles or reciprocating yarn guide mechanisms. These transmission modes generally have the following problems: transmission gap and cumulative error, which can cause the phases of the winding units to be out of sync, thereby affecting winding accuracy and product consistency.
[0004] Using a multi-motor driving scheme requires a complex synchronization control system and high-precision encoder feedback, which is costly and complex to debug the control algorithm, and is prone to synchronization failure. In traditional winding equipment, the spacing of the yarn guide comb or the dividing plate for arranging multiple yarns is usually fixed, or needs to be adjusted by replacing parts, manually adjusting screws one by one, and the like, thereby making it difficult to effectively adjust the spacing of the yarns.
[0005] Therefore, it is necessary to provide an improved composite material mesh processing and forming method to solve the above problems. SUMMARY
[0006] The present application aims to provide a composite material mesh processing and forming method that can solve at least one of the above technical problems. The specific scheme is as follows:
[0007] According to the specific embodiment of the present application, the present application provides a composite material mesh processing and forming method, comprising: continuously conveying a first direction composite material strand from a feeding device, and automatically monitoring the arrival of the first direction composite material strand at a first designated position using at least one sensor; using a lead wire device to lead out a second direction composite material strand, so that the second direction composite material strand performs a winding and weaving operation with the first direction composite material strand at a second designated position; after monitoring that the first direction composite material strand reaches the first designated position, automatically driving a cutting device to cut the first direction composite material strand to obtain a composite material mesh after winding and weaving forming; based on a curing temperature strategy, controlling the heating and curing of the composite material mesh after winding and weaving forming to obtain a composite material mesh product.
[0008] According to the specific embodiments of the present application, the present application provides a composite material mesh processing forming system which performs the composite material mesh processing forming method described in the present application, comprising: a feeding device for conveying a first direction composite material strand to a first specified position; a lead device for leading out a second direction composite material strand, the second direction composite material strand being used to perform a winding weaving operation with the second direction composite material strand at a second specified position; a cutting device which is automatically driven to cut the first direction composite material strand to obtain a winding woven formed composite material mesh after the sensor monitors that the first direction composite material strand reaches the first specified position; and a curing device which controls heating and curing of the winding woven formed composite material mesh based on a curing temperature strategy to obtain a composite material mesh product.
[0009] Compared with the prior art, the above-mentioned scheme of the embodiments of the present application has at least the following beneficial effects:
[0010] The first direction composite material strand is continuously conveyed from the feeding device, the second direction composite material strand is led out by the lead device, so that the second direction composite material strand performs a winding weaving operation with the first direction composite material strand at the second specified position, the position information of the front ends of the first direction composite material strand and the second direction composite material strand is monitored, and the cutting device is automatically driven to cut the first direction composite material strand after reaching the first specified position, so that a more accurate winding woven formed composite material mesh can be obtained, the length consistency of the fiber sections in the subsequent winding / interweaving process can be effectively ensured, and the yield and product quality are improved; the winding woven formed composite material mesh is heated and cured based on the curing temperature strategy to obtain a composite material mesh product with higher precision and higher stability. BRIEF DESCRIPTION OF DRAWINGS
[0011] The drawings incorporated into the specification and forming a part thereof, illustrate embodiments consistent with the present application and, together with the specification, serve to explain the principles of the present application. It is apparent that the drawings described below are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor on the basis of these drawings. In the drawings:
[0012] Figure 1 A flowchart of the composite material mesh processing forming method provided by the embodiments of the present application is shown in the drawings;
[0013] Figure 2 A structure schematic diagram of the lead device in an example of the composite material mesh processing forming method provided by the embodiments of the present application is shown in the drawings;
[0014] Figure 3A structure diagram of a lead device of a composite mesh processing and forming method provided by the embodiment of the application is shown in the figure.
[0015] Figure 4 A partial diagram of forming a woven mesh with a cross-wound relationship in the composite mesh processing and forming method provided by the embodiment of the application is shown in the figure.
[0016] Figure 5 An exploded view of a driving gear set in the lead device of the composite mesh processing and forming method provided by the embodiment of the application is shown in the figure.
[0017] Figure 6 An exploded view of a beam expander assembly in the beam expander assembly of the lead device of the composite mesh processing and forming method provided by the embodiment of the application is shown in the figure. DETAILED DESCRIPTION
[0018] In order to make the objectives, technical solutions and advantages of the application clearer, the following will further describe the application with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the application, but not all the embodiments of the application. Based on the embodiments in the application, all other embodiments obtained by those skilled in the art without creative work fall within the protection scope of the application.
