A high-thickness flat fabric needle punching machine with powder spreading function and a needle punching method

Abstract

The present invention relates to a high-thickness flat fabric needling machine with a powdering function, comprising a frame, a lifting mechanism, a needling mechanism, a powdering mechanism, a fabric needling workbench and a position detection sensor; the frame comprises a main frame and a needling guide device, and the two parallel sides of the main frame are equipped with a needling guide device; the lifting mechanism comprises a first motor, a planetary reducer and a first screw, and the first motor is a servo motor with a brake; the needling mechanism comprises an SDAJ adjustable cylinder, a needle and a support rod, and the needling mechanism completes the needling movement through the needling guide device under the drive of the lifting mechanism; the powdering mechanism is fixedly connected to the needling mechanism, and is selected through program control to perform needling and powdering work respectively; the fabric needling platform comprises a workbench with a foam bottom felt fixed on the upper surface; and also comprises a needling method using the needling machine. The present invention can flexibly and automatically adjust the positions of the needle plate and the stripping plate, and the finished product has good quality and meets the use requirements of the aircraft.

Description

Technical Field

[0001] The invention belongs to the technical field of composite material high-thickness fabric manufacturing equipment, and in particular relates to a high-thickness flat fabric needle punching machine with a powder spreading function and a needle punching method. Background Art

[0002] High-thickness needle-punched fabrics and their composite materials are mostly used for key core components such as skins and cabins of ultra-long-range hypersonic aircraft, and have superb thermal protection performance. At present, high-thickness flat needle-punched fabrics are usually needle-punched using traditional flat needle-punching machines. Since traditional flat needle-punching machines do not have the function of detecting the pressure of the stripping plate, as the thickness of the fabric gradually increases and changes, the existing flat needle-punching machines often have the situation where the stripping plate applies too much pressure on the needle-punched fabric, which often leads to delamination damage between the layers of the needle-punched fabric. For high-thickness fabrics that are needle-punched layer by layer, each unit layer of the needle-punched fabric should have high interlayer performance. Therefore, the flat needle-punching machine for preparing high-thickness fabrics needs to effectively deal with the problem of difficult-to-control pressure of the stripping plate.

[0003] In addition, compared with ordinary needle-punched fabrics, high-thickness fabrics require multiple layer-by-layer needling to form. Therefore, if the flat-plate needling machine can flexibly and automatically adjust the positions of the needle plate and the stripping plate, the production efficiency will be greatly improved. The traditional flat-plate needling machine (such as the flat-plate needling machine recorded in the invention patent with publication number CN114908481A) that adopts an eccentric wheel slider mechanism, a crank-type lifting mechanism, etc. to realize the reciprocating motion of needling is not only complex in structure, but also cannot flexibly adjust the positions of the needle plate and the stripping plate relative to the workbench, and the needling depth is inconvenient to adjust; in addition, the worm gear and screw lifter is used to lift the entire set of needling faucet mechanisms as a whole. After multiple liftings, the cumulative error is large, and the position of the stripping plate and the distance from the upper surface of the fabric are difficult to accurately control, which often leads to excessive squeezing of the fabric by the stripping plate, resulting in delamination damage of the needle-punched fabric.

[0004] In addition, when the existing flat needle punching machine is needle punching high-thickness fabrics, it is difficult to ensure the quality of the needle punching molding on all sides. Moreover, the composite materials formed by the high-thickness fabrics needle punched by the existing flat needle punching machine and the reinforced resin matrix are also easy to oxidize under high temperature conditions and have weak anti-ablation performance. After such high-thickness flat fabrics are made into the core components of aircraft, they have poor durability under extreme conditions and are difficult to meet the requirements of ultra-long-distance work of aircraft. Therefore, it is necessary to improve the flat fabric needle punching machine and the needle punching method. Summary of the invention

[0005] In order to solve the technical problems existing in the known technology, the present invention provides a high-thickness flat fabric needling machine with a powder sprinkling function and a needling method, which is specially used for needling high-thickness fabrics. The positions of the needle plate and the stripping plate can be flexibly and automatically adjusted, and the finished product has good quality, which meets the use requirements of aircraft.

