A method for manufacturing a carbon fiber propeller of a multi-rotor unmanned aerial vehicle

Abstract

The present application relates to the unmanned aerial vehicle technical field, especially to a kind of carbon fiber propeller of multi-rotor unmanned aerial vehicle's manufacturing method, by selecting T800 carbon fiber reinforced fast curing system epoxy resin prepreg, M30 carbon fiber reinforced fast curing system epoxy resin prepreg, braided type 3K carbon fiber reinforced fast curing system epoxy prepreg fast curing system carbon fiber prepreg and single-component sheet foaming material, the forming die of carbon fiber propeller and propeller core is designed, the fiber layering angle and sheet foaming stacking form of design are not used, hot pressing and cold pressing are combined, and then the carbon fiber propeller is manufactured by the method of machining, surface treatment and dynamic balance check.The present application uses carbon fiber prepreg and high-multiplying self-foaming propeller core preforming, carbon fiber propeller is manufactured using mould pressing forming process, product is light and high-strength, manufacturing process is simple, cost is low, consistency is good, and can provide stable guarantee for the flight power of multi-rotor unmanned aerial vehicle.

Description

Technical Field

[0001] This invention belongs to the field of unmanned aerial vehicle (UAV) technology, and specifically relates to a method for manufacturing carbon fiber propellers for multi-rotor UAVs. Background Technology

[0002] In recent years, industrial-grade multi-rotor drones, as a type of aerial drone, have gained widespread application in the power industry, firefighting, law enforcement, forest fire prevention, and agricultural spraying due to their small size, flexible takeoff and landing, ease of operation, and ability to carry various aerial cameras, fire extinguishing devices, and pesticide spraying equipment. Their relatively simple structure and low manufacturing cost have enabled them to solve significant problems in these industries by efficiently, effectively, and rapidly acquiring reconnaissance information, hazard information, violation records, and pesticide spraying. The propellers in the power system, as a key component of drones, have always attracted much attention. Traditional injection-molded engineering plastic propellers, beech wood blades, and composite wood core propellers limit the stability and endurance of drones. While various new carbon fiber propeller molding processes exist, they are generally complex to manufacture, costly, and have unstable performance. Therefore, we need to propose a method for manufacturing carbon fiber propellers for multi-rotor drones to address these problems. Summary of the Invention

[0003] To address the above problems, this invention provides a method for manufacturing carbon fiber propellers for multi-rotor unmanned aerial vehicles, comprising the following steps:

[0004] S1. Based on the three-dimensional digital model characteristics of the blade, the interlayer structure of the sandwich structure is designed, and then the digital model of the blade core is designed. Based on the external dimensions of the blade, targeted local scaling is performed to obtain the blade core digital model.

[0005] S2. Based on the pre-designed molding process, design the molds for the blades and the core to obtain the blade mold and the core mold.

[0006] S3. Select sheet-like single-component foaming material with a foaming ratio of 1:30 for layering and laying. Place the layered foaming material into the propeller core mold for heating and curing. After curing, cool, open the mold, perform surface treatment and processing to obtain the propeller core. The propeller core is generally composed of three layers of sheet-like foam, with four layers in some areas. The first layer of sheet-like foam in the propeller core is cut with a cleaver from top to bottom. The second layer of sheet-like foam is cut with a foam carbon board template two. The third layer of sheet-like foam is cut with a foam carbon board template one.

[0007] S4. T800 carbon fiber reinforced rapid curing epoxy resin prepreg, M30 carbon fiber reinforced rapid curing epoxy resin prepreg, and woven 3K carbon fiber reinforced rapid curing epoxy resin prepreg are selected and pre-molded and laid on the propeller core. After laying, the prepreg is heated and cured. After curing, the propeller blade is cooled, molded, processed and surface treated to obtain the propeller blade.

[0008] S5, the paddle is balanced by the paddle balance tester, and the position and angle are estimated according to the imbalance greater than 80mg given by the paddle balance tester. The copper foil is used for preliminary marking of the counterweight, and the counterweight is re-measured until the imbalance is less than 80mg.

