An induction welding tip for thermoplastic composite truss in-orbit folding deployment assembly and a welding method thereof

Abstract

The application discloses an inductive welding end for thermoplastic composite truss in-orbit folding expansion assembly and a welding method thereof, and relates to the technical field of aerospace. The application solves the problem that the space utilization rate is not high during launching of the existing foldable large space truss, and the rigidity and precision requirements of the large space truss cannot be ensured. The inductive welding end comprises a motion and loading unit, a welding head unit and an alternating magnetic field generating unit. The motion and loading unit comprises a motion assembly, a loading assembly and a sensor assembly. The motion assembly is used for forming a welding end together with the welding head unit. The loading assembly is used for driving the motion assembly to move up and down, and is also used for driving the motion assembly to load pressure to the welding head unit. The sensor assembly is used for detecting the pressure change of the welding head unit. The alternating magnetic field generating unit is used for converting electromagnetic energy into heat energy, and is also used for transferring the heat energy to the welding head unit. The application is suitable for in-orbit folding expansion assembly of large space thermoplastic composite truss in the field of aerospace.

Description

Technical Field

[0001] This invention relates to the field of aerospace technology. Background Technology

[0002] Currently, large space trusses used in aerospace are generally constructed using a ground-based manufacturing and on-orbit unfolding method due to their excessively large envelope size. However, this construction method is not suitable for the construction of large space trusses due to factors such as rocket envelope size, hypergravity launch, and reliability.

[0003] Large space trusses, such as hexagonal two-dimensional trusses, triangular prisms, and three-dimensional trusses commonly used in the aerospace field, can now be assembled in orbit using one-dimensional truss beam materials required to form the large space truss structure through an in-orbit bending and expansion assembly process. However, the in-orbit bending and expansion assembly process still faces the following challenges:

[0004] 1. Large space trusses must be assembled with a certain level of precision during the expansion process. Any part that does not meet the precision requirements may cause the entire truss structure to malfunction.

[0005] 2. To achieve on-orbit bending and expansion assembly, the monitoring and adjustment of key parameters during the welding process are highly demanding, and the accuracy of key parameters during the welding process must be guaranteed.

[0006] 3. To avoid interference during bending, the excess parts of the web members of the one-dimensional truss beam to be bent need to be cut off to make room for truss bending and welding machine operation. Therefore, a cutting tool with high cutting precision is required.

[0007] 4. The bending of trusses involves various bending forms, resulting in different member configurations at different welding positions during the bending process. Therefore, various weld head configurations are required during the welding process. Summary of the Invention

[0008] This invention addresses the problems of low space utilization and inability to ensure the rigidity and precision requirements of existing large-scale space trusses during launch.

[0009] To achieve the above objectives, the present invention provides the following solution:

[0010] This invention provides an induction welding end for on-orbit bending and expansion assembly of thermoplastic composite trusses, the induction welding end comprising a motion and loading unit, a welding head unit, and an alternating magnetic field generating unit;

[0011] The motion and loading unit includes a motion component, a loading component, and a sensor component;

[0012] The motion component is used to form a welding end with the welding head unit;

[0013] The loading component is used to drive the motion component to move up and down, and also to drive the motion component to apply pressure to the welding head unit;

[0014] The sensor assembly is used to detect pressure changes in the welding head unit;

[0015] The alternating magnetic field generating unit is used to convert electromagnetic energy into thermal energy and to transfer the thermal energy to the welding head unit.

[0016] Furthermore, in a preferred embodiment, the aforementioned motion component includes a base welding head mounting bracket, a base welding head fixing screw, and a base welding head and slider support connecting plate;

[0017] The loading assembly includes a slider, a slide rail, a lead screw, a motor, a power transmission support plate, and a motor mounting bracket;

[0018] The base welding head is fixed to the base welding head mounting bracket by the base welding head fixing set screw;

[0019] The base welding head mounting bracket is fixed to the slider via the slider support connecting plate;

[0020] The slider is slidably connected to the slide rail;

[0021] The slide rail is fixed to the power transmission support plate;

[0022] The lead screw is rotatably connected to the slider;

[0023] The motor is used to drive the lead screw to rotate;

[0024] The motor mounting bracket is fixed to the motor.

