A rapid shaping device and method for a composite material product

Abstract

The application relates to the technical field of rapid shaping of composite material products, in particular to a rapid shaping device and method for composite material products; the device comprises a workbench and a positioning module horizontally arranged on the workbench; a product base plate is clamped and positioned through the positioning module, and the product base plate is used for supporting a composite material product; an air cooling module is vertically arranged on the workbench through a support table and has a cooling end which is arranged opposite to the product base plate and is used for cooling the composite material product; four edges of the positioning module are respectively surrounded by edge cutting modules which are used for cutting flash of the composite material product; the application can automatically position and clamp the composite material product, keep pressure, edge, air cooling and automatic edge cutting, has high automation degree and does not need manual intervention; the application has high composite material processing effect and high efficiency.

Description

Technical Field

[0001] This invention relates to the field of rapid shaping of composite material products, specifically to a device and method for rapid shaping of composite material products. Background Technology

[0002] With the rapid development of the new energy vehicle industry in recent years, the demand for lightweight vehicles is increasing. Fiber-reinforced composite material products are in high demand. Compression molding is an economical and efficient molding method for composite material products, offering advantages such as repeatability, high efficiency, high dimensional accuracy, stable performance, and smooth surface finish requiring no secondary finishing. Its application in the automotive field is growing. During compression molding, composite material products are produced using a molding die. After molding, the product is removed and typically allowed to cool naturally to room temperature. However, because the temperature after demolding is still as high as 70-100℃, allowing it to cool in air often leads to warping and deformation, reducing the product's precision. This is especially problematic for products that require assembly with other parts, such as battery housings, where the flatness of the assembly surfaces is crucial. Conventional natural cooling cannot guarantee the flatness of these surfaces, resulting in gaps during final assembly, failing to meet assembly requirements, and posing safety hazards. Furthermore, trimming the small flash from the molded product is a time-consuming process.

[0003] For example, Chinese invention patent CN110774345A discloses a clamping device for cutting plastic sheets with high clamping stability, which includes a support plate. Fixed plates are welded to both sides of the top of the support plate. A gear and rack drive a limiting frame to move, thereby clamping the plastic sheet and enabling it to clamp plastic sheets of different widths. However, this clamping device only clamps the product and cannot guarantee the position of the holes. Furthermore, the clamping force is not adjustable and there is no feedback, which can cause some damage to the product. Another example is a cooling device for plastic sheet production disclosed in Chinese invention patent CN114571684A. This invention first cools the plastic sheet in a water-cooling box, then conveys it to the discharge port via a conveyor belt. A picker at the discharge port removes the plastic sheet and slides it into a second conveyor belt. Air-cooled fans on both sides of the second conveyor belt provide a second cooling. The air cooling after water cooling can accelerate the cooling process of the plastic sheet. However, this invention lacks a clamping mechanism and cannot prevent the product from deforming due to cooling. Summary of the Invention

[0004] I. Technical problems to be solved

[0005] This invention addresses the aforementioned deficiencies in existing technologies by proposing a rapid shaping device and method for composite material products. It solves the problem of how to shape composite material products after demolding, while also addressing how to improve production efficiency and ensure product quality.

[0006] II. Technical Solution

[0007] To solve the above-mentioned technical problems, the present invention provides a rapid shaping device for composite material products, including a worktable and a positioning module horizontally arranged on the worktable; a product pad is positioned and clamped by the positioning module, and the product pad is used to support the composite material product; an air-cooling module is vertically mounted on the worktable by a support platform and its cooling end is positioned facing the product pad to cool the composite material product; and cutting modules for cutting the burrs of the composite material product are respectively arranged around the four sides of the positioning module.

[0008] Preferably, the positioning module includes a slide table and crisscrossing grooves on the surface of the slide table; clamping blocks are slidably disposed in the grooves; multiple sets of clamping blocks are disposed on the slide table to limit and clamp the product pad and the composite material product placed on the support pad; the pressurizing module is vertically fixed on the support platform, and multiple sets of pressurizing modules are disposed on the top of the support platform in a rectangular array to press and fix the four sides of the composite material product respectively.