[0019] It should also be noted that the terms “comprising”, “containing” or any other variant thereof are intended to cover non-exclusive inclusion, so that the products or devices including a series of elements not only include those elements, but also include other elements not explicitly listed or inherent to such products or devices. Without more limitations, the element defined by the statement “comprising one” does not exclude the presence of another identical element in the product or device including the element.
[0020] The following will be described in detail with reference to the accompanying drawings. Figures 1 to 4 The optional embodiments of the method of the application will be described in detail.
[0021] The application provides a composite mesh processing and forming method. As shown in the figure, the composite mesh processing and forming method comprises the following steps. Figure 1
[0022] Firstly, in step S101, the first-direction composite wire bundle is continuously conveyed from the feeding device, and the arrival of the first-direction composite wire bundle at the first designated position is automatically monitored by using at least one sensor.
[0023] Specifically, the first-direction composite wire bundle refers to a composite wire bundle conveyed along a first direction, and the composite wire bundle comprises prepreg fibers and impregnated yarns.
[0024] For example, the composite wire harness is a carbon fiber, glass fiber or aramid fiber bundle in the form of a prepreg, or a dry fiber treated by in-line impregnation.
[0025] It should be noted that in the present application, the first direction is a horizontal direction, and the second direction is a vertical direction intersecting the horizontal direction.
[0026] In a specific embodiment, the composite wire harness, i.e. the first direction composite wire harness, is continuously drawn out from the feeding device, for example using an automated feeding mode, such as a clamping roller or a traction wheel driven by a stepper motor. Figure 3 The feeding device is shown in FIG. 1.
[0027] In the present embodiment, the first direction composite wire harness is one bundle.
[0028] It should be noted that in other embodiments, the first direction composite wire harness can be two bundles, etc. In addition, in other embodiments, for the case where the first direction composite wire harness is two bundles, the feeding device can be a lead device with feeding function, etc. as shown in FIG. 2. Figure 3 The above is only described as an optional example and cannot be understood as a limitation of the present application.
[0029] Specifically, at least one sensor is provided, for example, a laser distance sensor is provided, which is used to monitor the length of the first direction composite wire harness on the feeding path in the first direction, or the position reached by the front end of the first direction composite wire harness.
[0030] When the laser distance sensor monitors that the first direction composite wire harness reaches the first designated position (i.e. represents that the length of the first direction composite wire harness reaches the set length), a cutting signal is sent to the control device, and when the control device receives the cutting signal, the cutting device is controlled to cut the first direction composite wire harness at the first designated position to form a first direction composite wire harness segment, which is used to perform a winding weaving operation with a second direction composite wire harness drawn out along the second direction.
[0031] Optionally, the cutting device is an electric scissors or a laser cutter. In the present embodiment, the cutting device is an ultrasonic cutting knife.
[0032] Using an ultrasonic cutting knife in combination with a laser distance sensor can accurately ensure accurate cutting at the first designated position, and obtain a composite material segment with a flat cutting end face and accurate length. It can effectively ensure the length consistency of the fiber segment in the subsequent winding / interlacing process, thereby improving the yield.
[0033] It should be noted that, for the sensor, in other embodiments, the sensor further includes an optical sensor. The above is described only as an optional example, and cannot be understood as a limitation to the present application.
[0034] Further, the front end of the cut first direction composite material strand segment is fixed on a fixed point (for example, a point on a side boundary of a rectangular mesh mold, or a center point of a center core shaft, etc.) of a mesh or mesh disc forming mold (for example, a rectangular mesh mold movable along the second direction or a rotatable circular core shaft, etc.).
[0035] Next, in step S102, the second direction composite material strand is drawn out by the lead device, so that the second direction composite material strand performs a winding weaving operation with the first direction composite material strand at a second specified position.
[0036] In the present embodiment, the second direction composite material strand refers to a composite material strand drawn out in the second direction by the lead device.
[0037] Optionally, the size of the second direction composite material strand is different from the size of the first direction composite material strand.
[0038] It should be noted that the second direction composite material strand includes prepreg fibers and impregnated yarns. In the present example, the second direction composite material strand is glass fiber in the form of prepreg. However, it is not limited thereto, and in its embodiments, it can also be aramid fiber strand, etc. The above is described only as an optional example, and cannot be understood as a limitation to the present application.