[0006] The present invention includes the following technical solutions:

[0007] A high-thickness flat fabric needle-punching machine with a powder-sprinkling function, comprising a frame, a lifting mechanism, a needle-punching mechanism, a powder-sprinkling mechanism, a fabric needle-punching workbench and a position detection sensor; the frame comprises a main frame and a needle-punching guide device, the main frame is placed on a horizontal plane and is a cubic frame as a whole, a base for mounting a fabric needle-punching platform is arranged in the main frame, and two parallel sides of the main frame are provided with a needle-punching guide device; the needle-punching guide device comprises a first guide rod, a first linear bearing and a guide shaft support, the first linear bearing is arranged on the needle-punching mechanism, and both ends of the first guide rod are fixedly connected to the guide shaft support after passing through the first linear bearing, and the guide shaft support is fixed to the main frame by screws;

[0008] The lifting mechanism includes a first motor, a planetary reducer and a first screw rod, wherein the first motor is a servo motor with a brake; the first motor is threadedly connected to the planetary reducer, and the first screw rod is fixedly connected to the output shaft of the planetary reducer through a coupling;

[0009] The acupuncture mechanism comprises an SDAJ adjustable cylinder, a needle and a support rod. The acupuncture mechanism completes the acupuncture movement under the drive of the lifting mechanism through the acupuncture guide device; the piston rod of the SDAJ adjustable cylinder is output under the guidance of the second guide rod and the second linear bearing; the support rod is fixed under the top plate, and the end thereof is successively installed with a pressure sensor and a stripping plate, and the top plate is fixed with a first linear bearing; the clamping part of the needle is installed between the support plate and the needle plate, and the working part passes through the needle hole of the needle plate and is exposed;

[0010] The powder spreading mechanism includes a third motor, a linear module, and a nozzle installed on a slide of the linear module. The third motor drives the linear module to control the back and forth movement of the slide of the linear module to spread powder. The powder spreading mechanism is fixedly connected to the acupuncture mechanism, and moves along the acupuncture direction with the acupuncture mechanism to spread powder.

[0011] The fabric needling platform comprises a workbench with a foam bottom felt fixed on the upper surface, the fabric to be needled is placed on the foam bottom felt, and the fabric to be needled is fixed by a foam fence around it; a plurality of sliders are arranged under the workbench, and the sliders are connected to the guide rails installed on the base; the workbench realizes automatic feeding of the fabric to be needled under the drive of the position adjustment mechanism.

[0012] Furthermore, the main frame is composed of a first crossbeam and other square tubes, and adjacent square tubes are connected by welding or screws; the base is welded by several square tubes and fixed to the main frame by screws; the upper side of the first crossbeam is fixed to the screw support frame by screws, and the upper side of the screw support frame is fixed to the reducer support frame by screws. The main frame supports the screw support frame, the reducer support frame and the base.

[0013] Furthermore, the screw support frame and the reducer support frame are both N-shaped; the planetary reducer is fixed on the reducer support frame, and the upper and lower ends of the first screw are respectively connected to the screw support frame and the first crossbeam through the screw bearing seat.

[0014] Furthermore, the acupuncture mechanism also includes a screw nut mounting plate and a vertical plate; the two vertical plates are fixed on both sides below the screw nut mounting plate by screws, and the lower end surfaces of the vertical plates are fixedly connected to the top plate; the two SDAJ adjustable cylinders are respectively arranged on the outsides of the two vertical plates, and their cylinder bodies are fixedly connected to the vertical plates by screws, and the piston rods are fixedly connected to the support plate; the screw nut mounting plate is fixedly connected to the first screw through the first screw nut.

[0015] Furthermore, the position adjustment mechanism includes a second motor and a second screw rod, the left end of the second screw rod is installed on the base, and the right end is connected to the output shaft of the second motor through a coupling; a second screw rod nut and a workbench are installed in the middle of the second screw rod, and the second screw rod nut is fixed on the workbench.

[0016] Furthermore, the second motor is threadedly connected to the motor frame, the motor frame is fixed to the frame support by screws, and the frame support is fixed to the right side of the base; the right side of the second screw rod is installed on the motor frame, and the left end of the second screw rod is installed on the base by connecting with the screw rod support.

[0017] Furthermore, the position detection sensor includes an upper acupuncture mechanism position detection sensor fixed on one side of the screw support frame, a lower acupuncture mechanism position detection sensor fixed on one side of the first beam, and a left workbench position detection sensor and a right workbench position detection sensor fixed on the left and right sides of the upper surface of the base.

[0018] Furthermore, when the lifting mechanism drives the acupuncture mechanism to approach the upper acupuncture mechanism position detection sensor to reach the detection distance, the upper acupuncture mechanism position detection sensor receives a signal, and the acupuncture mechanism reaches its upper limit position and no longer moves upward; when the lifting mechanism drives the acupuncture mechanism to approach the lower acupuncture mechanism position detection sensor to reach the detection distance, the lower acupuncture mechanism position detection sensor receives a signal, and the acupuncture mechanism reaches its lower limit position and no longer moves downward. The upper and lower limit positions of the acupuncture mechanism are set to determine the safe working range of its movement along the acupuncture direction.

[0019] Furthermore, when the workbench approaches the left workbench position detection sensor and reaches the detection distance, the left workbench position detection sensor receives a signal, and the workbench reaches its left limit position and no longer moves to the left; when the workbench approaches the right workbench position detection sensor and reaches the detection distance, the right workbench position detection sensor receives a signal, and the workbench reaches its right limit position and no longer moves to the right. The fabric needle punching platform is set with left and right limit positions to determine the safe working range of the workbench.