[0009] Preferably, the pressurization module includes a pressure plate cylinder, which is fixedly mounted in an elongated slide groove via a slider; the output shaft of the pressure plate cylinder passes through the support platform and is vertically positioned towards the worktable; the protruding pressure plate is horizontally fixed to the output end of the pressure plate cylinder via a double connecting plate.

[0010] Preferably, the air-cooled module is a cooling fan, and multiple cooling fans are provided, which are centrally embedded in the top of the support platform.

[0011] Preferably, the edge trimming module includes a burr trimming unit and a rounded corner trimming unit; four sets of burr trimming units are provided, and the four sets of burr trimming units are arranged in parallel on the four sides of the slide table; four sets of rounded corner trimming units are provided, and the four sets of rounded corner trimming units are arranged vertically on the top of the support table in a rectangular array.

[0012] Preferably, the flash trimming unit includes a linear reciprocating driver, which is arranged parallel to the long side of the slide table on one side; a servo motor is horizontally fixed to the output end of the linear reciprocating driver via a moving platform; and a grinding wheel head is coaxially fixed to the output shaft of the servo motor.

[0013] Preferably, the rounded corner trimming unit includes a flash cylinder, which is vertically fixed on the support platform and its output shaft passes through the support platform and is vertically oriented towards the worktable; the rounded corner blade is fixedly installed at the output end of the flash cylinder.

[0014] Preferably, a pressure sensor is also installed inside the product pad.

[0015] Preferably, a temperature sensor is also provided on the inner side of the product pad.

[0016] A rapid shaping method for composite material products includes the following steps:

[0017] S1: Power-on program initialization, device self-tests the status of electrical components, displays the values ​​of each temperature sensor and pressure sensor;

[0018] S2: Human-machine interface, setting the cylinder output pressure P and the required temperature T after the product is cooled; the initial value needs to be set on the first start, and the next start can default to the previous setting value.

[0019] S3: The air-cooling module cools the product temperature to T according to the setting. The control device automatically compares the temperature difference with the threshold ε2 to achieve temperature control.

[0020] S4: The pressurizing module presses the protruding pressure plate onto the product according to the settings. The control device automatically compares the pressure difference with the threshold ε1 to achieve pressure control.

[0021] S5: According to the required quality of the product, place the product on a flat product pad and cut off the small burrs around the product.

[0022] S6: According to the required quality of the product, accurately position the mounting holes of the product and ensure that the surface around the mounting holes is flat.

[0023] III. Beneficial Effects

[0024] Compared with existing technologies, this invention controls the clamping force during the product manufacturing process to ensure that the clamping device clamps the product edge with appropriate force without damaging the product. During clamping, it ensures that the protrusions enter the mounting holes, preventing deformation of the mounting holes and maintaining the flatness of the surrounding surfaces. When the device temperature or pressure becomes abnormal, an alarm signal is issued. The waste edge trimming unit and the rounded corner trimming unit work together to automatically remove the burrs around the perimeter of the composite material product. These are controlled by servo motors and cylinders, respectively, requiring no manual labor and completing the process automatically, intelligently, and quickly, reducing time consumption. Four sets of cooling fans are evenly installed on the top of the product, blowing air evenly onto the product surface to achieve uniform cooling and reduce deformation. The cooling process runs in parallel with the trimming process, shortening the processing cycle. Attached Figure Description

[0025] Figure 1 This is a three-dimensional view of a rapid shaping device for composite material products;

[0026] Figure 2 This is a front view of a rapid shaping device for composite material products;

[0027] Figure 3 This is a schematic diagram of the pressure module in a rapid shaping device for composite material products.

[0028] Figure 4 This is a schematic diagram of a product pad in a rapid shaping device for composite material products.

[0029] Figure 5 This is a cross-sectional view of the pressure structure in a rapid shaping device for composite material products.

[0030] Figure 6 This is a flowchart of a rapid shaping process for a composite material product rapid shaping device.