[0009] Further, the paddle mold and the paddle core mold are both made of upper and lower combined molds made of P20 steel, and the paddle mold and the paddle core mold are both provided with positioning columns and fastening bolt holes.

[0010] Further, the paddle core can be one-time formed according to the single-component sheet-shaped characteristics of the single-component sheet-shaped high-ratio foaming material, and the curved surface shape required for forming can be directly used after surface treatment.

[0011] Further, the paddle mold is provided with an acute angle mold closing line for quickly breaking off the edge scraps, so that the product profile is demolded and finished without secondary processing.

[0012] Further, the sequence of pre-forming overall laying of the paddle core is: woven type 3K carbon fiber reinforced rapid curing system epoxy prepreg, T800 carbon fiber reinforced rapid curing system epoxy prepreg, paddle core, T800 carbon fiber reinforced rapid curing system epoxy prepreg, and woven type 3K carbon fiber reinforced rapid curing system epoxy prepreg.

[0013] Further, the woven type 3K carbon fiber reinforced rapid curing system epoxy prepreg is the first layer on the surface, the FAW of the woven type 3K carbon fiber reinforced rapid curing system epoxy prepreg is 198g / m 2 , the RC is 37%, the second layer on the surface is selected from T800 carbon fiber reinforced rapid curing system epoxy prepreg ± 45° yarn, the FAW is 150g / m 2 , the RC is 37%, and the internal paddle core is sheet-shaped high-ratio foaming material, 250g / m 2 .

[0014] Further, the heating and curing methods of the paddle core and the paddle in the production are both selected from hot press molding, the temperature and pressure acting on the surface of the carbon fiber paddle product are realized by pressure limiting of the mold cavity of the paddle core mold and the paddle mold, so as to complete the curing and forming, the curing temperature of the hot press is 150±5℃, the curing time is 50±5min, and the hot press molding is 40±5kg / cm 2 .

[0015] Further, the cooling methods of the paddle core and the paddle in the production are both selected from cold press molding, the temperature and pressure acting on the surface of the carbon fiber paddle product are realized by pressure limiting of the mold cavity of the paddle core mold and the paddle mold, so as to complete the cooling and shrinkage, the cooling temperature of the cold press is 15±5℃, and the cooling time is 30±5min.

[0016] Further, the paddle balance tester adopts the test-weighting-test link procedure for debugging, the weighting material is balanced, the primary counterweight is a copper foil mark position, and the ultimate counterweight is a copper cylinder with a thickness of 0.2 mm, which is fixed by fast curing epoxy glue, and the dynamic balance of the debugged paddle is less than 80 mg.

[0017] The beneficial effects of the present application are:

[0018] The present application selects T800 carbon fiber reinforced fast curing system epoxy resin prepreg, M30 carbon fiber reinforced fast curing system epoxy resin prepreg, and woven type 3K carbon fiber reinforced fast curing system epoxy prepreg, designs the forming die of the carbon fiber paddle and the paddle core, designs the fiber layer angle and the laminated sheet foam form, adopts hot pressing and cold pressing, and then processes the carbon fiber paddle through mechanical processing, surface treatment and dynamic balance verification, and the foam material characteristics and the specific design of the paddle core can complete the production of the paddle core at one time, the curved surface shape is obtained without secondary processing, the shape and weight of the laminated sheet foam material are consistent, the carbon fiber paddle can be pasted and preformed on the paddle core, and finally the mold pressing is completed, the overall production process of the carbon fiber paddle is simple and easy to operate, the production efficiency is high, the cost is low, and the performance is stable and consistent.

[0019] Other features and advantages of the present application will be set forth in the following description, and in part will become apparent to those skilled in the art from the description, or can be learned by practice of the present application. The objects and other advantages of the present application can be achieved and obtained by the structures indicated in the description, claims and drawings. BRIEF DESCRIPTION OF DRAWINGS

[0020] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments or the prior art description. Obviously, the drawings in the following description are some embodiments of the present application, and for those skilled in the art, other drawings can also be obtained without creative labor on the basis of these drawings.