[0020] Furthermore, four second linear bearings are fixed on the top plate, and the four second guide rods pass through the second linear bearings respectively, and the ends thereof are successively installed with a support plate and a needle plate, and the installation positions thereof are located at the four corners of the rectangular support plate and the needle plate.

[0021] Furthermore, the foam bottom felt is fixed to the upper surface of the workbench by gluing, and the bottom of the foam fence is directly adhered to the foam bottom felt by double-sided tape.

[0022] Furthermore, the third motor is threadedly connected to the linear module, the linear module is fixedly connected to the linear module mounting plate by screws, and the linear module mounting plate is fixed on the top plate of the acupuncture mechanism; the powder spreading mechanism is fixedly connected to the acupuncture mechanism by the linear module mounting plate, and the drag chain for placing the powder conveying pipe is installed on the linear module by the drag chain mounting plate.

[0023] A method for needling a high-thickness flat fabric, using the high-thickness flat fabric needling machine with a powder spreading function, comprises the following steps:

[0024] S1, setting parameters such as the total thickness of the fabric to be needled, the thickness increase of the fabric per needled pass, the lifting height of the needle punching mechanism, the initial position of powder sprinkling, the initial position of needling, the needling depth and the needling step amount;

[0025] S2, placing a unit layer of fabric to be needled in a foam fence on a workbench, fixing the fabric on all sides with the foam fence, and setting the initial position of the workbench at the right limit position;

[0026] S3, the control system switches to the powdering mode, the position adjustment mechanism controls the workbench to reach the powdering initial position from the right limit position of the workbench; the powdering mechanism starts to operate, the spray gun sprays the functional powder filler, the third motor drives the linear module to move, and the slider on the linear module drives the spray gun to move; the position adjustment mechanism and the powdering mechanism move together so that the functional powder filler is evenly sprayed on the fabric to be needled; after the functional powder filler is sprayed, the position adjustment mechanism drives the workbench to the needle punching initial position, and the equipment is temporarily stopped after the powdering is completed; a unit layer of fabric to be needled located in the foam fence is laid on the upper surface of the fabric after the powdering; the control system switches to the needle punching mode and prepares to start the needle punching mechanism;

[0027] S4, the first motor of the lifting mechanism drives the first screw to rotate, and the first screw nut transmits the movement to the needling mechanism. The needling mechanism starts to move downward along the needling direction from its upper limit position. During this period, the piston rod of the SDAJ adjustable cylinder completes the output, pushes the support plate and the needle plate to drive the needle to advance, and under the action of the SDAJ adjustable cylinder, the working part of the needle passes through the stripping plate and is exposed. As the needling movement continues, the needle pierces the fabric to be needling, and then the stripping plate begins to contact the fabric to be needling and continues to press down. After reaching the needling target height, the lifting mechanism stops running and the needling mechanism completes the downward needling movement; the piston rod of the SDAJ adjustable cylinder is reset, and the support plate and the needle plate drive the needle to retract. After the retraction is completed, the lifting mechanism begins to lift upward along the needling direction. During this process, the stripping plate leaves the surface of the needling fabric; after the needling mechanism reaches the lifting height, a single needling is completed;

[0028] S5, the position adjustment mechanism drives the workbench to move to the left by a predetermined step amount, and when the needle-punched fabric moves to the position of the next needling point, step S4 is repeated until the single-layer needling of the entire product is completed;

[0029] S6, after the single-layer needling is completed, the position adjustment mechanism drives the workbench back to its right limit position, and the equipment stops;

[0030] Steps S2 to S6 are repeated to perform needling of the next layer until the predetermined preform thickness is reached.

[0031] The present invention has the following advantages and positive effects:

[0032] 1. A pressure sensor is provided at the stripping plate of the needle punching mechanism in the present invention to monitor the pressure applied by the stripping plate to the needle punched fabric, thereby avoiding the occurrence of delamination between the layers of the needle punched fabric caused by excessive pressure applied by the stripping plate.

[0033] 2. The lifting mechanism of the present invention adopts a combination of a ball screw and a servo motor (i.e., a first screw and a first motor). Compared with the traditional flat needle loom, it can realize precise control of the position of the stripping plate to ensure the forming thickness of the fabric; in addition, facing preforms of different configurations and fiber materials, the needle insertion speed can be adjusted in a targeted manner to improve the quality of acupuncture.

[0034] 3. The present invention adopts the SDAJ adjustable cylinder as the power element of the acupuncture mechanism. The acupuncture depth can be adjusted by simply changing the stroke of the cylinder piston rod, and the acupuncture depth adjustment is convenient.

[0035] 4. The present invention adopts a foam fence as an auxiliary positioning tool around the fabric to be needled on the workbench, which ensures that the position of the high-thickness fabric is fixed during the needle-punching process and improves the needle-punching forming quality.