[0031] In the picture:

[0032] 1 represents the workbench;

[0033] 2 is the positioning module; 21 is the slide table; 22 is the slide groove; 23 is the clamping block; 24 is the pressurizing module; 241 is the pressure plate cylinder; 242 is the convex pressure plate; 25 is the slider;

[0034] 3 is the product pad; 31 is the pin; 32 is the pressure sensor; 33 is the temperature sensor;

[0035] 4 is the trimming module; 41 is the flash trimming unit; 411 is the linear reciprocating driver; 412 is the servo motor; 413 is the moving platform; 414 is the grinding wheel head; 42 is the rounded corner trimming unit; 421 is the flash cylinder; 422 is the rounded corner blade;

[0036] 5 represents the air-cooled module; 51 represents the cooling fan;

[0037] 6 is the support platform; 61 is the elongated oval groove. Detailed Implementation

[0038] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and should not be construed as limiting the scope of the invention.

[0039] Example 1:

[0040] like Figures 1 to 6 As shown, the rapid shaping device for composite material products in this embodiment includes a workbench 1 and a positioning module 2 horizontally arranged on the workbench 1; a product pad 3 is positioned and clamped by the positioning module 2, and the product pad 3 is used to support the composite material product; an air-cooling module 5 is vertically mounted on the workbench 1 via a support platform 6 and its cooling end is positioned directly opposite the product pad 3 to cool the composite material product; and cutting modules 4 for cutting the burrs of the composite material product are also arranged around the four sides of the positioning module 2.

[0041] When composite material products need to be processed, the staff first takes the product pad 3 corresponding to the current composite material product and places the product pad 3 on the positioning module 2 to fix and clamp the product pad 3. Then, the composite material product is placed on the product pad 3 and its assembly surface is made to abut against the product pad 3 and fixed by the pin 31, which is composed of a cylindrical pin and a diamond pin. Each long side of the product pad 3 is equipped with a pin, one is a cylindrical pin and the other is a diamond pin. After the composite material product is fixed, the air cooling module 5 and the edge trimming module 4 are turned on in sequence to perform air cooling and edge trimming on the composite material product.

[0042] like Figure 1 and Figure 2 As shown, the positioning module 2 includes a slide table 21 and crisscrossing grooves 22 on the surface of the slide table 21; clamping blocks 23 are slidably arranged in the grooves 22; multiple sets of clamping blocks 23 are arranged, and the multiple sets of clamping blocks 23 are slidably arranged on the slide table 21 to limit and clamp the product pad 3 and the composite material product placed on the support pad; the pressure module 24 is vertically fixed on the support platform 6, and multiple sets of pressure modules 24 are arranged in a rectangular array and vertically arranged on the top of the support platform 6 to press and solidify the four sides of the composite material product respectively.

[0043] Four sets of clamping blocks 23 are provided. The four sets of clamping blocks 23 are respectively set on both sides of the slider 25 along the long side of the slide table 21 and are respectively set close to the corner of the slide table 21. Each clamping block 23 is also provided with a locking element to lock the adjusted clamping block 23. When it is necessary to limit the clamping of the product pad 3 and the composite material product, the work only needs to adjust the appropriate distance between the four sets of clamping blocks 23 according to the length of the short side of the current product pad 3, and then place the product pad 3 within the distance and lock it on both sides by clamping blocks 23. After the two sides of the composite material product are limited and fixed, the pressure module 24 is started to work, and the four sides of the composite material product are pressed and fixed by multiple sets of pressure modules 24. The upper surface of the support table 6 is also provided with multiple sets of elongated oval slide grooves 61. The pressure module 24 is fixed in the elongated oval slide groove 61 by the slider 25 and can slide back and forth along the long side of the elongated oval slide groove 61 to adapt to product pads 3 of different sizes.