[0039] As shown in Figure 2 , Figure 3 The lead device 100 includes a single-link driving shaft 20 and a plurality of conveying units 31, wherein the single-link driving shaft 20 is used to synchronously drive the plurality of conveying units 31. The plurality of conveying units 31 are used to convey a plurality of second direction composite material strands 60 and perform a winding weaving operation with the second direction composite material strands 60 after adjusting the strand spacing. The single-link driving shaft 20 of the lead device 100 is used to synchronously drive the plurality of conveying units 31. The lead device 100 is used to draw out two second direction composite material strands after automatically adjusting the strand spacing by the beam expanding assembly 23, and perform a winding weaving operation with the first direction composite material strands along the first direction at a second specified position, wherein the first direction is perpendicular to the second direction.
[0040] From Figure 3As can be seen, when the first inclined thread part of each driving gear set 21 on the single connecting rod driving shaft 20 is engaged with the second inclined thread part corresponding to the respective position, the plurality of conveying units 31 are simultaneously driven to move along the second direction, and the second direction composite material strands 60 are simultaneously moved in each conveying unit 31 and drawn out from the strand outlet of the beam expanding assembly 23. Each conveying unit 31 draws out two second direction composite material strands.
[0041] The uniformity and accuracy of the fiber arrangement are ensured by the synchronous driving, thereby improving the mechanical properties and appearance quality of the finished product.
[0042] In a specific embodiment, when it is monitored that the second direction composite material strands drawn out from the strand outlet of the beam expanding assembly 23 of the lead wire device 100 reach the second specified position and the first direction composite material strands reach the first specified position, the control device is used to control the conveying units of the lead wire device to rotate in the clockwise direction or the counterclockwise direction, so that the plurality of second direction composite material strands drawn out from the beam expanding assembly rotate in the clockwise direction or the counterclockwise direction to wrap the first direction composite material strands and form a cross-wrapping relationship with the first direction composite material strands (i.e., perform a winding weaving operation) to obtain a woven net having a cross-wrapping relationship. For example, two second direction composite material strands located on the upper and lower sides sandwich a first direction composite material strand in the middle, and the two second direction composite material strands rotate in the clockwise direction or the counterclockwise direction to wrap the first direction composite material strand to form a warp-weft cross-wrapping relationship, which will be described in detail below with reference to FIG. 6. Figure 4 .
[0043] Optionally, the first direction composite material strands conveyed in the first direction reach the first specified position and are clamped by a specific clamp or temporarily bound by a hot melt glue point or a quick curing adhesive to provide a stable anchor point for subsequent winding / interweaving and prevent the first direction composite material fibers from loosening or shifting at the initial stage of winding / interweaving.
[0044] It should be noted that the above is only described as an optional example and cannot be understood as a limitation on the present application.
[0045] Next, in step S103, when it is monitored that the first direction composite material strands reach the first specified position, the cutting device is automatically driven to cut the first direction composite material strands to obtain a composite material net after winding weaving.
[0046] In one specific embodiment, when the composite material wire bundle in the first direction is detected to have reached the first designated position, the automatic driving cutting device cuts the composite material wire bundle in the first direction, the feeding device continuously feeds the composite material wire bundle in the first direction, and repeatedly performs the winding and weaving operation with the composite material wire bundle in the second direction until the resulting mesh with the warp and weft interlacing relationship fills the rectangular mesh mold, so as to obtain the composite material mesh after winding and weaving.
[0047] Specifically, when the formed mesh with a warp and weft interlacing relationship fills the rectangular mesh mold, the composite material wire bundle in the first direction is cut by a cutting device to obtain a finished composite material mesh after winding and weaving, namely, the finished composite material mesh.
[0048] Optionally, if each conveying unit has more than two second-direction composite material wire bundles, for example, three second-direction composite material wire bundles per conveying unit, the three second-direction composite material wire bundles and the first-direction composite material wire bundles form a mesh in a preset interlacing pattern. By controlling the forward and reverse rotation of the conveying unit (i.e., clockwise or counterclockwise rotation), the interlacing and fixing of the second-direction composite material wire bundles and the first-direction composite material wire bundles at the interlacing points can be precisely achieved, forming a multi-layered, multi-directional composite material mesh with a cross-wound relationship, thereby constructing the required mesh structure. For example, circumferential or spiral winding can be achieved by forward rotation, and cross-wound or a complex mesh interlacing structure can be achieved by reverse rotation in conjunction with the rotation of the rectangular mesh mold and the second-direction movement of the winding head eye, thereby obtaining a composite material mesh with higher rigidity and strength. The tension sensor can monitor in real time and the tension controller can automatically adjust to ensure that each composite material wire bundle is subjected to uniform force during winding / interlacing, avoiding wrinkles or breakage.
[0049] It should be noted that the above is only an optional example and should not be construed as a limitation of this application.