[0021] Figure 1 A schematic diagram of a single-component sheet foam lamination according to an embodiment of the present application is shown;

[0022] Figure 2 A schematic diagram of carbon fiber prepreg pasting of a carbon fiber paddle according to an embodiment of the present application is shown;

[0023] Figure 3 A lower die schematic diagram of a paddle core forming die according to an embodiment of the present application is shown;

[0024] Figure 4 Fig. 3 shows a schematic diagram of an upper mold of a carbon fiber paddle forming mold according to an embodiment of the present application;

[0025] Figure 5 Fig. 4 shows a schematic diagram of a lower mold of a carbon fiber paddle forming mold according to an embodiment of the present application;

[0026] Figure 6 Fig. 5 shows a schematic diagram of an upper mold of a forming mold according to an embodiment of the present application;

[0027] Figure 7 Fig. 6 shows a schematic diagram of a carbon fiber paddle structure according to an embodiment of the present application;

[0028] Figure 8 Fig. 7 shows a schematic diagram of a carbon fiber paddle cross-section structure according to an embodiment of the present application. DETAILED DESCRIPTION

[0029] In order to make the objectives, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are some but not all of the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work fall within the scope of protection of the present application.

[0030] The embodiments of the present application provide a manufacturing method of a carbon fiber paddle of a multi-rotor unmanned aerial vehicle, comprising the following steps:

[0031] S1, designing an interlayer structure of a sandwich structure according to three-dimensional model characteristics of a paddle blade, designing a three-dimensional model shape of a paddle core of an internal structure of the paddle blade, and obtaining a three-dimensional model of the paddle core by performing a local scaling according to an external dimension of the paddle blade.

[0032] S2, designing a mold of the paddle blade and the paddle core according to a pre-designed mold pressing process, and obtaining a mold of the paddle blade and a mold of the paddle core,

[0033] The mold of the paddle blade and the mold of the paddle core are both upper and lower combined molds made of P20 steel, and the mold of the paddle blade and the mold of the paddle core are both provided with positioning columns and fastening bolt holes.

[0034] The mold of the paddle core can form a curved surface shape required at one time according to a single-component sheet characteristic of a single-component sheet high-ratio foaming material, and can be directly used after surface treatment.

[0035] S3, selecting a single-component sheet high-ratio foaming material to perform a laminated laying of a single-component sheet foaming material, placing the laminated foaming material into the mold of the paddle core to perform heating and curing, cooling, mold opening, surface treatment and processing after the curing is completed, and obtaining the paddle core.

[0036] The sheet-shaped single-component high-ratio foaming material has a foaming ratio of 1:30, three layers of sheet-shaped foaming are arranged on the whole of the paddle core, and four layers of sheet-shaped foaming are arranged locally, the first layer of sheet-shaped foaming from top to bottom is cut by a chopper, the second layer of sheet-shaped foaming is cut by a foam carbon plate template II, and the third layer of sheet-shaped foaming is cut by a foam carbon plate template I.

[0037] S4, T800 carbon fiber reinforced fast curing system epoxy resin prepreg, M30 carbon fiber reinforced fast curing system epoxy resin prepreg, and woven 3K carbon fiber reinforced fast curing system epoxy prepreg are selected to be pre-attached on the paddle core, and after the pre-attachment is completed, heating and curing are performed, cooling, mold opening, processing and surface treatment are performed after the curing is completed, and a paddle blade is obtained.

[0038] The paddle blade mold is provided with an acute angle mold closing line for quickly breaking off the leftover materials, so that the product profile is demolded to be a finished product without secondary processing, the pre-attachment sequence of the paddle core is woven 3K carbon fiber reinforced fast curing system epoxy prepreg, T800 carbon fiber reinforced fast curing system epoxy resin prepreg, a paddle core, T800 carbon fiber reinforced fast curing system epoxy resin prepreg and woven 3K carbon fiber reinforced fast curing system epoxy prepreg, the woven 3K carbon fiber reinforced fast curing system epoxy prepreg is a first layer on the surface, the FAW of the woven 3K carbon fiber reinforced fast curing system epoxy prepreg is 198 g / m 2 , the RC is 37%, a second layer on the surface is selected to be T800 carbon fiber reinforced fast curing system epoxy resin prepreg ±45° yarn, the FAW is 150 g / m 2 , the RC is 37%, and the internal paddle core is a sheet-shaped high-ratio foaming material, 250 g / m 2 .

