Composite material fiber placement path estimation method, device, system, and medium

Abstract

The application provides a composite material fiber laying path estimation method, device, system and medium, comprising the following steps: empty running recording step: starting the fiber laying machine and making the fiber laying head of the fiber laying machine in an empty running state, collecting the actual fiber laying track of the fiber laying head in the empty running stage in real time, and importing the actual track data corresponding to the actual fiber laying track into a data analysis system; comparative analysis step: comparing and analyzing the actual track data and the theoretical track data in the data analysis system; judging whether the actual track data exceeds the allowable deviation, repeating the empty running recording step until the actual deviation of the actual track data is not greater than the allowable deviation. The application can judge whether the composite material component has quality problems in advance, reduce the waste of composite materials, and improve the component manufacturing efficiency.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of composite material manufacturing, and in particular to a composite material fiber laying path estimation method, device, system and medium. BACKGROUND

[0002] Composite materials are a clear development trend for modern large aircraft main structure materials. As automatic tape laying machines and automatic fiber laying machines for laying and manufacturing composite whole components, they have developed rapidly and are widely used, becoming one of the key equipment for modern large aircraft manufacturing, and their application is increasingly perfect.

[0003] Modern large aircraft main structure design and manufacturing has increasingly adopted composite whole components, and has developed from relatively simple composite components such as large wing spars and skin wall plates to large aircraft whole barrel body sections and small and medium aircraft whole barrel bodies, and the component size is getting larger and the overall structure is getting more complex. Traditional automatic fiber winding machines (AFW) and automatic tape laying machines (ATL) have been difficult to meet the actual application needs of aircraft manufacturing. Therefore, the winding function of the AFW machine and the layering, compaction, cutting and re-laying processing capacity of the ATL machine are integrated on one device, which is a high-end automatic fiber laying machine (AFP).

[0004] However, the fiber laying / tape laying equipment has complex control logic and mechanical structure, and in application, the actual fiber laying path may be different from the planned path, that is, the fiber laying path deviation occurs. Such deviation is difficult to be directly recorded or recognized by the equipment system. Once the allowable deviation is exceeded, the product quality will be directly affected. For example, when manufacturing a wall plate, the fiber laying head causes the gap to become larger and the lap joint problem due to shaft deflection, thereby causing triangular gaps or long strip-shaped gaps to be formed.

[0005] The existing solution is usually to indirectly monitor / evaluate the fiber laying result by manual judgment. The disadvantage is that the above solution can only be applied in the actual fiber laying process. However, monitoring in the actual fiber laying process has certain limitations, including:

[0006] Firstly, the path deviation is often related to the fiber laying path planning or the equipment motion system, and once it occurs, the laying path needs to be re-planned or the equipment needs to be corrected, which is difficult to solve quickly. In addition, finding problems in the actual laying process will often cause material waste.

[0007] Secondly, problems cannot be found before laying, and repeated tests are required, which is time-consuming and costly.

[0008] The existing Chinese patent (publication number: CN113176265A) discloses a composite material automatic fiber placement lap joint and gap defect on-machine detection system and method, which fixes a line laser sensor to the end placement head of a composite material automatic fiber placement machine to meet the urgent demand for defect detection in the composite material automatic fiber placement process. However, this method can only be applied in the actual fiber placement process, and still has the above-mentioned two shortcomings. SUMMARY

[0009] In view of the above-mentioned shortcomings of the prior art, the technical problem to be solved by the present application is to provide a composite material fiber placement path estimation method, device, system and medium, which can pre-judge whether the composite material component has quality problems, reduce the waste of composite materials, and improve the manufacturing efficiency of the component.

