A device for manufacturing a continuous rail based on roll-pole pultrusion and disc roll-pole material and a manufacturing method thereof

Abstract

A device and method for continuous on-orbit manufacturing of rods based on pultrusion molding and coiled rod materials are disclosed, relating to the field of aerospace on-orbit manufacturing technology. This invention addresses the problems of existing space truss structures, which are mostly deployable, subject to mechanical environmental influences during launch, unable to be transported in large sizes, have high launch costs, and long manufacturing-launch-service cycles. Furthermore, the invention addresses the low efficiency and inability to rapidly manufacture continuous truss structures using 3D printing technology. The device employs a longitudinal beam manufacturing unit to manufacture longitudinal beams, which are then fed to a secondary beam winding unit. The secondary beam winding unit outputs three rods, adjusts their bending angle, and winds them onto the longitudinal beams. After winding, the rods are fed to an ultrasonic welding unit for welding. The welded secondary beams and longitudinal beams are then fed to a truss traction unit for traction. An overall support structure supports the longitudinal beam manufacturing unit, secondary beam winding unit, ultrasonic welding unit, and truss traction unit. This invention is suitable for continuous on-orbit manufacturing based on pultrusion molding and coiled rod materials.

Description

Technical Field

[0001] This invention relates to the field of on-orbit manufacturing technology for aerospace. Background Technology

[0002] Existing spacecraft such as SAR satellites, space solar power stations, space radio telescopes, and the International Space Station all employ large space support structures, most of which are truss structures, such as quadrilateral, herringbone, and circular woven truss structures.

[0003] With the development of the times, the development of large spacecraft in the aerospace field will evolve from the current scale of 10-100m to a larger scale, expected to reach 0.1-10km. Furthermore, with the increase in scale, launch space will be limited, and the launch weight will exceed tens of thousands of tons. Existing ground manufacturing methods and launch technologies will be unable to meet future demands, mainly in the following aspects:

[0004] 1. The truss structures required for existing spacecraft are mostly large in size. Due to the overall size of the rocket fairing, they need to be transported multiple times, resulting in high transportation costs and increasing the time required from manufacturing to service.

[0005] 2. Large truss structures cannot be assembled on the ground, and the precision of on-orbit assembly technology is limited, affecting the service life and stability of large structures.

[0006] 3. The truss structure occupies most of the space during transportation, but the space utilization rate is low, which reduces the upper limit of the load that can be carried in a single transportation.

[0007] 4. The mechanical environment during transportation is harsh, requiring improvements in the reliability and safety of large truss structures.

[0008] 5. Existing space-based on-orbit 3D printing technology for manufacturing large trusses has a long cycle and low manufacturing efficiency, making it difficult to achieve rapid manufacturing of large truss structures. Summary of the Invention

[0009] This invention addresses the problems in the current technical field where space truss structures are mostly deployable, subject to mechanical environmental influences during transport, unable to transport large sizes, have high transport costs, and have long manufacturing-launch-service cycles. Furthermore, the continuous truss manufacturing method using 3D printing technology is inefficient and cannot be manufactured quickly.

[0010] To achieve the above objectives, the present invention provides the following solution:

[0011] This invention provides a continuous on-orbit manufacturing device based on pultrusion molding of coiled rods and continuous on-orbit manufacturing of coiled rod materials. The device includes an overall support structure, a longitudinal beam manufacturing unit, a secondary beam winding unit, an ultrasonic welding unit, and a truss traction unit.

[0012] The longitudinal beam manufacturing unit is used to manufacture longitudinal beams and also to transport the longitudinal beams to the sub-beam winding unit;

[0013] The sub-beam winding unit is used to output three rods, and also to adjust the curvature of the three rods. The adjusted three rods are then used as sub-beams to wind around the longitudinal beam to form a transverse beam and an oblique beam. After winding, the rods are conveyed to the ultrasonic welding unit.

[0014] The ultrasonic welding unit is used to weld the sub-beam to the longitudinal beam, and to transport the welded sub-beam and longitudinal beam to the truss traction unit.

[0015] The truss traction unit is used to pull the welded longitudinal beams;

[0016] The overall support structure is used to support the longitudinal beam manufacturing unit, the sub-beam winding unit, the ultrasonic welding unit, and the truss traction unit.