[0039] The heating and curing modes of the paddle core and the paddle blade in the manufacturing process are selected to be hot press molding, the temperature and pressure acting on the surface of the carbon paddle product are realized by limiting the pressure of the mold cavity of the paddle core mold and the paddle blade mold, so that the curing and forming are completed, the curing temperature of the hot press is 150±5℃, the curing time is 50±5min, and the hot press molding is 40±5kg / cm 2 .

[0040] The cooling modes of the paddle core and the paddle blade in the manufacturing process are selected to be cold press molding, the temperature and pressure acting on the surface of the carbon paddle product are realized by limiting the pressure of the mold cavity of the paddle core mold and the paddle blade mold, so that the cooling and shrinkage are completed, the cooling temperature of the cold press is 15±5℃, and the cooling time is 30±5min.

[0041] S5, the paddle is balanced by the paddle balance tester, according to the unbalance amount greater than 80mg given by the paddle balance tester, the position and angle are estimated, the copper foil is used for preliminary marking of the weight, and the weight is measured again until the unbalance amount is less than 80mg.

[0042] The paddle balance tester adopts the test-weighting-test link procedure for debugging, the weighting balancing material, the primary weight is the copper foil marked position, and the final weight is the copper cylinder with a thickness of 0.2mm, which is fixed by fast curing epoxy glue, and the dynamic balance amount of the paddle after debugging is less than 80mg.

[0043] In summary, please refer to the attached Figure 1 , complete the laminated sheet foaming, put into the mold cavity of the molding mold of the attached Figure 3 and 4 , through pressurization and heating, pressurized cooling, demolding, surface treatment, processing, and make self-foaming paddle core.

[0044] Please refer to the attached Figure 2 , complete the laying of carbon fiber prepreg on the surface of the paddle core, put into the molding mold of the attached Figure 5 and 6 , through pressurization and heating, pressurized cooling, demolding, processing, surface treatment, and make carbon fiber paddle.

[0045] By selecting T800 carbon fiber reinforced fast curing system epoxy resin prepreg, M30 carbon fiber reinforced fast curing system epoxy resin prepreg, and woven 3K carbon fiber reinforced fast curing system epoxy prepreg, the forming mold of the carbon fiber paddle and the paddle core is designed, the fiber layer angle and the sheet foaming layer form are designed, the hot pressing and cold pressing are combined, and the carbon fiber paddle is made by mechanical processing, surface treatment and dynamic balance verification. By using the characteristics of the foaming material and the specific scaling design of the paddle core, the paddle core can be completed at one time, and the curved surface shape can be obtained without secondary processing. The shape and weight of the laminated sheet foaming material are consistent; then the carbon fiber paddle can be laid on the paddle core for preforming, and finally the mold pressing is completed. The overall manufacturing process of the carbon fiber paddle is simple and easy to operate, the production efficiency is high, the cost is low, and the performance is stable and consistent.

[0046] Although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that the technical solutions recorded in the foregoing embodiments can be modified, or some technical features can be replaced by equivalents; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present application.