[0025] Furthermore, in a preferred embodiment, the sensor assembly includes a pressure sensor, a pressure sensor mounting bracket, and an alternating magnetic field generator mounting plate;

[0026] The mounting end of the pressure sensor is fixed to the mounting plate of the alternating magnetic field generator via the pressure sensor mounting bracket.

[0027] The alternating magnetic field generator mounting plate is fixed to the power transmission support plate.

[0028] Furthermore, in a preferred embodiment, the motion and loading unit further includes a front handle and a rear handle;

[0029] The front handle is fixed to the slider support connecting plate;

[0030] The rear handle is fixed to the mounting plate of the alternating magnetic field generator.

[0031] Furthermore, in a preferred embodiment, the welding head unit includes a welding head assembly, a welding head base heat insulation pad, a welding head fixing screw, a welding head mounting plate, a pressure sensor fixing screw, and a pressure sensor screw heat insulation pad.

[0032] The sensor assembly also includes a pressure sensor heat insulation pad;

[0033] The heat insulation pad of the welding head base is disposed between the welding head assembly and the welding head mounting plate;

[0034] The welding head assembly is fixed to the welding head mounting plate by the welding head fixing screw;

[0035] The pressure sensor fixing screw is fixed to the welding head mounting plate by the pressure sensor screw heat insulation pad;

[0036] The pressure sensor heat insulation pad is disposed between the pressure end of the pressure sensor and the pressure sensor fixing screw;

[0037] The pressure end of the pressure sensor is fixed to the welding head mounting plate by the pressure sensor fixing screw.

[0038] Furthermore, in a preferred embodiment, the welding head assembly includes a welding head, a thermocouple, a heat insulation pad, a fixing plate, a heating bushing, a heat insulation fixing cylinder, and a retaining ring.

[0039] The alternating magnetic field generating unit includes series coils;

[0040] The thermocouple is fixed to the welding head;

[0041] The welding head is fixed to the fixing plate by the heat insulation pad;

[0042] The heating bushing is fitted onto the welding head;

[0043] The heat-insulating fixing sleeve is fitted onto the heating bushing;

[0044] The heat-insulating fixing cylinder is connected in series within the series coil;

[0045] The retaining ring is fixed at the junction of the heating bushing and the heat insulation fixing cylinder.

[0046] Furthermore, in a preferred embodiment, the welding head includes a welding head for three-bar bending and a welding head for two-bar bending.

[0047] Furthermore, in a preferred embodiment, the alternating magnetic field generating unit further includes a protective cover, a ZVS chip, and a cooling fan;

[0048] The series coil is fixed on the ZVS chip;

[0049] The ZVS chip is used to convert the generated alternating current into an alternating magnetic field, and also to convert the alternating magnetic field into heat energy, which is then transferred to the series coil.

[0050] The ZVS chip is fixed on the alternating magnetic field generator mounting plate;

[0051] The protective cover is fixed to the mounting plate of the alternating magnetic field generator;

[0052] The cooling fan is fixed to the protective cover.

[0053] The present invention also provides a welding method for the induction welded end of a thermoplastic composite truss for on-rail bending and expansion assembly, the method being implemented based on the induction welded end of a thermoplastic composite truss for on-rail bending and expansion assembly described in any one of the above claims.

[0054] The present invention also provides a triangular prism three-dimensional truss, which is achieved by the welding method described above for the induction welding end of a thermoplastic composite truss for on-orbit bending and expansion assembly.

[0055] The beneficial effects of this invention are as follows:

[0056] 1. This invention provides an induction welding end for on-orbit bending and expansion assembly of thermoplastic composite trusses. The welding end comprises a motion component and a welding head unit. A loading component drives the motion component to move up and down, thereby applying pressure to the welding head unit. Since the welding pressure significantly affects the bending effect and welding quality, a sensor component detects pressure changes in the welding head unit, thus improving welding quality. Simultaneously, an alternating magnetic field generator converts electromagnetic energy into heat energy, which is then transferred to the welding head unit. This enables the welding of existing large-scale foldable space trusses, solving the problems of low space utilization during launch and the inability to ensure the stiffness and precision requirements of large-scale space trusses.

[0057] 2. The invention provides a welding method for the induction welding end of thermoplastic composite trusses for on-orbit bending and expansion assembly, which solves the problem of on-orbit bending and welding of large space trusses in the space environment. At the same time, it can monitor and adjust key parameters during the welding process, thereby improving welding accuracy. Compared with existing foldable space trusses, the large space trusses assembled by on-orbit bending and welding have a higher space utilization rate and improved welding accuracy.