[0010] In order to solve the above technical problems, the present application provides a composite material fiber placement path estimation method, comprising the following steps:

[0011] Empty running recording step: starting the fiber placement machine and making the fiber placement head of the fiber placement machine in an empty running state, collecting the actual fiber placement track of the fiber placement head in the empty running stage in real time, and importing the actual track data corresponding to the actual fiber placement track into a data analysis system;

[0012] Comparative analysis step: comparing and analyzing the actual track data and the theoretical track data in the data analysis system; judging whether the actual track data exceeds the allowable deviation, if not, it means that the actual fiber placement track is consistent with the preset planning track, and the empty running state of the fiber placement head is switched to the placement state; if yes, it means that the actual fiber placement track is inconsistent with the preset planning track, the design strategy of the fiber placement track or the structure state of the fiber placement machine is adjusted and optimized, and the empty running recording step is repeated until the actual deviation of the actual track data is not greater than the allowable deviation.

[0013] Preferably, the composite material fiber placement path estimation method further comprises a program preparation step: importing a preset fiber placement program into the control system of the fiber placement machine.

[0014] Preferably, the empty running recording step further comprises: using an optical tracker to collect the actual fiber placement track of the fiber placement head in real time.

[0015] Preferably, the tool center point of the fiber placement head is calibrated; a target tracked by the optical tracker is arranged on the fiber placement head, and the spatial relationship between the target and the tool center point is calibrated.

[0016] Preferably, the actual track data collected by the optical tracker is transmitted to the upper computer.

[0017] Preferably, a track analysis program is configured on the upper computer, and the track analysis program is used for out-of-tolerance judgment and analysis of the actual track data and the theoretical track data.

[0018] The application further provides a fiber laying quality estimation device, comprising:

[0019] An empty running recording module is used to execute the empty running recording step;

[0020] A comparative analysis module is used to execute the comparative analysis step.

[0021] The application further provides a fiber laying path estimation system, comprising:

[0022] A host computer comprises a memory and a processor, wherein the memory is used to store a computer program, and the processor is used to run the computer program stored in the memory to execute the composite material fiber laying path estimation method;

[0023] A data collector is in communication connection with the host computer;

[0024] An auxiliary tool with multiple targets is arranged on the fiber laying head.

[0025] A camera is in communication connection with the data collector, and the camera is used to capture the position information of the targets.

[0026] Preferably, the auxiliary tool comprises a support, and targets are arranged on the branch ends of different orientations of the support.

[0027] The application further provides a computer readable storage medium, wherein the computer readable storage medium stores a computer program, and the computer program is run by a processor to realize the composite material fiber laying path estimation method.

[0028] As described above, the method, apparatus, system, and medium for predicting the composite material fiber placement path of the present invention have the following beneficial effects: The main innovation of the prediction method lies in two steps: The first step, the idle run recording step: Start the fiber placement machine and make the fiber placement head of the machine idle run, collect the actual fiber placement trajectory of the fiber placement head in real time during the idle run stage, and import the actual trajectory data corresponding to the actual fiber placement trajectory into the data analysis system; it should be noted that the fiber placement head needs to idle run for at least one whole layup, and the actual trajectory data of the fiber placement head is continuously and in real time recorded by imaging technology; The second step, the comparative analysis step: First, a data analysis system needs to be configured, and ideal theoretical trajectory data is pre-stored in the data analysis system; then, the theoretical trajectory data is retrieved in the data analysis system. This serves as the standard data for comparing actual trajectory data. Furthermore, the actual trajectory data and theoretical trajectory data at each location are compared and analyzed one by one. Next, it is determined whether the actual trajectory data exceeds the allowable deviation. If not, it indicates that the actual filament placement trajectory is consistent with the preset planned trajectory, and the filament placement head is switched from idle running to laying state, thus forming a high-quality composite material component. If so, it indicates that the actual filament placement trajectory is inconsistent with the preset planned trajectory, which will lead to defects such as gaps in the final formed composite material component. Then, the design strategy of the filament placement trajectory or the structural state of the filament placement machine is adjusted and optimized. Finally, the above idle running and data collection steps are repeated until the actual deviation of the actual trajectory data is not greater than the allowable deviation, thereby ensuring the high quality of the final formed composite material component. Therefore, the composite material filament placement path prediction method of the present invention can predict in advance whether quality problems will occur in composite material components, reduce composite material waste, and improve component manufacturing efficiency. Attached Figure Description

[0029] Figure 1 The flowchart shown is a method for predicting the fiber placement path of composite materials according to the present invention;

[0030] Figure 2 This is a usage status diagram of the wire placement path prediction system.