[0036] 5. The present invention integrates a powder spreading mechanism, and by adding functional powder fillers (the fillers are oxide powders, specifically aluminum oxide, boron oxide powder, etc.) during the fabric needling process, the high-thickness fabric-reinforced composite material made of the fabric prepared by the present invention has enhanced high-temperature resistance, oxidation resistance and ablation resistance.

[0037] 6. The needle punching method adopted in the present invention uniformly embeds functional powder fillers between fabric layers through a powder spreading mechanism during the preparation stage of high-thickness fabrics, and during the needling process, the needles will bring part of the powder fillers into the yarns of the base fabric, so that the functional powder fillers are embedded in various positions of the needle-punched fabric, including between layers and inside the base fabric. The functional powder fillers are further embedded in the high-thickness fabric as the needling proceeds, so that the high-thickness fabric reinforced composite material has higher antioxidant and ablation resistance at high temperature, which can meet the needs of ultra-long-range operation of aircraft. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 It is a schematic diagram of the overall three-dimensional structure of the present invention;

[0039] Figure 2 It is a front view of the present invention as a whole;

[0040] Figure 3 It is a schematic diagram of the three-dimensional structure of the frame of the present invention;

[0041] Figure 4 It is a three-dimensional structural schematic diagram of the acupuncture mechanism and the powder spreading mechanism of the present invention;

[0042] Figure 5 is a rear view of the acupuncture mechanism of the present invention;

[0043] Figure 6 It is a schematic diagram of the three-dimensional structure of the fabric needling platform of the present invention;

[0044] In the figure, 1-a flat acupuncture machine; 10-a machine frame; 11-a main frame; 111-a first crossbeam; 12-a screw support frame; 13-a reducer support frame; 14-a base; 15-acupuncture guide device; 151-a first guide rod; 152-a first linear bearing; 153-a guide shaft support;

[0045] 20-lifting mechanism; 21-first motor; 22-planetary reducer; 23-first screw rod; 24-first screw rod nut;

[0046] 30-needling mechanism; 31-screw nut mounting plate; 32-vertical plate; 33-top plate; 34-SDAJ adjustable cylinder; 35-support plate; 36-needle plate; 37-puncture needle; 38-support rod; 39 pressure sensor; 310-stripping plate; 311-second guide rod; 312-second linear bearing; 313-first linear bearing;

[0047] 40-powder spreading mechanism; 41-third motor; 42-linear module; 43-module mounting plate; 44-drag chain; 45-drag chain mounting plate; 46-sprinkler; 47-sprinkler mounting plate;

[0048] 50-fabric needling platform; 51-workbench; 52-foam bottom felt; 53-foam fence; 54-position adjustment mechanism; 541-second motor; 542-motor frame; 543-frame support; 544-second screw rod; 545-second screw rod nut; 546-screw rod support; 55-slider; 56-slide rail; 57-slide rail mounting plate;

[0049] 60-position detection sensor; 61-upper needling mechanism position detection sensor; 62-lower needling mechanism position detection sensor; 63-left workbench position detection sensor; 64-right workbench position detection sensor; 7-fabric to be needled. DETAILED DESCRIPTION

[0050] In order to further disclose the content, features and effects of the present invention, the following examples are given and described in detail with reference to the accompanying drawings.

[0051] Example: See attached Figure 1-6 A high-thickness flat fabric needling machine with a powder sprinkling function comprises a frame 10, a lifting mechanism 20, a needling mechanism 30, a powder sprinkling mechanism 40, a fabric needling workbench 50 and a position detection sensor 60.

[0052] like Figure 1-3As shown, the frame 10 includes a main frame 11, a screw support frame 12, a reducer support frame 13, a base 14 and a needling guide part 15. The main frame 11 is composed of a first crossbeam 111 and other square tubes, which is generally a cubic frame, and adjacent square tubes are connected by welding or screws. The main frame 11 is placed on a horizontal plane and supports the screw support frame 12, the reducer support frame 13 and the base 14. The screw support frame 12 and the reducer support frame 13 are both n-shaped, and the screw support frame 12 is fixed to the upper side of the first crossbeam 111 by screws. The reducer support frame 13 is fixed to the upper side of the screw support frame 12 by screws. The base 14 is welded by a plurality of square tubes and fixed to the main frame 11 by screws. The main frame 11 is in the cubic frame and mainly supports the fabric needling platform 50. The needling guide part 15 includes a first guide rod 151, a first linear bearing 152 and a guide shaft support 153. The first linear bearing 152 is disposed on the acupuncture mechanism 30. After the first guide rod 151 passes through the first linear bearing 152, both ends are fixedly connected to the guide shaft support 153, and the guide shaft support 153 is fixed to the main frame by screws. The four first guide rods 151 are fixedly connected to the guide shaft support 153 and are placed on one side of the main frame 11 in pairs.