[0017] Furthermore, in a preferred embodiment, the aforementioned secondary beam winding unit includes three rod straightening manufacturing modules, a first fixed support, a first slewing bearing, a first slewing support, a large slewing structure, and a slewing gear;

[0018] The first fixed support is fitted inside the first slewing bearing;

[0019] The first slewing bearing is fixed to the large slewing structure by the first slewing support;

[0020] The large slewing structure is mounted on the slewing gear;

[0021] The three rod straightening manufacturing modules are evenly fixed on the large rotating structure;

[0022] The three rod straightening manufacturing modules are used to output three rods, adjust the curvature of the three rods, and use the adjusted three rods as secondary beams. Under the rotation of the rotary gear, the secondary beams are wound around the longitudinal beam to form a crossbeam and an oblique beam, thus completing the winding with the longitudinal beam.

[0023] The first slewing bearing is used to drive the first fixed support to generate different height differences.

[0024] Furthermore, in a preferred embodiment, the above-mentioned rod straightening manufacturing module includes a material box shell, a curved rod drum, a second rotary bearing, a straightening heating block, a mold fixing plate, a straightening mold, a heating ceramic, and a 45° rotatable extruder.

[0025] The crank drum is fixed inside the material box housing by the second rotary bearing;

[0026] The straightening heating block is disposed inside the outer shell of the material box and fixed at the discharge point of the curved drum;

[0027] The straightening mold is fixed at the discharge point of the straightening heating block by the mold fixing plate;

[0028] The heating ceramic is fixed at the discharge point of the straightening mold;

[0029] The 45° rotatable extruder head is fixed on the heating ceramic;

[0030] The curved rod drum is used to convey the coiled rod to the straightening heating block;

[0031] The straightening heating block is used to straighten the coiled rod and then convey it to the straightening mold;

[0032] The straightening mold is used to convey the straightened rod to the heating ceramic.

[0033] The heating ceramic is used to heat the received rod and feed it to a 45° rotatable extruder.

[0034] The 45° rotatable extruder is used to process the bending angle of the rod to form a secondary beam, and then the secondary beam is wound around the longitudinal beam to form a crossbeam and a diagonal beam, thus completing the winding with the longitudinal beam.

[0035] Furthermore, in a preferred embodiment, the above-mentioned rod straightening manufacturing module also includes a fastening and anti-loosening structure, a movable hinge, a bottom fixed support, and a fixed base plate;

[0036] The fastening and anti-loosening structure is installed inside the material box shell and fixed between the straightening heating block and the discharge port of the curved rod drum to prevent the rod from falling off.

[0037] The movable hinge is fixed on the upper and lower sides of the straightening mold to accommodate the angular change of the rod during the winding process;

[0038] The bottom fixed support is fixed to the outer shell of the material box by the fixed base plate, and is used to support the outer shell of the material box;

[0039] The bottom fixed support is fixed to the large rotating structure.

[0040] Furthermore, in a preferred embodiment, the ultrasonic welding unit includes a second fixed support, a micro-motion cam support, a drive gear, a second rotary support, an ultrasonic welding machine, a slidable double-sided fixed plate, and a stop bar;

[0041] The second fixed support is fixed to one side of the micro-motion cam support;

[0042] The drive gear is connected to the micro-motion cam support gear;

[0043] The second rotary support is fixed on the other side of the micro-motion cam support.

[0044] The ultrasonic welding machine is used to be fixed to the second rotary support by the sliding double-sided fixing plate;

[0045] The ultrasonic welding machine is slidably connected to the slidable double-sided fixed plate;

[0046] The stop bar is connected to the trigger end of the ultrasonic welding machine;

[0047] The micro-motion cam support is used to achieve reciprocating motion through the drive gear, thereby driving the second rotary support to achieve reciprocating motion;

[0048] The outer edge profile of the cam supported by the micro-motion cam is used to trigger the ultrasonic welding machine via the stop bar.

[0049] Furthermore, in a preferred embodiment, the ultrasonic welding unit further includes a compression spring;

[0050] The compression spring interacts with the housing of the ultrasonic welding machine to achieve the return process.

[0051] Furthermore, in a preferred embodiment, the ultrasonic welding unit further includes a support rib.

[0052] The supporting rib is fixed to the second fixed support to provide support.

[0053] Furthermore, in a preferred embodiment, the truss traction unit includes two drive shafts, two bevel gears, a central support, and three sets of traction modules;

[0054] The three sets of traction modules are used to achieve a star-shaped connection through the central support;

[0055] The three sets of traction modules are used to achieve series transmission through the two drive shafts and two bevel gears;

[0056] The traction module is used to pull the welded longitudinal beam.

[0057] Furthermore, in a preferred embodiment, the traction module includes an upper traction drive module and a lower traction drive module;

[0058] The upper traction transmission module is connected to the central support;

[0059] The lower traction drive module is equipped with a chain drive with a gripper design.

[0060] The upper traction transmission module is used to connect with the lower traction transmission module through the chain transmission with the gripper design, so as to pull the welded longitudinal beam.