[0031] Component designation explanation

[0032] 1. Thread laying head

[0033] 2 Targets

[0034] 3. Host computer

[0035] 4. Data Acquisition Unit

[0036] 5 cameras

[0037] 6 supports Detailed Implementation

[0038] The present application will be described in detail by specific embodiments, and other advantages and effects of the present application can be easily understood by those skilled in the art from the disclosure of the specification.

[0039] It should be understood that the structures, proportions, sizes, etc. shown in the drawings attached to the specification are only used to illustrate the disclosure and to facilitate understanding and reading by those skilled in the art, and are not intended to limit the conditions under which the present application can be implemented, and therefore do not have technical significance. Any modification of the structure, change of the proportional relationship, or adjustment of the size, without affecting the effects and purposes that can be achieved by the present application, should still fall within the scope of the technology disclosed by the present application. At the same time, the terms such as "upper", "lower", "left", "right", "middle" and "one" used in the specification are only for the purpose of clear understanding, and are not intended to limit the scope of the present application, and the change or adjustment of the relative relationship without substantial change of the technical content is also considered as the scope of the present application.

[0040] As shown in Figure 2 The present application has a filament placement head 1 for laying up a prepreg (usually a prepreg filament or a prepreg tape) on a mold surface to form a composite component. The forming quality of the composite component directly affects the overall performance of the aircraft or spacecraft, so the composite component is an important indicator for measuring the advancement of the aircraft or spacecraft, and even the aviation manufacturing level of a country. The composite component is usually formed by layer-by-layer stacking of carbon fiber sheets on a curved mold, and each layer usually has its own fiber laying direction and its own laying range to meet the design requirements for structural performance. For each layer, the filament placement head lays a plurality of carbon fiber tows side by side to form a tow tape according to the laying angle, the layer boundary and the pre-planned three-dimensional trajectory of the current layer, so as to form a complete current layer. After a layer is laid, the above-mentioned filament placement head is automatically driven by a numerical control motion system to lay the tow tape on the previous layer according to the laying information such as the three-dimensional trajectory of each tow tape in the next layer, so as to complete the next layer.

[0041] However, in the actual filament laying process, the actual filament laying trajectory of the filament placement head 1 may deviate from the pre-planned trajectory to some extent, resulting in the occurrence of gap defects.

[0042] In order to pre-evaluate whether the above-mentioned filament placement head 1 can form a good quality composite component, as shown in Figure 1 The present application provides a method for estimating the filament laying path of a composite material, comprising the following steps:

[0043] The empty running recording step: starting the filament winding machine and making the filament head 1 of the filament winding machine in an empty running state, recording the actual filament path of the filament head 1 in the empty running stage in real time, and importing the actual path data corresponding to the actual filament path into the data analysis system;

[0044] The comparative analysis step: comparing and analyzing the actual path data and the theoretical path data in the data analysis system; judging whether the actual path data exceeds the allowable deviation, if not, indicating that the actual filament path is consistent with the preset planning path, and switching the empty running state of the filament head 1 to the laying state; if yes, indicating that the actual filament path is inconsistent with the preset planning path, adjusting and optimizing the design strategy of the filament path or the structure state of the filament winding machine, and repeating the above empty running recording step until the actual deviation of the actual path data is not greater than the allowable deviation.