[0053] like Figure 1-2 As shown, the lifting mechanism 20 includes a first motor 21, a planetary reducer 22, a first screw 23 and a first screw nut 24. The first motor 21 is set as a servo motor that can achieve precise control and has a brake. The first motor 21 is threadedly connected to the planetary reducer 22, and the planetary reducer 22 is fixed on the reducer support frame 13. The upper and lower ends of the first screw 23 are respectively connected to the screw support frame 12 and the first crossbeam 111 through the screw bearing seat. The first screw 23 is fixedly connected to the output shaft of the planetary reducer 22 through a coupling. The first screw nut 24 passes through the first screw 23 and is fixedly connected to the screw nut mounting plate 31 of the acupuncture mechanism 30, driving the acupuncture mechanism 30 to reciprocate up and down along the acupuncture direction.

[0054] like Figure 4-5 As shown, the acupuncture mechanism 30 includes a screw nut mounting plate 31, a vertical plate 32, a top plate 33, an SDAJ adjustable cylinder 34, a support plate 35, a needle plate 36, a needle 37, a support shaft 38, a pressure sensor 39, a stripping plate 310, a second guide rod 311 and a second linear bearing 312. The two vertical plates 32 are fixed to the two sides below the screw nut mounting plate 31 by screws, and the lower end surface of the vertical plate 32 is fixedly connected to the top plate 33. Two SDAJ adjustable cylinders 34 are respectively arranged on the outer sides of the two vertical plates 32, and their cylinder bodies are fixedly connected to the vertical plates 32 by screws, and the piston rods are fixedly connected to the support plate 35.

[0055] Four second linear bearings 312 are fixed on the top plate 33. After the four second guide rods 311 pass through the second linear bearings 312, the ends are installed on the support plate 35 and the needle plate 36 in sequence. The installation positions are located at the four corners of the rectangular support plate 35 and the needle plate 36. The clamping part of the needle 37 is installed between the support plate 35 and the needle plate 36, and the working part passes through the needle hole of the needle plate 36 to be exposed. The second guide rods 311 and the second linear bearings 312 are arranged on the top plate 33 and the support plate 35 to guide the output of the piston rod of the SDAJ adjustable cylinder 34. The two support rods 38 are fixed under the top plate 33, and the pressure sensors 39 and the stripping plate 310 are installed on the ends in sequence. The four first linear bearings 152 are fixed on the top plate by screws, and the acupuncture mechanism 30 completes the acupuncture movement through the acupuncture guide part 15 driven by the lifting mechanism 20.

[0056] like Figure 1-2 as well as Figure 4 As shown, the powder spreading mechanism 40 includes a third motor 41, a linear module 42, a linear module mounting plate 43, a drag chain 44, a drag chain mounting plate 45, a nozzle 46 and a nozzle mounting plate 47. The third motor 41 is threadedly connected to the linear module 42. The drag chain 44 for placing the powder conveying pipe is installed on the linear module 42 through the drag chain mounting plate 45, and the nozzle 46 is installed on the slide of the linear module 42 through the nozzle mounting plate 47. The linear module 42 is driven by the third motor 41 to control the back and forth movement of the slide of the linear module 42 to spread powder. The linear module 42 is fixedly connected to the linear module mounting plate 43 by screws, and the linear module mounting plate 43 is fixed on the top plate 33 of the needling mechanism 30. The powder spreading mechanism 40 is fixedly connected to the needling mechanism 30 through the linear module mounting plate 43, and moves along the needling direction with the needling mechanism 30 to spread powder on fabrics to be needled of different thicknesses.

[0057] like Figure 1-2 as well as Figure 6 The fabric needling platform 50 includes a workbench 51, a foam bottom felt 52, a foam fence 53, a position adjustment mechanism 54, a slider 55, a guide rail 56, and a guide rail mounting plate 57. A plurality of sliders 55 are fixed below the workbench 51 by screws, and the sliders 55 are connected to the guide rails 56. The guide rails 56 are fixed to the guide rail mounting plate 57 by screws below, and the guide rail mounting plate 57 is fixedly mounted on the base 14.

[0058] The foam base felt 52 is fixed to the upper surface of the workbench 51 by gluing, and the needle-punched fabric 7 is placed on the foam base felt 52. The bottom of the foam fence 53 has double-sided adhesive and can be directly pasted on the foam base felt 52. The needle-punched fabric 7 is fixed by the foam fence 53 around.

[0059] like Figure 6As shown, the position adjustment mechanism 54 includes a second motor 541, a motor frame 542, a frame support 543, a second screw rod 544, a second screw rod nut 545 and a screw rod support 546. The second motor 541 is threadedly connected to the motor frame 542, and the motor frame 542 is fixed to the frame support 543 by screws, and the frame support 543 is fixed to the right side of the base 14. The right side of the second screw rod 544 is installed on the motor frame 542, and the right end is connected to the output shaft of the second motor 541 through a coupling. The second screw rod nut 545 passes through the second screw rod 544 and is fixed to the right side of the workbench 51. The left end of the second screw rod 544 is installed on the base 14 by connecting with the screw rod support 546. The position adjustment mechanism 54 realizes that the workbench 51 drives the fabric 7 to be needled to be automatically fed.