[0058] This invention is applicable to the on-orbit bending and expansion assembly of large-scale space thermoplastic composite trusses in aerospace applications. Attached Figure Description

[0059] Figure 1 This is a schematic diagram of the induction welding end of an on-orbit bending and expansion assembly of a thermoplastic composite truss, as described in Embodiment 1.

[0060] Figure 2 These are schematic diagrams of the motion and loading units described in embodiments two to four;

[0061] Figure 3 This is a schematic diagram of the welding head unit described in Embodiment 5;

[0062] Figure 4 This is a schematic diagram of the welding head assembly described in Embodiment Six;

[0063] Figure 5 This is a schematic diagram of the structure of the welding head for bending the three rods as described in Embodiment Seven;

[0064] Figure 6 This is a schematic diagram of the welding head for double-rod bending as described in Embodiment Seven;

[0065] Figure 7 This is a schematic diagram of the alternating magnetic field generating unit described in Embodiment 8;

[0066] Figure 8 This is a structural schematic diagram of the triangular prism three-dimensional truss described in Embodiment 10.

[0067] Among them, 1 is the motion and loading unit, 1-1 is the base welding head mounting bracket, 1-2 is the slider-support connecting plate, 1-3 is the front handle, 1-4 is the slider, 1-5 is the lead screw, 1-6 is the motor mounting bracket, 1-7 is the motor, 1-8 is the pressure sensor heat insulation pad, 1-9 is the pressure sensor mounting bracket, 1-10 is the base welding head fixing screw, 1-11 is the rear handle, 1-12 is the slide rail, 1-13 is the alternating magnetic field generator mounting plate, 1-14 is the base welding head, 1-15 is the pressure sensor, and 1-16 is the power transmission support plate; 2-welding head unit, 2-1 is the welding head assembly, 2-1-1 is the heat... The components are: 2-1-2 (welding head), 2-1-2-1 (three-rod bending welding head), 2-1-2-1-2 (double-rod bending welding head), 2-1-3 (heat insulation pad), 2-1-4 (fixing plate), 2-1-5 (heating bushing), 2-1-6 (heat insulation fixing cylinder), 2-1-7 (retaining ring); 2-2 (welding head base heat insulation pad), 2-3 (welding head fixing set screw), 2-4 (welding head mounting plate), 2-5 (pressure sensor fixing screw), 2-6 (pressure sensor screw heat insulation pad); 3 (alternating magnetic field generating unit), 3-1 (series coil), 3-2 (protective cover), 3-3 (ZVS chip), 3-4 (cooling fan). Detailed Implementation

[0068] The specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings and examples. The following examples will help those skilled in the art to further understand the present invention, but do not limit the present invention in any way. It should be noted that those skilled in the art can make several changes and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention.

[0069] Implementation Method 1. See Figure 1 This embodiment describes an induction welding end for on-orbit bending and expansion assembly of thermoplastic composite trusses. The induction welding end includes a motion and loading unit 1, a welding head unit 2, and an alternating magnetic field generating unit 3.

[0070] The motion and loading unit 1 includes a motion component, a loading component, and a sensor component;

[0071] The motion component is used to form a welding end with the welding head unit 2;

[0072] The loading component is used to drive the motion component to move up and down, and also to drive the motion component to apply pressure to the welding head unit 2;

[0073] The sensor assembly is used to detect pressure changes in the welding head unit 2;

[0074] The alternating magnetic field generating unit 3 is used to convert electromagnetic energy into thermal energy and to transfer the thermal energy to the welding head unit 2.

[0075] In practical applications, this implementation method, such as Figure 1 As shown, the motion component of the motion and loading unit 1 and the welding head unit 2 form the welding end, and the motion component has the functions of vertical movement and pressure loading. The function of the motion component is realized by the loading component, which drives the motion component to move up and down, and simultaneously applies pressure. The sensor component is used to detect pressure changes at the welding end, realizing a sensing welding end and improving welding quality.

[0076] The alternating magnetic field generating unit 3 is used to convert electromagnetic energy into thermal energy and to transfer the thermal energy to the welding head unit 2, thereby realizing heat transfer.