[0044] like Figure 1 and Figure 3As shown, the pressurization module 24 includes a pressure plate cylinder 241, which is fixedly mounted in an elongated groove 61 via a slider 25. The output shaft of the pressure plate cylinder 241 passes through the support platform 6 and is vertically positioned towards the worktable 1. The protruding pressure plate 242 is horizontally fixed to the output end of the pressure plate cylinder 241 via a double connecting plate 243. The pressure plate cylinder 241 pushes the protruding pressure plate 242 downward to ensure the flatness of the mounting hole and its surrounding plane of the composite material product, thus preventing the edge of the composite material product from warping. Furthermore, one pressure plate cylinder 241 can control the operation of two sets of protruding pressure plates 242, further reducing the cost of the device. When the convex pressure plate 242 is pressed down, its convex points will be inserted into the mounting holes of the composite material product, thereby preventing deformation of the mounting holes. Through the cooperation of the convex pressure plate 242 and the product pad 3, the structure is simple, the clamping is quick, and it is convenient to place and remove the product. It also ensures the clamping force and the force is evenly distributed in the clamping part. At the same time, with the pressure sensor 32 built into the product pad 3, the actual pressure value is monitored in real time to ensure that the force on the ring edge of the composite material product is even, so that the product performance reaches the best. The convex points in the middle of the convex pressure plate 242 ensure that the mounting holes on the ring edge of the composite material product are not deformed when clamping, and at the same time ensure the flatness of the mounting surface.

[0045] like Figure 2 As shown, the air-cooling module 5 is a cooling fan 51. Multiple cooling fans 51 are provided, and multiple cooling fans 51 are centrally embedded in the top of the support platform 6. At least four cooling fans 51 are provided, and the four cooling fans 51 are embedded in the top of the support platform 6 in a rectangular array. When it is necessary to cool the composite material product, the operator can connect an external power supply to drive the cooling fans 51 to work. The cooling fans 51 emit air and conduct it towards the composite material product, thereby achieving the cooling of the composite material product.

[0046] The edge trimming module 4 includes a burr trimming unit 41 and a rounded corner trimming unit 42. There are four sets of burr trimming units 41, which are arranged in parallel on the four sides of the slide table 21. There are four sets of rounded corner trimming units 42, which are arranged vertically on the top of the support table 6 in a rectangular array.

[0047] Four sets of flash trimming units 41 are set parallel to the four sides of the positioning module 2, respectively, to cut off the flash on the four sides of the composite material product one by one; correspondingly, four sets of rounded corner trimming units 42 arranged in a rectangular array on the top of the support platform 6 are used to uniformly cut off the four rounded corner flashes of the composite material product.

[0048] like Figure 1 and Figure 2As shown, the trimming unit 41 includes a linear reciprocating driver 411, which is arranged parallel to the long side of the slide table 21 on one side; a servo motor 412 is horizontally fixed to the output end of the linear reciprocating driver 411 via a moving platform 413; and a grinding wheel head 414 is coaxially fixed to the output shaft of the servo motor 412.

[0049] The linear reciprocating driver 411 is a lead screw slide. When it is necessary to remove the flash on one side of the short side of the composite material product, the external power supply is first connected to drive the servo motor 412 to work. The output shaft of the servo motor 412 rotates, which drives the grinding wheel head 414 to rotate synchronously. Then, the linear reciprocating driver 411 is driven to work, which drives the servo motor 412 to move horizontally along the short side of the composite material product until the flash on one side of the short side of the composite material product is removed.

[0050] like Figure 2 As shown, the rounded corner trimming unit 42 includes a flash cylinder 421, which is vertically fixed on the support platform 6 and its output shaft passes through the support platform 6 and is vertically oriented towards the worktable 1; the rounded corner blade 422 is fixedly installed at the output end of the flash cylinder 421 and is coaxially arranged with the corner of the composite material product to be trimmed, thereby ensuring that when the rounded corner blade 422 descends vertically under the drive of the flash cylinder 421, it can completely remove the flash at the rounded corner of the composite material product.

[0051] The product pad 3 is also equipped with a pressure sensor 32 and a temperature sensor 33. The pressure sensor 32 is used to detect the pressure of the composite material product during the clamping process in real time, and the temperature sensor 33 is used to detect the temperature of the composite material product in real time. The temperature of the composite material product is compared with the preset temperature and fed back to the temperature regulation and control module to adjust the output air volume of the fan. The temperature sensor 33 measures the product temperature to achieve human-machine interaction. At the same time, it works with four sets of cooling fans 51 to blow air for cooling. The airflow covers the entire surface of the composite material product. The air volume of the fan is adjusted according to the temperature to achieve rapid cooling and high efficiency and energy saving.