[0050] Next, in step S104, based on the curing temperature strategy, the composite material mesh after winding and weaving is heated and cured to obtain the finished composite material mesh.
[0051] The curing temperature of the composite material mesh being heated and cured is monitored in real time by a temperature sensor installed inside the curing equipment. The monitored curing temperature is compared with a preset curing temperature curve, and the power output of the heating equipment is automatically adjusted based on the comparison result to adjust the curing temperature of the composite material mesh in real time.
[0052] Specifically, the preset curing temperature curve includes the heating rate, the holding time, the holding temperature, and the cooling rate.
[0053] In one specific embodiment, the wound-woven composite mesh (e.g., on a mold or after demolding) is transferred to a curing device, such as an autoclave, oven, or infrared heating device, to induce a cross-linking reaction and form a robust composite structure. During the curing process, the wound-woven composite mesh is heated and cured according to a curing temperature strategy to obtain the finished composite mesh. The curing temperature strategy specifically refers to automatic control of the curing temperature and a closed-loop feedback control mechanism. The curing temperature is between 60°C and 250°C.
[0054] Specifically, multiple temperature sensors (such as thermocouples) are installed inside the curing equipment to monitor the temperature of the composite material mesh after winding and weaving within the equipment in real time. This real-time temperature data is transmitted to the control device. The control device pre-fits a curing temperature curve (including heating rate, isothermal time, isothermal temperature, and cooling rate) for specific composite material systems and mesh structures, such as carbon fiber, glass fiber, or aramid fiber bundles, based on historical experimental data. The control device compares the real-time monitored temperature with the pre-fitted temperature curve and, based on the comparison result, automatically adjusts the power output of the heating elements (such as heating tubes and infrared lamps) within the curing equipment using a PID (proportional-integral-derivative) controller to ensure that the actual temperature remains consistent with the curing temperature fitting curve.
[0055] The closed-loop feedback mechanism includes: increasing the heating power when the actual temperature is lower than the corresponding set value in the curing temperature fitting curve; and decreasing the heating power when the actual temperature is greater than or equal to the corresponding set value in the curing temperature fitting curve. This closed-loop feedback control mechanism effectively compensates for the effects of environmental temperature fluctuations, heating inertia, and other factors, ensuring the accuracy and stability of the curing temperature. This improves the mechanical properties and appearance quality of the final cured product, resulting in composite material meshes with higher stability.
[0056] After curing, the finished composite mesh is obtained. Optionally, post-processing steps such as edge trimming, surface polishing, coating treatment, or drilling are performed to meet the appearance and functional requirements of the final product.
[0057] It should be noted that the composite material mesh products with layered processing in this application have a wide range of applications, especially suitable for automobiles, ships, wind turbine blades, etc.
[0058] Compared with the prior art, this application continuously feeds the first-direction composite material wire bundle from the feeding device and uses a lead-out device to lead out the second-direction composite material wire bundle, so that the second-direction composite material wire bundle and the first-direction composite material wire bundle can perform a winding and braiding operation at a second designated position. The position information of the front end of the first-direction composite material wire bundle and the second-direction composite material wire bundle is monitored. When they reach the first designated position, the cutting device is automatically driven to cut the first-direction composite material wire bundle. This can obtain a more precise wound and woven composite material net, which can effectively ensure the consistency of fiber length in subsequent winding / interlacing processes, thereby improving the yield and quality of the finished product. Based on the curing temperature strategy, the wound and woven composite material net is heated and cured to obtain a composite material net product with higher precision and higher stability.
[0059] Furthermore, by using an ultrasonic cutting blade in conjunction with a laser rangefinder, it is possible to accurately ensure a precise cut at the first designated position, resulting in a composite material segment with a flat cut end and accurate length.
[0060] Furthermore, the use of a single-link drive shaft and a drive gear assembly with helical thread meshing synchronously drives multiple sets of lead wire driven mechanisms. Structurally, this ensures synchronous transmission of all driven units. Because the single-link drive shaft synchronously drives multiple lead wire driven mechanisms, there is no accumulated transmission backlash, improving synchronization accuracy and significantly reducing product defects caused by phase errors. This effectively reduces overall errors, thereby improving the quality and yield of the composite material mesh. The winding and expanding assembly enables rapid adjustment of the spacing between multiple yarns through synchronous adjustment, greatly improving production flexibility and efficiency, and allowing for quick response to the production needs of products with different specifications.