[0077] This embodiment provides an induction welding end for on-orbit bending and expansion assembly of thermoplastic composite trusses. The welding end comprises a motion component and a welding head unit. A loading component drives the motion component to move up and down, thereby applying pressure to the welding head unit. Since the magnitude of the welding pressure has a significant impact on the bending effect and welding quality, a sensor component is used to detect pressure changes in the welding head unit, thus improving welding quality. Simultaneously, an alternating magnetic field generator unit converts electromagnetic energy into heat energy, which is then transferred to the welding head unit. This enables the welding of existing large-scale foldable space trusses, solving the problems of low space utilization during launch and the inability to ensure the stiffness and precision requirements of large-scale space trusses.

[0078] Implementation Method 2. See also Figure 2 This embodiment is an example of the motion component and loading component in the induction welding end of the thermoplastic composite truss for on-rail bending and expansion assembly as described in Embodiment 1. The motion component includes a base welding head mounting support 1-1, a base welding head fixing screw 1-10, a base welding head 1-14, and a slider-support connecting plate 1-2.

[0079] The loading assembly includes a slider 1-4, a slide rail 1-12, a lead screw 1-5, a motor 1-7, a power transmission support plate 1-16, and a motor mounting bracket 1-6;

[0080] The base welding head 1-14 is fixed to the base welding head mounting support 1-1 by the base welding head fixing screw 1-10;

[0081] The base welding head mounting support 1-1 is fixed on the slider 1-4 by the slider-support connecting plate 1-2;

[0082] The slider 1-4 is slidably connected to the slide rail 1-12;

[0083] The slide rail 1-12 is fixed on the power transmission support plate 1-16;

[0084] The lead screw 1-5 is rotatably connected to the slider 1-4;

[0085] The motors 1-7 are used to drive the lead screws 1-5 to rotate;

[0086] The motor mounting bracket 1-6 is fixed on the motor 1-7.

[0087] In practical applications, this implementation method, such as Figure 2 As shown, the base welding head mounting bracket 1-1 cooperates with the base welding head fixing screw 1-10 to position and fix the base welding head 1-14, serving as a moving component of the welding end, and this moving component has the functions of vertical movement and pressure loading.

[0088] The slide rail 1-12 is fixed on the power transmission support plate 1-16. The slider 1-4 is slidably connected to the slide rail 1-12, and the lead screw 1-5 is rotatably connected to the slider 1-4. The motor 1-7 drives the lead screw 1-5 to rotate, thereby driving the slider 1-4 to move up and down along the slide rail 1-12 as a loading component. At the same time, the slider-support connecting plate 1-2 connects the base welding head mounting support 1-1 to the slider 1-4, realizing the conversion of the power brought by the lead screw 1-5 into the displacement loading of the base welding head mounting support 1-1 moving up and down. The displacement loading of the up and down movement realizes the loading of pressure, completing the power transmission. That is, the loading component drives the motion component to move up and down and realizes the pressure loading function.

[0089] Implementation Method 3. See also Figure 2 This embodiment is an example of a sensor assembly used in the induction welding end of an on-rail bending and expansion assembly of a thermoplastic composite truss, as described in Embodiment 2. The sensor assembly includes a pressure sensor 1-15, a pressure sensor mounting bracket 1-9, and an alternating magnetic field generator mounting plate 1-13.

[0090] The mounting end of the pressure sensor 1-15 is fixed on the alternating magnetic field generator mounting plate 1-13 by the pressure sensor mounting bracket 1-9;

[0091] The alternating magnetic field generator mounting plate 1-13 is fixed on the power transmission support plate 1-16.

[0092] In practical applications, this implementation method, such as Figure 2 As shown, the mounting end of the pressure sensor 1-15 is fixed to the alternating magnetic field generator mounting plate 1-13 via the pressure sensor mounting bracket 1-9, and the alternating magnetic field generator mounting plate 1-13 is fixed to the power transmission support plate 1-16, thereby fixing the mounting end of the pressure sensor 1-15.

[0093] Implementation Method Four. See also Figure 2 This embodiment is based on the induction welding end of the thermoplastic composite truss for on-rail bending and expansion assembly described in Embodiment 3, with the addition of a front handle 1-3 and a rear handle 1-11.

[0094] The front handle 1-3 is fixed on the slider-support connecting plate 1-2;

[0095] The rear handle 1-11 is fixed on the alternating magnetic field generator mounting plate 1-13.