[0045] In the present application, the main innovation of the estimation method is in two steps: the first step, the empty running recording step: starting the filament winding machine and making the filament head 1 of the filament winding machine in an empty running state, recording the actual filament path of the filament head 1 in the empty running stage in real time, and importing the actual path data corresponding to the actual filament path into the data analysis system; it should be noted that the filament head 1 needs to run empty at least one whole layer, and the actual path data of the filament head 1 is recorded continuously and in real time by image technology means; the second step, the comparative analysis step: first, a data analysis system needs to be configured, and the ideal theoretical path data is pre-stored in the data analysis system; then, the theoretical path data is called in the data analysis system as the comparison standard data of the actual path data; further, the actual path data and the theoretical path data of each position are compared and analyzed one by one; then, it is judged whether the actual path data exceeds the allowable deviation, if not, indicating that the actual filament path is consistent with the preset planning path, and the empty running state of the filament head 1 is switched to the laying state, thereby forming a good quality composite material component; if yes, indicating that the actual filament path is inconsistent with the preset planning path, which will cause the finally formed composite material component to have a defect problem similar to a gap; then, the design strategy of the filament path or the structure state of the filament winding machine is adjusted and optimized, for example, adjusting the regional division in the filament path design, redesigning the filament path of each layer, for example, with the application of equipment, the position of each axis of the filament head drifts, the trajectory error gradually increases, at this time the equipment is calibrated, for example, the deformed tooling is repaired; finally, the above empty running recording step is repeated until the actual deviation of the actual path data is not greater than the allowable deviation, thereby ensuring that the finally formed composite material component has good quality.

[0046] Therefore, the composite material filament winding path estimation method of the present application can judge whether the composite material component has a quality problem in advance, reduce the waste of composite materials, and improve the manufacturing efficiency of the component.

[0047] In order to make the above-mentioned fiber placement head 1 run empty, the above-mentioned composite material fiber placement path estimation method further comprises a program preparation step: importing a preset fiber placement program into the control system of the fiber placement machine.

[0048] In order to improve the convenience of information collection, the above-mentioned empty running recording step further comprises: using an optical tracker to collect the actual fiber placement trajectory of the fiber placement head 1 in real time.

[0049] In order to simplify the fiber placement head 1, a point is used to represent the entire fiber placement head 1, and the tool center point (tool center point is referred to as TCP) of the above-mentioned fiber placement head 1 is calibrated; in order to facilitate coordinate data conversion, a target 2 tracked by the optical tracker is arranged on the fiber placement head 1, and the spatial relationship between the target 2 and the tool center point is calibrated.

[0050] In order to store, retrieve and process the above-mentioned actual trajectory data, the actual trajectory data collected by the optical tracker is transmitted to the host computer 3.

[0051] In order to automatically analyze whether the actual fiber placement trajectory is consistent with the preset planned trajectory, the host computer 3 is configured with a trajectory analysis program, and the trajectory analysis program is used for out-of-tolerance judgment analysis of the actual trajectory data and the theoretical trajectory data.

[0052] The application also provides a fiber placement quality estimation device, comprising:

[0053] An empty running recording module, the empty running recording module is used to execute the above-mentioned empty running recording step;

[0054] A comparative analysis module, the comparative analysis module is used to execute the above-mentioned comparative analysis step.

[0055] The application also provides a fiber placement path estimation system, comprising:

[0056] A host computer 3, the host computer 3 comprises a memory and a processor, wherein the memory is used to store a computer program, and the processor is used to run the computer program stored in the memory to execute the above-mentioned composite material fiber placement path estimation method;

[0057] A data collector 4, the data collector 4 is communicatively connected to the host computer 3;

[0058] An auxiliary tool with a plurality of targets 2, the auxiliary tool is arranged on the fiber placement head 1;

[0059] A camera 5, the camera 5 is communicatively connected to the data collector 4, and the camera 5 is used to capture the position information of the target 2.

[0060] The overall structure of the fiber placement path estimation system of the application is simple, the layout is reasonable, and the estimation efficiency of the composite material fiber placement path is improved.

[0061] In order to capture the position information of the target 2 by the camera 5 when the filament laying head 1 changes the position, the auxiliary tool comprises a support 6, and the support 6 is provided with the target 2 on the branch end of different orientations. Specifically, the support 6 comprises a main branch, one end of the main branch is fixed on the side wall of the roller frame of the filament laying head 1, and the other end of the main branch is divided into a plurality of branch rods, and the free end of each branch rod is clamped with one target 2, and the target 2 can be a light-emitting ball or a reflective ball. As shown in Figure 2 the figure, the number of targets 2 is three, and the number of cameras 5 is four, of course, the number of targets 2 and the number of cameras 5 can be set arbitrarily according to the field conditions and actual needs.