[0052] Example 2:

[0053] This embodiment of a rapid shaping method for composite material products includes the following steps:

[0054] S1: Power-on program initialization, device self-tests the status of electrical components, displays the values ​​of each temperature sensor 33 and pressure sensor 32;

[0055] S2: Human-machine interface, setting the cylinder output pressure P and the required temperature T after the product is cooled; the initial value needs to be set on the first start, and the next start can default to the previous setting value.

[0056] S3: The air-cooled module 5 cools the product temperature to T according to the setting. The control device automatically compares the temperature difference with the threshold ε2 to achieve temperature control.

[0057] S4: The pressurizing module 24 presses the protruding pressure plate 242 onto the product according to the setting. The control device automatically compares the pressure difference with the threshold ε1 to achieve pressure control.

[0058] S5: According to the required quality of the product, place the product on a flat product pad 3 and cut off the small burrs around the product.

[0059] S6: According to the required quality of the product, accurately position the mounting holes of the product and ensure that the surface around the mounting holes is flat.

[0060] This application can automate the positioning, clamping, pressure holding, air cooling, and automatic edge cutting of composite material products. It has a high degree of automation and requires no manual intervention; it also has high processing effect and high efficiency for composite materials.

[0061] Taking battery box products as an example, the working process and steps are explained as follows:

[0062] STEP1 Product Positioning: Place the flat surface of the product on the positioning pad. Position the product by using one side of the pad and two pins mounted on the pad, along with the flat surface and holes of the product. One of the pins is a chamfered pin, which restricts the six degrees of freedom of the battery box.

[0063] STEP2 Force Control Clamping: The pressure sensor measures the pressure P1 and converts it into clamping pressure P; then the cylinder output force is set to press the protruding pressure plate onto the ring edge of the composite material product, and the protrusion correctly enters the mounting hole of the ring edge.

[0064] STEP3 Pressure Comparison: The pressure sensor measures the actual pressure P2 and compares |P2-P| with the relative pressure difference threshold ε1. If it is less than ε1, proceed to STEP4; otherwise, the buzzer will sound, prompting you to reset the cylinder output force.

[0065] STEP4 Air Cooling: After clamping is completed, the temperature sensor measures the surface temperature T1 of the composite material product and converts it into the relative temperature T of 40°C for the composite material product; then the four cooling fans at the top start to air cool the composite material product. If T1 ≤ temperature T3, the cooling fans blow air normally; if T1 > temperature T3, the fan speed is increased.

[0066] STEP5 Temperature Comparison: After a period of time t of air cooling, the fan stops rotating. Then, the temperature sensor measures the surface temperature T2 of the composite material product again. Compare |T2-T| with the relative temperature difference threshold ε2. If it is less than ε2, the air cooling step is complete; otherwise, return to STEP4.

[0067] STEP 6: Remove flash: Power on, motor starts, grinding wheels on the moving platform on all four sides of the composite material product begin to rotate. At the same time, the moving platform drives the grinding wheels forward with the linear reciprocating drive to remove the flash around the composite material product. When the displacement sensor reaches the set value, the motor reverses and the moving platform resets. Then, the four sets of flash cylinders at the top simultaneously press the rounded corner blades down to cut off the rounded corner flash. STEP 6 is performed in parallel with STEP 4.

[0068] Pressure sensor control method: The device is not pressed or clamped at the beginning. The pressure sensor can first measure the pressure difference. After clamping is completed, the pressure is measured and the pressure difference is measured.

[0069] Temperature sensor control method: The device does not blow air at first, the thermometer measures the temperature difference, the fan blows air, and after a period of time, the temperature difference is measured again.