[0060] like Figure 1-2 As shown, the position detection sensor 60 includes an upper acupuncture mechanism position detection sensor 61, a lower acupuncture mechanism position detection sensor 62, a left workbench position detection sensor 63 and a right workbench position detection sensor 64, all of which are proximity sensors with a detection distance of 10 mm. The upper acupuncture mechanism position detection sensor 61 is fixed to one side of the screw support frame 12 through a sensor bracket. The lower acupuncture mechanism position detection sensor 62 is fixed to one side of the first crossbeam 111 through a sensor bracket. When the upper acupuncture mechanism position detection sensor 61 senses the upper surface of the screw nut mounting plate 31 (when the detection signal changes from 0 to 1), the acupuncture mechanism 30 driven by the lifting mechanism 20 no longer moves upward, and the acupuncture mechanism 30 reaches its upper limit position. When the lower acupuncture mechanism position detection sensor 62 senses the lower surface of the screw nut mounting plate 31 (when the detection signal changes from 0 to 1), the acupuncture mechanism 30 driven by the lifting mechanism 20 no longer moves downward, which means that the acupuncture mechanism 30 reaches its lower limit position. The needling mechanism 30 is provided with upper and lower limit positions in order to determine its safe working range of movement along the needling direction (the working range of the needling mechanism is 500 mm).

[0061] The left workbench position detection sensor 63 and the right workbench position detection sensor 64 are fixed on the left and right sides of the upper surface of the base 14 through their respective sensor brackets. The workbench 51 is controlled by the position adjustment mechanism 54. When the left workbench position detection sensor 63 senses the left side of the workbench 51 (when the detection signal changes from 0 to 1), the workbench 51 no longer moves to the left, and the workbench 51 reaches its left limit position. The workbench 51 is controlled by the position adjustment mechanism 54. When the right workbench position detection sensor 64 senses the right side of the workbench 51 (when the detection signal changes from 0 to 1), the workbench 51 no longer moves to the right, and the workbench 51 reaches its right limit position. The fabric needling platform 50 is provided with left and right limit positions in order to determine the safe working range of the workbench 51 (the horizontal working range of the workbench is 1000mm).

[0062] See attached Figure 1-6 The present invention also includes a method for needling a high-thickness flat fabric, using the high-thickness flat fabric needling machine with powdering function, comprising the following steps:

[0063] S1, setting parameters such as the total thickness of the fabric to be needled 7, the thickness increment of the fabric per needled pass, the lifting height of the needle punching mechanism, the initial position of powder sprinkling, the initial position of needling, the needling depth and the needling step amount;

[0064] S2, laying a unit layer of fabric to be needled in a foam fence 53 on a workbench 51, fixing the fabric on all sides with the foam fence 53, the layer is located at the right limit position of the workbench 51, and the initial position of the workbench 51 is set at the right limit position;

[0065] S3, the control system switches to the powdering mode, and then starts the equipment; the position adjustment mechanism 54 controls the workbench 51 to reach the powdering initial position from the initial position and the right limit position of the workbench, the powdering mechanism 40 starts to operate, the spray gun 46 sprays the functional powder filler, the third motor 41 drives the linear module 42 to move, the slider on the linear module 42 drives the spray gun 46 to move, the position adjustment mechanism 54 and the powdering mechanism 40 move together so that the functional powder filler is evenly sprayed on the fabric to be needled 7, after the functional powder filler is sprayed, the position adjustment mechanism 54 drives the workbench 51 to the designated needle punching initial position, and the equipment is temporarily stopped after the powdering is completed; a unit layer of fabric to be needled located in the foam fence 53 is laid on the upper surface of the fabric after the powdering, and the foam fence 53 is used to fix the fabric around; the control system switches to the needle punching mode, and prepares to start the needle punching mechanism 30;

[0066] S4, the first motor 21 of the lifting mechanism 20 drives the first screw 23 to rotate, and the first screw nut 24 transmits the motion to the needling mechanism 30, and the needling mechanism 30 starts to move downward along the needling direction from its upper limit position. During this period, the piston rod of the SDAJ adjustable cylinder 34 completes the output, pushes the support plate 35 and the needle plate 36 to drive the needle 37 to advance, and the working part of the needle 37 passes through the stripping plate 310 and is exposed under the action of the SDAJ adjustable cylinder 34. As the needling movement continues, the needle 3 7 pierces the fabric to be needled, and then the stripping plate 310 begins to contact the fabric to be needled and continues to press down. After reaching the target height of needling, the lifting mechanism 20 stops running and the needling mechanism 30 completes the downward needling movement; the piston rod of the SDAJ adjustable cylinder 34 is reset, and the support plate 35 and the needle plate 36 drive the needle 37 to retract. After the retraction is completed, the lifting mechanism 20 begins to lift upward along the needling direction. During this process, the stripping plate 310 leaves the surface of the needled fabric; after the needling mechanism 30 reaches the lifting height, a single needling is completed;