[0096] In practical applications, this implementation method, such as Figure 2As shown, the front handle 1-3 is fixed on the slider-support connecting plate 1-2, and the rear handle 1-11 is fixed on the alternating magnetic field generator mounting plate 1-13, so as to facilitate gripping and reversing during the movement process.

[0097] Implementation Method 5. See also Figure 3 This embodiment illustrates the welding head unit 2 and sensor assembly in the induction welding end of an on-rail bending and expansion assembly of a thermoplastic composite truss as described in Embodiment 4. The welding head unit 2 includes a welding head assembly 2-1, a welding head base heat insulation pad 2-2, a welding head fixing screw 2-3, a welding head mounting plate 2-4, a pressure sensor fixing screw 2-5, and a pressure sensor screw heat insulation pad 2-6.

[0098] The sensor assembly also includes pressure sensor heat insulation pads 1-8;

[0099] The heat insulation pad 2-2 of the welding head base is disposed between the welding head assembly 2-1 and the welding head mounting plate 2-4;

[0100] The welding head assembly 2-1 is fixed to the welding head mounting plate 2-4 by the welding head fixing screw 2-3;

[0101] The pressure sensor fixing screw 2-5 is fixed to the welding head mounting plate 2-4 by the pressure sensor screw heat insulation pad 2-6;

[0102] The pressure sensor heat insulation pad 1-8 is disposed between the pressure end of the pressure sensor 1-15 and the pressure sensor fixing screw 2-5;

[0103] The pressure end of the pressure sensor 1-15 is fixed to the welding head mounting plate 2-4 by the pressure sensor fixing screw 2-5.

[0104] In practical applications, this implementation method, such as Figure 3 As shown, the welding head assembly 2-1 is fixed to the welding head mounting plate 2-4 by the welding head fixing screw 2-3, forming the welding part of the welding head unit.

[0105] The pressure sensor heat insulation pad 1-8 is placed between the pressure end of the pressure sensor 1-15 and the pressure sensor fixing screw 2-5 to isolate the transfer of heat.

[0106] The pressure end of pressure sensor 1-15 is fixed to the other side of welding head mounting plate 2-4 by pressure sensor fixing screw 2-5. When the base welding head 1-14 in the moving assembly moves downward, it applies pressure to welding head assembly 2-1, thereby causing welding head mounting plate 2-4 to press pressure sensor 1-15. This allows pressure sensor 1-15 to detect the clamping pressure between base welding head 1-14 and welding head assembly 2-1, thus achieving a sensing welding end and improving welding quality. Simultaneously, a pressure sensor heat insulation pad 1-8 is disposed between the pressure end of pressure sensor 1-15 and pressure sensor fixing screw 2-5 to insulate against heat transfer.

[0107] Implementation method six. See also Figure 4 This embodiment is an example of the welding head assembly 2-1 in the induction welding end of the thermoplastic composite truss for on-rail bending and expansion assembly as described in Embodiment 5. The welding head assembly 2-1 includes a welding head 2-1-2, a thermocouple 2-1-1, a heat insulation pad 2-1-3, a fixing plate 2-1-4, a heating bushing 2-1-5, a heat insulation fixing cylinder 2-1-6, and a retaining ring 2-1-7.

[0108] The alternating magnetic field generating unit 3 includes a series coil 3-1;

[0109] The thermocouple 2-1-1 is fixed on the welding head 2-1-2;

[0110] The welding head 2-1-2 is fixed to the fixing plate 2-1-4 by the heat insulation pad 2-1-3;

[0111] The heating bushing 2-1-5 is fitted onto the welding head 2-1-2;

[0112] The heat insulation fixing cylinder 2-1-6 is fitted onto the heating bushing 2-1-5;

[0113] The heat-insulating fixing cylinder 2-1-6 is connected in series inside the series coil 3-1;

[0114] The retaining ring 2-1-7 is fixed at the junction of the heating bushing 2-1-5 and the heat insulation fixing cylinder 2-1-6.

[0115] In practical applications, this implementation method, such as Figure 4 As shown, thermocouple 2-1-1 is threaded onto welding head 2-1-2 to monitor the temperature of welding head 2-1-2 in real time.

[0116] The welding head 2-1-2 is fixed on the fixed plate 2-1-4. Meanwhile, the heat insulation pad 2-1-3 is placed between the welding head 2-1-2 and the fixed plate 2-1-4 to isolate the transfer of heat.