Claims

1. A rapid shaping device for composite material products, the rapid shaping device for composite material products comprising a worktable (1) and a positioning module (2) horizontally arranged on the worktable (1), characterized in that: The product pad (3) is positioned and clamped by the positioning module (2), and the product pad (3) is used to support the composite material product; the air cooling module (5) is vertically mounted on the workbench (1) by the support platform (6) and the cooling end is set directly opposite the product pad (3) to cool the composite material product; the four sides of the positioning module (2) are also respectively surrounded by the cutting edge module (4) for cutting the burrs of the composite material product. The positioning module (2) includes a slide table (21) and a slide groove (22) that is crisscrossed on the surface of the slide table (21); a clamping block (23) is slidably arranged in the slide groove (22); multiple sets of clamping blocks (23) are provided, and multiple sets of clamping blocks (23) are slidably arranged on the slide table (21) to limit and clamp the product pad (3) and the composite material product placed on the product pad (3); the pressure module (24) is vertically fixed on the support platform (6), and multiple sets of pressure modules (24) are provided, and multiple sets of pressure modules (24) are arranged in a rectangular array vertically on the top of the support platform (6) to press the four sides of the composite material product respectively; The pressurization module (24) includes a pressure plate cylinder (241), which is fixedly installed in an elongated slide groove (61) by a slider (25); the output shaft of the pressure plate cylinder (241) passes through the support platform (6) and is set vertically toward the worktable (1); the protruding pressure plate (242) is horizontally fixed at the output end of the pressure plate cylinder (241) by a double connecting plate (243).

2. The rapid shaping device for composite material products according to claim 1, characterized in that, The air-cooled module (5) is a cooling fan (51). Multiple cooling fans (51) are provided, and multiple cooling fans (51) are centrally embedded on the top of the support platform (6).

3. The rapid shaping device for composite material products according to claim 1, characterized in that, The edge trimming module (4) includes a burr trimming unit (41) and a rounded corner trimming unit (42); the burr trimming unit (41) is provided in four groups, and the four groups of burr trimming units (41) are arranged in parallel on the four sides of the slide table (21); the rounded corner trimming unit (42) is provided in four groups, and the four groups of rounded corner trimming units (42) are arranged vertically on the top of the support platform (6) in a rectangular array.

4. The rapid shaping device for composite material products according to claim 3, characterized in that, The trimming unit (41) includes a linear reciprocating driver (411), which is arranged parallel to the long side of the slide (21) on one side of the slide (21); a servo motor (412) is horizontally fixed to the output end of the linear reciprocating driver (411) via a moving platform (413); and a grinding wheel head (414) is coaxially fixed to the output shaft of the servo motor (412).

5. The rapid shaping device for composite material products according to claim 3, characterized in that, The rounded corner trimming unit (42) includes a trimming cylinder (421), which is vertically fixed on the support platform (6) and the output shaft of the trimming cylinder (421) passes through the support platform (6) and is vertically facing the worktable (1); the rounded corner blade (422) is fixedly installed at the output end of the trimming cylinder (421).

6. The rapid shaping device for composite material products according to claim 1, characterized in that, A pressure sensor (32) is also provided inside the product pad (3).

7. The rapid shaping device for composite material products according to claim 1, characterized in that, A temperature sensor (33) is also provided on the inner side of the product pad (3).

8. A method for a rapid shaping device for composite material articles according to any one of claims 1-7, comprising the following steps: S1: Start-up program initialization, device self-tests the status of electrical components, displays the values ​​of each temperature sensor (33) and pressure sensor (32); S2: Human-machine interface, setting the cylinder output pressure P and the required temperature T after the product is cooled; the initial value needs to be set on the first start, and the next start will default to the previous setting value. S3: The air-cooled module (5) cools the product temperature to T according to the setting. The control device automatically compares the temperature difference with the threshold ε2 to achieve temperature control. S4: The pressurizing module (24) presses the protruding pressure plate (242) onto the product according to the setting. The control device automatically compares the pressure difference with the threshold ε1 to achieve pressure control. S5: According to the required quality of the product, place the product on a high and flat product pad (3) and cut off the small burrs around the product. S6: According to the required quality of the product, accurately position the mounting holes of the product and ensure that the surface around the mounting holes is flat.

Images