[0067] S5, the position adjustment mechanism 54 drives the workbench 51 to move to the left by a predetermined step amount, and when the needle-punched fabric 7 moves to the position of the next needling point, step S4 is repeated until the single-layer needling of the entire product is completed;

[0068] S6, after the single-layer needling is completed, the position adjustment mechanism 54 drives the workbench 51 back to its right limit position, and the equipment stops;

[0069] Steps S2 to S6 are repeated to perform needling of the next layer until the predetermined preform thickness is reached.

[0070] Although the preferred embodiments of the present invention are described above, the present invention is not limited to the above specific embodiments, which are merely illustrative and not restrictive. Under the guidance of the present invention, a person skilled in the art can make many forms without departing from the scope of the present invention and the claims. All of these belong to the protection scope of the present invention.

Claims

1. A high-thickness flat fabric needle-loom machine with powder-sprinkling function, characterized in that: It includes a frame, a lifting mechanism, a needling mechanism, a powder spreading mechanism, a fabric needling workbench and a position detection sensor; The frame includes a main frame and a needling guide device. The main frame is placed on a horizontal plane and is a cubic frame as a whole. A base for mounting a fabric needling platform is provided in the main frame. The needling guide device is installed on two parallel sides of the main frame. The needling guide device includes a first guide rod, a first linear bearing and a guide shaft support. The first linear bearing is arranged on the needling mechanism. After the first guide rod passes through the first linear bearing, both ends are fixedly connected to the guide shaft support. The guide shaft support is fixed on the main frame. The lifting mechanism includes a first motor, a planetary reducer and a first screw rod, wherein the first motor is a servo motor with a brake; the first motor is threadedly connected to the planetary reducer, and the first screw rod is fixedly connected to the output shaft of the planetary reducer through a coupling; The acupuncture mechanism comprises an SDAJ adjustable cylinder, a needle and a support rod. The acupuncture mechanism completes the acupuncture movement under the drive of the lifting mechanism through the acupuncture guide device; the piston rod of the SDAJ adjustable cylinder is output under the guidance of the second guide rod and the second linear bearing; the support rod is fixed under the top plate, and the end thereof is successively installed with a pressure sensor and a stripping plate, and the top plate is fixed with a first linear bearing; the clamping part of the needle is installed between the support plate and the needle plate, and the working part passes through the needle hole of the needle plate and is exposed; The powder spreading mechanism includes a third motor, a linear module, and a nozzle mounted on a slide of the linear module. The third motor drives the linear module to control the back and forth movement of the slide of the linear module to spread powder. The powder spreading mechanism is fixedly connected to the acupuncture mechanism, and moves along the acupuncture direction with the acupuncture mechanism to spread powder. The fabric needling platform comprises a workbench with a foam bottom felt fixed on the upper surface, the fabric to be needling is placed on the foam bottom felt, and the fabric to be needling is fixed by a foam fence around it; a plurality of sliders are arranged under the workbench, and the sliders are connected to the guide rails installed on the base; the workbench realizes automatic feeding of the fabric to be needling under the drive of the position adjustment mechanism.

2. A high-thickness flat fabric needle-looming machine with powder-sprinkling function according to claim 1, characterized in that: The main frame is composed of a first crossbeam and several other square tubes, and adjacent square tubes are connected by welding or screws; the base is welded by several square tubes and fixed to the main frame by screws; the upper side of the first crossbeam is fixed to the screw support frame by screws, and the upper side of the screw support frame is fixed to the reducer support frame by screws.

3. A high-thickness flat fabric needle-punching machine with powder-sprinkling function according to claim 1, characterized in that: The acupuncture mechanism also includes a screw nut mounting plate and a vertical plate; the two vertical plates are fixed on both sides below the screw nut mounting plate by screws, and the lower end surfaces of the vertical plates are fixedly connected to the top plate; the two SDAJ adjustable cylinders are respectively arranged on the outsides of the two vertical plates, and their cylinder bodies are fixedly connected to the vertical plates by screws, and the piston rods are fixedly connected to the support plates; the screw nut mounting plate is fixedly connected to the first screw through the first screw nut.

4. A high-thickness flat fabric needle-looming machine with powder-sprinkling function according to claim 1, characterized in that: The position adjustment mechanism includes a second motor and a second screw rod, the left end of the second screw rod is installed on the base, and the right end is connected to the output shaft of the second motor through a coupling; a second screw rod nut and a workbench are installed in the middle of the second screw rod, and the second screw rod nut is fixed on the workbench.