[0117] The heating sleeve 2-1-5 is fitted onto the welding head 2-1-2, so that the heating sleeve 2-1-5 receives heat and transfers the heat to the welding head 2-1-2.

[0118] The heat-insulating fixing cylinder 2-1-6 is fitted onto the heating bushing 2-1-5 and is connected in series within the series coil 3-1. This allows the heat-insulating fixing cylinder 2-1-6 to receive heat from the series coil 3-1 and transfer that heat to the welding head 2-1-2 through the heating bushing 2-1-5. Simultaneously, it fixes the relative position of the welding head 2-1-2 and the series coil 3-1, positioning the welding head 2-1-2 at the center of the cylinder of the series coil 3-1, while also insulating it from heat to prevent overheating of the series coil 3-1.

[0119] The retaining ring 2-1-7 is fixed at the junction of the heating bushing 2-1-5 and the heat insulation fixing cylinder 2-1-6, so that the retaining ring 2-1-7 fixes the welding head 2-1 on the welding head mounting plate 2-4 and fixes the auxiliary parts inside the welding head 2-1.

[0120] Implementation Method Seven. See also Figure 5 and Figure 6 This embodiment is illustrated by taking the welding head 2-1-2 in the induction welding end of the thermoplastic composite truss for on-rail bending and expansion assembly as described in Embodiment 6 as an example. The welding head 2-1-2 includes a three-bar bending welding head 2-1-2-1 and a two-bar bending welding head 2-1-2-2.

[0121] In practical applications, to adapt to different welding requirements, the welding head 2-1-2 can be implemented using a three-bar bending welding head 2-1-2-1, such as... Figure 5 As shown. Welding head 2-1-2 can also be achieved using a double-rod bending welding head 2-1-2-2, as shown. Figure 6 As shown.

[0122] Implementation method eight. See also Figure 7 This embodiment is described by way of example of an alternating magnetic field generating unit 3 in the induction welding end of an on-rail bending and expansion assembly of a thermoplastic composite truss, as described in Embodiment 6. The alternating magnetic field generating unit 3 also includes a protective cover 3-2, a ZVS chip 3-3, and a cooling fan 3-4.

[0123] The series coil 3-1 is fixed on the ZVS chip 3-3;

[0124] The ZVS chip 3-3 is used to convert the generated alternating current into an alternating magnetic field, and also to convert the alternating magnetic field into heat energy, which is then transferred to the series coil 3-1;

[0125] The ZVS chip 3-3 is fixed on the alternating magnetic field generator mounting plate 1-13;

[0126] The protective cover 3-2 is fixed on the alternating magnetic field generator mounting plate 1-13;

[0127] The cooling fan 3-4 is fixed on the protective cover 3-2.

[0128] In practical applications, this implementation method, such as Figure 7 As shown, the series coil 3-1 is fixed to the ZVS chip 3-3 by screws, and its relative position to the welding head 2-1 is determined by the heat-insulating fixing cylinder 2-1-6. The ZVS chip 3-3 converts the generated alternating current into an alternating magnetic field, and then converts the alternating magnetic field into heat energy, which is transferred to the series coil 3-1 to heat the heating sleeve 2-1-5.

[0129] ZVS chip 3-3 is fixed to alternating magnetic field generator mounting plate 1-13 by hexagonal studs; cooling fan 3-4 is fixed to protective cover 3-2 to achieve heat dissipation; protective cover 3-2 is fixed to alternating magnetic field generator mounting plate 1-13 by screws to achieve dust prevention.

[0130] Implementation Method Nine. This implementation method provides a welding method for the induction welded end of an on-rail bending and expansion assembly of a thermoplastic composite truss. The method is based on the induction welded end of an on-rail bending and expansion assembly of a thermoplastic composite truss described in any one of Implementation Methods One to Eight.

[0131] In practical application, this embodiment generates heat during the welding process by connecting the power supply, raising the temperature of the welding head. First, the welding head is heated to the bending temperature, causing the material rod to be bent to be in a viscous flow state. Then, it is bent by the pressure of the bending welding head. After bending, the welding head is further heated to the welding temperature, causing the bent material rod to be in a molten state at the overlap point. Under pressure, the two rods are welded together. Then, the temperature is lowered and the pressure is maintained to complete the welding process.