[0062] The application further provides a computer readable storage medium, and the computer readable storage medium is stored with a computer program, and the computer program is run by a processor to realize the composite material filament laying path estimation method.

[0063] In summary, the application can judge whether the composite material component has quality problems in advance, reduce the waste of composite materials, and improve the manufacturing efficiency of the component. Therefore, the application effectively overcomes the shortcomings of the prior art and has high industrial utilization value.

[0064] The above embodiments only exemplarily illustrate the principles and effects of the application, and are not used to limit the application. Any person skilled in the art can modify or change the above embodiments without departing from the spirit and scope of the application. Therefore, all equivalent modifications or changes completed by those skilled in the art without departing from the spirit and technical thought of the application should be covered by the claims of the application.

Claims

1. A method for predicting the fiber placement path of composite materials, characterized in that, Includes the following steps: Program preparation steps: Import the preset filament placement program into the control system of the filament placement machine; No-load recording steps: Start the filament placing machine and put the filament placing head (1) of the filament placing machine in the no-load state. Real-time acquisition of the actual filament placing trajectory of the filament placing head (1) during the no-load stage, and import the actual trajectory data corresponding to the actual filament placing trajectory into the data analysis system. Among them, the actual filament placing trajectory of the filament placing head (1) is acquired in real time using an optical tracker. Comparative analysis steps: In the data analysis system, compare and analyze the actual trajectory data and the theoretical trajectory data; determine whether the actual trajectory data exceeds the allowable deviation. If not, it means that the actual filament placement trajectory is consistent with the preset planned trajectory. Switch the idling state of the filament placement head (1) to the placement state. If yes, it means that the actual filament placement trajectory is inconsistent with the preset planned trajectory. Adjust and optimize the design strategy of the filament placement trajectory or the structural state of the filament placement machine. Repeat the idling data collection steps until the actual deviation of the actual trajectory data is not greater than the allowable deviation.

2. The method for predicting the fiber placement path of composite materials according to claim 1, characterized in that: The tool center point of the filament placement head (1) is calibrated; a target (2) is set on the filament placement head (1) and tracked by an optical tracker, and the spatial relationship between the target (2) and the tool center point is calibrated.

3. The method for predicting the fiber placement path of composite materials according to claim 2, characterized in that: The actual trajectory data collected by the optical tracker is transmitted to the host computer (3).

4. The method for predicting the fiber placement path of composite materials according to claim 3, characterized in that: The host computer (3) is equipped with a trajectory analysis program, which is used to perform error judgment analysis on the actual trajectory data and the theoretical trajectory data.

5. A device for predicting the quality of fiber placement, characterized in that, The method for predicting the composite fiber placement path as described in any one of claims 1 to 4 includes: The no-load acquisition module is used to execute the no-load acquisition steps. The comparison analysis module is used to perform the comparison analysis steps.

6. A fiber placement path prediction system, characterized in that, include: The host computer (3) includes a memory and a processor, wherein the memory is used to store computer programs and the processor is used to run the computer programs stored in the memory to perform the method for estimating the composite material fiber laying path as described in any one of claims 1 to 4. Data acquisition unit (4), the data acquisition unit (4) is connected to the host computer (3); An auxiliary tool with multiple targets (2) is located at the wire laying head (1). Camera (5) is connected to data acquisition unit (4) and is used to capture the position information of target (2).

7. The fiber placement path prediction system according to claim 6, characterized in that: The auxiliary tool includes a support (6), and targets (2) are provided on the branch ends of the support (6) in different orientations.

8. A computer-readable storage medium storing a computer program thereon, characterized in that: The computer program, when run by a processor, implements the method for predicting the composite material fiber placement path as described in any one of claims 1 to 4.

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