5. A high-thickness flat fabric needle-punching machine with powder-sprinkling function according to claim 4, characterized in that: The second motor is threadedly connected to the motor frame, the motor frame is fixed to the frame support by screws, and the frame support is fixed to the right side of the base; the right side of the second screw rod is installed on the motor frame, and the left end of the second screw rod is installed on the base by connecting with the screw rod support.

6. A high-thickness flat fabric needle-looming machine with powder-sprinkling function according to claim 1, characterized in that: The position detection sensor includes an upper acupuncture mechanism position detection sensor fixed on one side of the screw support frame, a lower acupuncture mechanism position detection sensor fixed on one side of the first beam, and a left workbench position detection sensor and a right workbench position detection sensor fixed on the left and right sides of the upper surface of the base.

7. A high-thickness flat fabric needle-looming machine with powder-sprinkling function according to claim 6, characterized in that: When the lifting mechanism drives the acupuncture mechanism to approach the upper acupuncture mechanism position detection sensor and reaches the detection distance, the upper acupuncture mechanism position detection sensor receives a signal, and the acupuncture mechanism reaches its upper limit position and no longer moves upward; when the lifting mechanism drives the acupuncture mechanism to approach the lower acupuncture mechanism position detection sensor and reaches the detection distance, the lower acupuncture mechanism position detection sensor receives a signal, and the acupuncture mechanism reaches its lower limit position and no longer moves downward.

8. The high-thickness flat fabric needle-looming machine with powder-sprinkling function according to claim 6, characterized in that: When the workbench is close to the left workbench position detection sensor and reaches the detection distance, the left workbench position detection sensor receives a signal, and the workbench reaches its left limit position and no longer moves to the left; when the workbench is close to the right workbench position detection sensor and reaches the detection distance, the right workbench position detection sensor receives a signal, and the workbench reaches its right limit position and no longer moves to the right.

9. The high-thickness flat fabric needle-looming machine with powder-sprinkling function according to claim 1, characterized in that: The foam bottom felt is fixed to the upper surface of the workbench by gluing, and the bottom of the foam fence is directly adhered to the foam bottom felt by double-sided adhesive.

10. A method for needling a high-thickness flat fabric, using the high-thickness flat fabric needling machine with powdering function as claimed in any one of claims 1 to 9, characterized in that: The following steps are involved: S1, setting the total thickness of the fabric to be needled, the thickness increase of the fabric per needled pass, the lifting height of the needle punching mechanism, the initial position of powder sprinkling, the initial position of needling, the needling depth and the needling step amount; S2, placing a unit layer of fabric to be needled in a foam fence on a workbench, and the initial position of the workbench is set at the right limit position; S3, the control system switches to the powdering mode, the position adjustment mechanism controls the workbench to reach the powdering initial position from the right limit position of the workbench; the powdering mechanism starts to operate, the spray gun sprays the functional powder filler, the third motor drives the linear module to move, and the slider on the linear module drives the spray gun to move; the position adjustment mechanism and the powdering mechanism move together so that the functional powder filler is evenly sprayed on the fabric to be needled; after the functional powder filler is sprayed, the position adjustment mechanism drives the workbench to the initial position of needle punching; a unit layer of fabric to be needled located in the foam fence is laid on the upper surface of the fabric after the powder is sprinkled; the control system switches to the needle punching mode and prepares to start the needle punching mechanism; S4, the first motor of the lifting mechanism drives the first screw to rotate, and the first screw nut transmits the movement to the needling mechanism. The needling mechanism starts to move downward along the needling direction from its upper limit position. During this period, the piston rod of the SDAJ adjustable cylinder completes the output, pushes the support plate and the needle plate to drive the needle to advance, and under the action of the SDAJ adjustable cylinder, the working part of the needle passes through the stripping plate and is exposed. As the needling movement continues, the needle pierces the fabric to be needling, and then the stripping plate begins to contact the fabric to be needling and continues to press down. After reaching the needling target height, the lifting mechanism stops running and the needling mechanism completes the downward needling movement; the piston rod of the SDAJ adjustable cylinder is reset, and the support plate and the needle plate drive the needle to retract. After the retraction is completed, the lifting mechanism begins to lift upward along the needling direction. During this process, the stripping plate leaves the surface of the needling fabric; after the needling mechanism reaches the lifting height, a single needling is completed; S5, the position adjustment mechanism drives the workbench to move to the left by a predetermined step amount, and when the needle-punched fabric moves to the position of the next needling point, step S4 is repeated until the single-layer needling of the entire product is completed; S6, after the single-layer needling is completed, the position adjustment mechanism drives the workbench back to its right limit position; Steps S2 to S6 are repeated to perform needling of the next layer until the predetermined preform thickness is reached.

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