[0061] Furthermore, this application utilizes a simpler and more reliable mechanical synchronization structure, reducing manufacturing costs and maintenance difficulty, and is less susceptible to electrical control system failures. Precise synchronization control and flexible spacing adjustment ensure the uniformity and accuracy of fiber arrangement, thereby improving the mechanical properties and appearance quality of the final cured product.
[0062] The following is in conjunction with the appendix Figures 2 to 6 Detailed description of optional embodiments of the system in this application.
[0063] This application provides a composite material mesh processing and forming system that performs the composite material mesh processing and forming method described in this application.
[0064] It should be noted that the composite material mesh products with layered processing in this application have a wide range of applications, especially suitable for automobiles, ships, wind turbine blades, etc.
[0065] like Figure 3As shown, the composite material mesh processing and forming system includes a feeding device 200, a wire guiding device 100, a curing device (not shown in the figure), and a cutting device (not shown in the figure).
[0066] Specifically, the feeding device 200 is used to transport the first-direction composite material wire bundle to a first designated position. The lead-in device 100 is used to lead out the second-direction composite material wire bundle 60, which is used to perform a winding and braiding operation with the second-direction composite material wire bundle at a second designated position. When the sensor detects that the first-direction composite material wire bundle has reached the first designated position, the cutting device automatically drives the cutting device to cut the first-direction composite material wire bundle to obtain a wound and braided composite material mesh. The curing equipment controls the heating and curing of the wound and braided composite material mesh based on a curing temperature strategy to obtain the finished composite material mesh.
[0067] from Figure 2 and Figure 3 As can be seen from the diagram, the lead wire device 100 includes a single-link drive shaft 20 and multiple conveying units 31, wherein the single-link drive shaft 20 is used to synchronously drive the multiple conveying units 31. The multiple conveying units 31 are used to convey multiple second-direction composite material wire bundles and, after adjusting the wire bundle spacing, perform a winding and braiding operation with the second-direction composite material wire bundles.
[0068] Specifically, multiple transmission units 31 are located above the drive mechanism, and each transmission unit 31 is synchronously connected to the single-link drive shaft 20. Each transmission unit 31 includes a transmission cylinder 32 and a beam expander assembly 33 connected to the transmission cylinder 32.
[0069] like Figure 3 and Figure 5 As shown, the drive mechanism is connected to the main drive source 40. The drive mechanism includes a single-link drive shaft 20 and a plurality of active gear kits 21 connected to the single-link drive shaft 20. Each active gear kit 21 includes a first helical thread portion 222.
[0070] Specifically, all the drive gear assemblies 12 of the single-link drive shaft 20 are located below the transmission cylinder 32. The lower end face of each transmission cylinder 32 has a second oblique thread that mates with the first oblique thread 222, so that when the first oblique thread 222 of each drive gear assembly 21 meshes with the corresponding second oblique thread, all transmission units 31 start driving simultaneously, and the two composite material wire harnesses 60 move simultaneously in each transmission cylinder 32 along the second direction (i.e., the wire exit direction), such as... Figure 2 The arrow direction is shown.
[0071] from Figure 2As can be seen from the description, the feeding device is a fiber winding or winding device for processing fiber materials. The feeding device 200 includes a base plate and a spindle assembly disposed on the base plate. The base plate serves as the supporting foundation for the entire device and has multiple mounting holes. The spindle assembly support frame is securely mounted on the base plate. The spindle assembly includes a drive shaft and a drive wheel (e.g., a pulley) for connecting to an external drive mechanism to provide rotational power to the drive shaft. One end of the spindle assembly is connected to a disc, which serves as a winding reel, guide wheel, or part of an auxiliary transmission mechanism. Furthermore, it also includes a drive or tension adjustment module for tension control or drive of the composite material wire harness (such as a glass fiber wire harness).
[0072] To ensure the composite fiber material is laid evenly and tightly on the winding mandrel, a reciprocating guide module is also provided. The reciprocating guide module includes a pair of parallel guide rails and a slider that can move back and forth along the guide rails. The slider integrates guide bearings or guide wheels to guide the composite material bundle.
[0073] The feeding device continuously and repeatedly feeds the composite material wire bundle in the first direction. Specifically, the composite material wire bundle in the first direction is accurately fed and laid on the mold at a predetermined speed and tension. When the length of the composite material wire bundle in the first direction reaches a specified length, that is, when it reaches a first specified position, it is automatically cut and wound and braided with the composite material wire bundle in the second direction.
[0074] In this example, each conveying unit 31's conveying cylinder 32 corresponds to a drive gear assembly 21. Each drive gear assembly 21 includes a first assembly 22 with a first helical thread 222 and a second assembly 23 that forms a fastening fit with the first assembly 22. See [link to relevant documentation]. Figure 3 and Figure 5 .