Claims

1. A method for manufacturing carbon fiber propellers for a multi-rotor unmanned aerial vehicle, characterized in that: It comprises the following steps: S1. Design the interlayer structure of the sandwich structure according to the three-dimensional model characteristics of the blade, and then design the model shape of the blade core, and perform targeted local scaling according to the size of the blade, to obtain the blade core model; S2. According to the pre-designed mold pressing process, the mold of the blade and the core is designed, and the mold of the blade and the core is obtained; S3. Select a sheet-shaped single-component foaming material with a foaming ratio of 1:30 for laminated laying, and the whole laminated foaming material is put into the core mold for heating and curing. After curing, cooling, mold opening, surface treatment and processing are performed to obtain the core. The laminated whole of the core is provided with three layers of sheet-shaped foaming, and the local part is provided with four layers. The first layer of sheet-shaped foaming is cut by a chopper, the second layer of sheet-shaped foaming is cut by a foam carbon plate template two, and the third layer of sheet-shaped foaming is cut by a foam carbon plate template one; S4. Select T800 carbon fiber reinforced rapid curing system epoxy resin prepreg, M30 carbon fiber reinforced rapid curing system epoxy resin prepreg, and braided 3K carbon fiber reinforced rapid curing system epoxy prepreg for pre-type overall laying on the core. After laying, heat curing is performed. After curing, cooling, mold opening, processing and surface treatment are performed to obtain the blade; S5. The blade is dynamically balanced by the blade balance tester. When the unbalance amount is greater than 80mg, the position and angle are estimated, and the copper foil is used for preliminary marking of the weight. The weight is re-measured until the unbalance amount is less than 80mg.

2. The method of claim 1, wherein: The blade mold and the core mold are both made of upper and lower combined molds made of P20 steel. The blade mold and the core mold are both provided with positioning columns and fastening bolt holes.

3. The method of claim 2, wherein the carbon fiber shaft is made of carbon fiber and epoxy resin. The core mold can form the required curved shape in one time according to the single-component sheet-shaped characteristics of the sheet-shaped single-component high-ratio foaming material, and can be directly used after surface treatment.

4. The method of claim 3, wherein the carbon fiber shaft is made of carbon fiber and epoxy resin. The blade mold is provided with an acute angle mold line for quickly breaking off the edge scraps, so that the product contour can be demolded as a finished product without secondary processing.

5. The method of claim 4, wherein the carbon fiber shaft is made of carbon fiber and epoxy resin. The sequence of the pre-type overall laying of the core is braided 3K carbon fiber reinforced rapid curing system epoxy prepreg, T800 carbon fiber reinforced rapid curing system epoxy resin prepreg, core, T800 carbon fiber reinforced rapid curing system epoxy resin prepreg and braided 3K carbon fiber reinforced rapid curing system epoxy prepreg.

6. The method of claim 5, wherein: The woven 3K carbon fiber reinforced fast curing system epoxy prepreg is the surface first layer, the FAW of the woven 3K carbon fiber reinforced fast curing system epoxy prepreg is 198 g / m 2 , the RC is 37%, the surface second layer is selected from T800 carbon fiber reinforced fast curing system epoxy resin prepreg ±45° union yarn, the FAW is 150 g / m 2 , the RC is 37%, and the internal core is a sheet-shaped high-multiplying foaming material, 250 g / m 2 .

7. The method of claim 6, wherein the carbon fiber shaft is made of carbon fiber and epoxy resin. The heating and curing mode of the core and the blade in the manufacturing process is selected by hot press molding, and the temperature and pressure acting on the surface of the carbon fiber blade product are realized by the mold cavity of the core mold and the blade mold, so as to complete the curing forming. The curing temperature of the hot press is 150±5℃, the curing time is 50±5min, and the hot press molding is 40±5kg / cm 2 .

8. The method of claim 7, wherein the carbon fiber shaft is made of carbon fiber and epoxy resin. The cooling mode of the core and the blade during production is selected to be mold pressing by a cold press. The mold cavity of the core mold and the blade mold limits the pressure, so that the temperature and pressure acting on the surface of the carbon blade product are realized, the cooling shrinkage is completed, and the cooling temperature of the cold press is 15±5℃, and the cooling time is 30±5min.

9. The method of claim 8, wherein the carbon fiber shaft is made of carbon fiber and epoxy resin. The blade balance tester adopts the test-weighting-test link program for debugging. The weighting balancing material is copper foil marked position for preliminary weighting, and the final weighting is a copper cylinder with a thickness of 0.2mm, which is fixed by rapid curing epoxy glue. The dynamic balance of the blade after debugging is less than 80mg.

Images