[0132] Implementation Method 10. See also Figure 8 This embodiment describes a three-dimensional triangular prism truss, which is implemented using an induction welding method for on-orbit bending and expansion assembly of thermoplastic composite trusses as described in Embodiment Nine.

[0133] In practical applications, this implementation method, such as Figure 8As shown, the triangular prism three-dimensional truss is composed of the existing one-dimensional truss. The main skeleton consists of three one-dimensional trusses arranged in parallel equilateral triangles. On the other hand, fixed-length one-dimensional trusses with the same perimeter as the cross-section of the triangular truss are bent and welded together with the three one-dimensional trusses, spaced 1m apart. The number of trusses varies with the required length of the triangular truss.

[0134] Specifically: First, using a truss trimming assembly, such as an ultrasonic cutter, two one-dimensional truss beams with excess web members are removed and overlapped at 90°. One of them is a longitudinal beam of the extended truss, and the other is a transverse beam. The overlap point is placed between welding head 2-1 and base welding head 1-14, and heated by series coil 3-1, with temperature monitored by thermocouple 2-1-1. Once welding head 2-1 reaches the bending temperature, motor 1-7 is started, causing welding head 2-1 and base welding head 1-14 to close, and the two longitudinal members of the transverse beam bend inward by 60° simultaneously. After bending, welding head 2-1 is heated to the welding temperature. Under pressure, the welding pressure is controlled by pressure sensor 1-15, and the two members are welded together. Then, the temperature is lowered and the pressure is maintained, completing the welding. The same process is then repeated at another overlap point, bending the crossbeam by 60° at each of the two points where it intersects with the longitudinal beam, and bending the crossbeam itself twice by 120°. This yields one corner of a triangular prism 3D truss. At this point, the longitudinal members of the longitudinal beam near the core of the triangular truss, along with the longitudinal members of the bent crossbeams on both sides, intersect at a single point. The welding head and base are then replaced, and these three members are bent and welded together at one point. The above steps are repeated for on-orbit expansion assembly, ultimately resulting in a five-meter-long triangular prism 3D truss, as shown below. Figure 8 As shown.

[0135] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0136] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0137] The above description is merely an embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention should be included within the scope of the claims of the present invention.

Claims

1. An induction welded end for on-rail bending and expansion assembly of thermoplastic composite trusses, characterized in that, The welding end is composed of a motion component and a welding head unit, and a loading component drives the motion component to move up and down, thereby realizing the function of the motion component to apply pressure to the welding head unit. Since the magnitude of the welding pressure has a significant impact on the bending effect and welding quality, a sensor component is used to detect the pressure change of the welding head unit. At the same time, an alternating magnetic field generating unit is used to convert electromagnetic energy into heat energy and transfer it to the welding head unit, thereby realizing the welding of existing foldable large space trusses. The induction welding end includes a motion and loading unit (1), a welding head unit (2), and an alternating magnetic field generating unit (3). The motion and loading unit (1) includes a motion component, a loading component, and a sensor component; The motion component is used to form a welding end with the welding head unit (2), and the motion component is configured to move up and down relative to the welding head unit (2), and the welding head unit (2) is fixedly set; the loading component is used to drive the motion component to move up and down, and is also used to drive the motion component to apply pressure to the welding head unit (2); the sensor component is used to detect the pressure change of the welding head unit (2); The motion assembly includes a base welding head mounting bracket (1-1), a base welding head fixing screw (1-10), a base welding head (1-14), and a slider-support connecting plate (1-2). The loading assembly includes a slider (1-4), a slide rail (1-12), a lead screw (1-5), a motor (1-7), a power transmission support plate (1-16), and a motor mounting bracket (1-6). The base welding head (1-14) is fixed on the base welding head mounting bracket (1-1) by the base welding head fixing set screw (1-10); The base welding head mounting bracket (1-1) is fixed on the slider (1-4) by the slider-support connecting plate (1-2); The slider (1-4) is slidably connected to the slide rail (1-12); The slide rail (1-12) is fixed on the power transmission support plate (1-16); The lead screw (1-5) is rotatably connected to the slider (1-4); The motor (1-7) is used to drive the lead screw (1-5) to rotate; The motor mounting bracket (1-6) is fixed on the motor (1-7); The sensor assembly includes a pressure sensor (1-15), a pressure sensor mounting bracket (1-9), and an alternating magnetic field generator mounting plate (1-13). The mounting end of the pressure sensor (1-15) is fixed on the alternating magnetic field generator mounting plate (1-13) by the pressure sensor mounting bracket (1-9); The alternating magnetic field generator mounting plate (1-13) is fixed on the power transmission support plate (1-16); The welding head unit (2) includes a welding head assembly (2-1), a welding head base heat insulation pad (2-2), a welding head fixing screw (2-3), a welding head mounting plate (2-4), a pressure sensor fixing screw (2-5), and a pressure sensor screw heat insulation pad (2-6). The sensor assembly also includes a pressure sensor heat insulation pad (1-8). The heat insulation pad (2-2) of the welding head base is disposed between the welding head assembly (2-1) and the welding head mounting plate (2-4); The welding head assembly (2-1) is fixed to the welding head mounting plate (2-4) by the welding head fixing screw (2-3); The pressure sensor fixing screw (2-5) is fixed to the welding head mounting plate (2-4) by the pressure sensor screw heat insulation pad (2-6); The pressure sensor heat insulation pad (1-8) is disposed between the pressure end of the pressure sensor (1-15) and the pressure sensor fixing screw (2-5); The pressure end of the pressure sensor (1-15) is fixed to the welding head mounting plate (2-4) by the pressure sensor fixing screw (2-5); The alternating magnetic field generating unit (3) is used to convert electromagnetic energy into thermal energy and to transfer thermal energy to the welding head unit (2).