[0075] Specifically, each drive gear assembly 21 is formed with a plurality of first oblique thread portions corresponding to each transmission unit 31, for driving the transmission cylinder 32 in the transmission unit 31 to lead out a plurality of composite material wire bundles along the second direction.
[0076] Furthermore, a second oblique thread portion 322 is formed on the conveying cylinder 32 to engage with the first oblique thread portion 222. The bundle expansion assembly 33 is used to arrange and guide multiple composite material bundles 60, i.e., composite material bundles in the second direction (see details). Figure 2In this process, multiple drive gear assemblies of the single-link drive shaft 20 simultaneously drive their respective corresponding transmission units 31. When the first helical thread portion 222 of each drive gear assembly meshes with the corresponding second helical thread portion 322, the composite material wire harness 60 moves simultaneously along the second direction in each transmission cylinder 32 and is led out from the outlet 330 of the bundle expander assembly 33 to perform a controllable braiding operation on the wire harness in the first direction, which is different from the second direction. By using helical gear meshing, compared with spur gears, the meshing is smoother, and the transmission impact and noise are less, which is beneficial to improving the overall operational stability and service life of the device.
[0077] Optionally, the composite material wire bundle includes glass fiber bundles and carbon fiber bundles. In this example, the composite material wire bundle is a glass fiber bundle. For example, it is a wire bundle bound using a binding device.
[0078] like Figure 5 As shown, both the first assembly 22 and the second assembly 23 are hollow components. The first assembly 22 includes a first oblique thread portion 222 and a stepped portion 223 connected to the first oblique thread portion 222. The stepped portion 223 includes a base portion 2231 and a recessed portion 2232 extending outward from the base portion. At least one opening 2233 is formed on the stepped portion 223. In this example, four openings 2233 are formed on the stepped portion 223. The four openings 2233 are evenly distributed along the outer periphery of the stepped portion 223. The recessed portion 2232 is a conical ring or a conical cylinder. The inner diameter of the recessed portion 2232 is slightly smaller than the inner diameter of the single-link drive shaft 20. Furthermore, the second component 23 is an annular member with a notch 230. The second component 23 includes an inner wall surface 231 and a slotted portion 233 recessed from the inner wall surface 231 to the outer wall surface 232. The slotted portion 233 includes a first slotted wall surface 2331, a second slotted wall surface 2332, and a slotted bottom 2333 connected to the first slotted wall surface 2331 and the second slotted wall surface 2332. The slotted bottom 2333 is arc-shaped.
[0079] During installation, the first component 22 is heated (thermal expansion) or the single-link drive shaft 20 is cooled (cold contraction), and then the two are quickly assembled together. After both return to room temperature, due to the dimensional difference, the first component, when fitted onto the single-link drive shaft 20 at a designated position, generates a significant clamping force on the single-link drive shaft. This designated position corresponds to the position of each conveyor cylinder 23, ensuring that the first oblique thread portion 222 and the second oblique thread portion 322 of the conveyor cylinder 32 can mesh. The inner wall surface 231 of the second component 23 is fitted onto the stepped portion 223 of the first component 22, and the slotted portion 233 and notch 230 of the second component 23 form a tight-fitting structure with the opening 2233 of the first component 22. This allows the first component 22 to fit onto the single-link drive shaft 20, and the second component 23 to be fitted and fixed onto the first component 22, thus forming a tight-fitting structure. Specifically, screws are inserted into the preset holes 235 of the second component 23 to lock and fix the first component 22 and the second component 23 together to the single-link drive shaft 20. The first component 22 and the second component 23 of the multiple drive gear components 21 cooperate with the single-link drive shaft 20 to form a fastening structure. The fastening structure is a key structure that enables synchronous drive and can effectively improve the reliability of the overall structure.
[0080] Optionally, the second component 23 is further provided with a recess 236 at a position corresponding to the preset hole 235, through which the recess 236 (see details) Figure 5 It can accurately determine the tightness of the first assembly 22, the second assembly 23 and the single linkage drive shaft 20.
[0081] It should be noted that, in other embodiments, the first oblique thread portion 222 of the first kit 22 may be integrally formed with the single linkage drive shaft 20, that is, the first oblique thread portion 222 is formed on the single linkage drive shaft 20. The above is only described as an optional example and should not be construed as a limitation of this application.
[0082] To address the challenges of adjusting wire harness spacing and the inability to quickly adapt to different process requirements, this application optimizes the structure of the transmission unit 31 by adding a wire harness expansion component 33 to the transmission cylinder 32, which effectively enables controllable adjustment of the wire harness spacing.
[0083] like Figure 6 As shown, the beam expander assembly 33 includes a first beam expander 34 and a second beam expander 35 that is closer to the cable outlet than the first beam expander 34. Viewed from the side that mates with the first beam expander 34, the second beam expander 35 includes a beam expander groove 351 and two openings 330 that penetrate the beam expander groove 351. The two openings 330 serve as the cable outlet, i.e., the cable outlet 330.
[0084] In this example, two composite material wire bundles 60 are led out through the transmission unit and from the outlet 330 of the bundle expander 33 (increasing the spacing between the two composite material wire bundles 60). The bundle expander 33 is used to adjust the distance between the two composite material wire bundles.
[0085] from Figure 6 As can be seen from the image, both the first expander 34 and the second expander 35 are circular components. The first expander 34 serves as a wire guide. The first expander 34 includes two first mounting holes 345 and a wire groove sandwiched between the two mounting holes 345. The wire groove contains two wire holes 340, which are used to pour the composite material wire bundle from the conveyor cylinder 32 into the second expander 35. Viewed from the outlet side, the second expander 35 includes a second mounting hole 355 that mates with the first mounting hole 345, and outlets 330 located on the upper and lower sides, respectively. The expander assembly 33 is installed onto the conveyor cylinder 32 through the first mounting hole 345 and the second mounting hole 355. The two second mounting holes 355 are symmetrically arranged on the left and right sides.
[0086] Specifically, the second expander 35 also includes an expander groove 351 corresponding to the conductor groove. The two outlets 330 are located within the expander groove 351. The first vertical distance between the two outlets 330 is greater than the second vertical distance between the two conductor holes 340, so that when two composite material wire bundles are introduced from the first expander 34, after passing through the outlets 330 in the expander groove 351 of the second expander 35, the spacing between the two composite material wire bundles is adjusted (specifically, the spacing between the two composite material wire bundles is increased), effectively realizing the controllable adjustment of the wire bundle spacing.
[0087] Optionally, the second bundle expander 35 is a replaceable component, which can be replaced according to the need to increase or decrease the wire harness spacing. When it needs to be decreased, it is replaced with a second bundle expander in which the first vertical distance between the two outlets 330 is less than the second vertical distance between the two wire holes 340.
[0088] In another optional embodiment, the expansion groove 351 of the second expansion member 33 can be positioned as a through hole, and two adjustable rings can be suspended in the through hole. The adjustable rings correspond to the wire hole 340 and serve as the outlet for the wires. The distance between the adjustable rings can be adjusted according to the need to increase or decrease the wire harness spacing, thereby adjusting the spacing of the composite material wire harnesses leading out from the wire hole 340, effectively achieving controllable adjustment of the wire harness spacing.
[0089] from Figure 6As can be seen from the above, both the first mounting hole 345 and the second mounting hole 355 are circular holes, and the diameter of the second mounting hole 355 is larger than that of the second mounting hole 355.
[0090] Specifically, the conveying cylinder 32 is a rotatable cylinder that can rotate clockwise or counterclockwise, so that at least two composite material wire bundles 60 led out by the linkage structure can be controlled to perform the mesh weaving operation described in step S102 of the method of this application, and according to step S103, when the composite material wire bundle in the first direction is detected to have reached the first designated position, the cutting device is automatically driven to cut the composite material wire bundle in the first direction to obtain the composite material mesh after winding and weaving.
[0091] For example, a mesh weaving operation is performed on the first composite material wire bundle drawn out along a direction perpendicular to the second direction and the two composite material wire bundles (second composite material wire bundles) drawn out above. As the second composite material wire bundle is continuously drawn out, the mesh weaving operation is continuously performed with the first composite material wire bundle until a woven mesh is formed.
[0092] Specifically, the conveyor cylinder 32 rotates clockwise or counterclockwise at a designated position so that two composite material wire bundles 60 are wrapped around the first composite material wire bundle. The mesh weaving operation is repeated to form a woven mesh of a specified specification for subsequent operations, thereby completing the finished woven mesh and composite material mesh.
[0093] Compared with existing technologies, the system in this application utilizes a single-link drive shaft and a drive gear assembly in the lead wire device to synchronously drive multiple sets of lead wire driven mechanisms through a helical thread meshing method. Structurally, this ensures synchronous transmission of all driven transmission units. Because the single-link drive shaft synchronously drives multiple lead wire driven mechanisms, there is no accumulation of transmission backlash, improving synchronization accuracy, significantly reducing product defects caused by phase errors, and effectively reducing errors, thereby improving the quality and yield of the composite material mesh. Through the winding and expanding assembly, the spacing between multiple yarns can be quickly adjusted synchronously, greatly improving production flexibility and efficiency, and enabling rapid response to the production needs of products with different specifications.