2. The induction welded end for on-rail bending and expansion assembly of thermoplastic composite trusses according to claim 1, characterized in that, The motion and loading unit (1) also includes a front handle (1-3) and a rear handle (1-11). The front handle (1-3) is fixed on the slider-support connecting plate (1-2); The rear handle (1-11) is fixed on the alternating magnetic field generator mounting plate (1-13).

3. The induction welded end for on-rail bending and expansion assembly of thermoplastic composite trusses according to claim 1, characterized in that, The welding head assembly (2-1) includes a welding head (2-1-2), a thermocouple (2-1-1), a heat insulation pad (2-1-3), a fixing plate (2-1-4), a heating bushing (2-1-5), a heat insulation fixing cylinder (2-1-6), and a retaining ring (2-1-7). The alternating magnetic field generating unit (3) includes a series coil (3-1). The thermocouple (2-1-1) is fixed on the welding head (2-1-2); The welding head (2-1-2) is fixed to the fixing plate (2-1-4) by the heat insulation pad (2-1-3); The heating bushing (2-1-5) is fitted onto the welding head (2-1-2); The heat-insulating fixing cylinder (2-1-6) is fitted onto the heating bushing (2-1-5); The heat-insulating fixing cylinder (2-1-6) is connected in series inside the series coil (3-1); The retaining ring (2-1-7) is fixed at the junction of the heating bushing (2-1-5) and the heat insulation fixing cylinder (2-1-6).

4. The induction welded end for on-rail bending and expansion assembly of thermoplastic composite trusses according to claim 3, characterized in that, The welding head (2-1-2) includes a three-bar bending welding head (2-1-2-1) and a two-bar bending welding head (2-1-2-2).

5. The induction welded end for on-rail bending and expansion assembly of thermoplastic composite trusses according to claim 3, characterized in that, The alternating magnetic field generating unit (3) also includes a protective cover (3-2), a ZVS chip (3-3), and a cooling fan (3-4). The series coil (3-1) is fixed on the ZVS chip (3-3); The ZVS chip (3-3) is used to convert the generated alternating current into an alternating magnetic field, and also to convert the alternating magnetic field into heat energy and transfer it to the series coil (3-1). The ZVS chip (3-3) is fixed on the alternating magnetic field generator mounting plate (1-13); The protective cover (3-2) is fixed on the mounting plate (1-13) of the alternating magnetic field generator; The cooling fan (3-4) is fixed on the protective cover (3-2).

6. A welding method for the induction welding ends of thermoplastic composite trusses used in on-orbit bending and expansion assembly, characterized in that, The method is based on the induction welding end of the thermoplastic composite truss for on-orbit bending and expansion assembly as described in any one of claims 1-5.

7. A three-dimensional triangular prism truss, characterized in that, The three-dimensional truss is achieved by the induction welding method for the on-orbit bending and expansion assembly of thermoplastic composite trusses as described in claim 6.

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