[0094] Furthermore, by using an ultrasonic cutting blade in conjunction with a laser rangefinder, the cutting device is automatically driven to cut the composite material wire bundle in the first direction after reaching the first designated position. This ensures precise cutting at the first designated position and produces composite material segments with flat cut ends and accurate lengths. This results in a more precise composite material mesh after winding and weaving, effectively guaranteeing the consistency of fiber lengths in subsequent winding / interlacing processes, thereby improving yield and product quality.
[0095] Furthermore, this application utilizes a simpler and more reliable mechanical synchronization structure, reducing manufacturing costs and maintenance difficulty, and is less susceptible to electrical control system failures. Precise synchronization control and flexible spacing adjustment ensure the uniformity and accuracy of fiber arrangement, thereby improving the mechanical properties and appearance quality of the final cured product.
[0096] Finally, it should be noted that the various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the systems or apparatus disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the descriptions are relatively simple, and relevant parts can be referred to the method section.
[0097] The above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application.
Claims
1. A method for processing and molding composite material mesh, characterized in that, include: The first direction composite material wire bundle is continuously fed from the feeding device, and at least one sensor is used to automatically monitor the first direction composite material wire bundle to reach the first designated position. A second-direction composite material wire bundle is led out using a wire guide device, so that the second-direction composite material wire bundle, after adjusting the wire bundle spacing, performs a winding and braiding operation with the first-direction composite material wire bundle at a second designated position. When the composite material wire bundle in the first direction is detected to have reached the first designated position, the automatic driving cutting device cuts the composite material wire bundle in the first direction to obtain the composite material mesh after winding and weaving. Based on the curing temperature strategy, the composite material mesh after winding and weaving is heated and cured to obtain the finished composite material mesh.
2. The method for processing and forming composite material mesh according to claim 1, characterized in that, include: Using the lead wire device, two second-direction composite material bundles, whose spacing has been automatically adjusted by the bundle expansion component, are led out along the second direction, and then wound and braided with the first-direction composite material bundle along the first direction at a second designated position, wherein the first direction is perpendicular to the second direction.
3. The method for processing and forming composite material mesh according to claim 1 or 2, characterized in that, include: The control device controls the transmission unit of the lead wire device to rotate clockwise or counterclockwise, so that multiple second-direction composite material wire bundles drawn from the expansion assembly rotate clockwise or counterclockwise to wind around the first-direction composite material wire bundle and form a cross-winding relationship with the first-direction composite material wire bundle, so as to obtain a braided mesh with a cross-winding relationship.
4. The method for processing and forming composite material mesh according to claim 3, characterized in that, include: Multiple transmission units are synchronously driven by the single-link drive shaft of the lead wire device. When the first oblique thread of each drive gear assembly on the single-link drive shaft meshes with the second oblique thread corresponding to its respective position, the multiple transmission units are simultaneously driven to move along the second direction. The composite material wire bundle in the second direction moves simultaneously in each transmission unit and is led out from the outlet of the bundle expansion assembly until the winding and braiding operation is completed.
5. The method for processing and forming composite material mesh according to claim 1, characterized in that, include: The curing temperature of the composite material mesh being heated and cured is monitored in real time by a temperature sensor installed inside the curing equipment. The monitored curing temperature is compared with a preset curing temperature curve, and the power output of the heating equipment is automatically adjusted based on the comparison result to adjust the curing temperature of the composite material mesh in real time.
6. The method for processing and forming composite material mesh according to claim 1 or 5, characterized in that, include: The preset curing temperature curve includes the heating rate, the holding time, the holding temperature, and the cooling rate.
7. The method for processing and forming composite material mesh according to claim 4, characterized in that, include: At least two second-direction composite materials are drawn out from each conveying unit, the second-direction composite materials including prepreg fibers and impregnated yarns.
8. The method for processing and forming composite material mesh according to claim 1, characterized in that, The first-direction composite material wire harness includes prepreg fibers and impregnated yarns.
9. The method for processing and forming composite material mesh according to claim 1, characterized in that, The sensor is an optical sensor or a laser rangefinder.
10. The method for processing and forming composite material mesh according to claim 1, characterized in that, The cutting device is an electric scissors, an ultrasonic cutter, or a laser cutter.