[0061] The transmission fixing plate is used to fix the transmission chain of the lower traction transmission module;

[0062] The preload wheel is used to adjust the tension of the drive chain;

[0063] The adjustable slot is used to adjust the connection position between the upper traction transmission module and the central support.

[0064] This invention also provides a method for continuous on-rail manufacturing of rods based on pultrusion molding and coiled rod material, wherein the manufacturing method is implemented based on the device for continuous on-rail manufacturing of rods based on pultrusion molding and coiled rod material as described in any one of the above-mentioned methods, and the manufacturing method is as follows:

[0065] Step 1: After stretching the longitudinal beam to 700mm using the longitudinal beam manufacturing unit, it is then conveyed to the secondary beam winding unit;

[0066] Step 2: Use the secondary beam winding unit to output three rods, and adjust the curvature of the three rods before using them as secondary beams to wind around the longitudinal beam;

[0067] Step 3: Use an ultrasonic welding unit to weld the sub-beam to the longitudinal beam;

[0068] Step 4: After welding is completed, the welded longitudinal beam is pulled by the truss traction unit, and the secondary beam winding unit rotates 360° to enter the next winding welding cycle, thus realizing continuous manufacturing.

[0069] The beneficial effects of this invention are as follows:

[0070] 1. This invention provides a continuous on-orbit manufacturing device based on pultrusion molding and coiled rod material. Multiple units operate simultaneously in three modules, reducing the use of motors. For example, the sub-beam winding unit uses three rod straightening manufacturing modules to simultaneously manufacture the sub-beam and wind it onto the longitudinal beam; the ultrasonic welding unit uses three sets of ultrasonic welding machines to weld simultaneously; and the truss traction unit uses three sets of traction modules to simultaneously pull the welded longitudinal beam. Furthermore, the three sets of traction modules achieve series transmission through two drive shafts and two bevel gears. The parallel and series transmission methods of multiple units control the number of motors in each unit, significantly reducing the power consumption of the equipment and meeting the significant power requirements of on-orbit environments.

[0071] 2. This invention provides a continuous on-rail manufacturing device based on pultrusion molding of coiled rods and continuous coiled rod material. The resulting truss structure uses 4mm diameter rods as longitudinal beams and 1mm diameter rods as secondary beams. By using a preset winding method, the complexity of the winding process is greatly reduced. The winding procedure can also be changed to form trusses with different structural forms. It has a certain degree of versatility and meets the different requirements of truss structures in the on-rail environment, while ensuring the overall strength and rigidity of the truss.

[0072] 3. This invention provides a continuous on-rail manufacturing device based on pultrusion molding of coiled rods and coiled rod material. To reduce complex processes, the sub-beam directly uses 1mm coiled rod material that has been pre-treated by pultruding strip into rods. It is directly straightened by preheating, which reduces the tensile force generated by the sub-beam during the winding process and effectively reduces the power consumption of winding rotation. Two degrees of freedom are added to the straightening die of the sub-beam winding unit, namely a movable hinge and a 45° rotatable extruder. The rotatable design of the 45° rotatable extruder prevents the sub-beam from curving and meets the overall straightness requirements of the sub-beam. The 45° rotatable extruder prevents the heated sub-beam from being squeezed, achieving a higher cross-sectional roundness of the sub-beam, thereby improving the overall mechanical performance of the truss.

[0073] 4. This invention provides a continuous on-rail manufacturing device based on pultrusion molding of coiled rods and continuous coiled rod material. The secondary beam winding unit and ultrasonic welding unit adopt parallel transmission, which can well ensure the simultaneity of the control process. The truss traction unit has a special fixed-length stroke design for the chain drive, which can ensure accurate clamping of the truss nodes and the gripper parts to achieve traction. Under the premise of ensuring the stability of the winding procedure, different truss shapes can be manufactured by changing the position of the gripper on the chain, avoiding timing disorder and improving the reliability of the overall equipment control system.

[0074] This invention is applicable to the manufacturing of continuous on-rail systems based on pultrusion molding of coiled rods and coiled rod materials. Attached Figure Description

[0075] Figure 1 This is a schematic diagram of a continuous on-orbit manufacturing device based on pultrusion molding and coiled rod material, as described in Embodiment 1.

[0076] Figure 2 This is a structural schematic diagram of the secondary beam winding unit described in Embodiment 2;

[0077] Figure 3 These are perspective views of the rod straightening manufacturing module described in embodiments three and four;

[0078] Figure 4 This is a front view of the rod straightening manufacturing module described in embodiments three and four;

[0079] Figure 5These are schematic diagrams of the ultrasonic welding unit described in embodiments five and seven;

[0080] Figure 6 These are schematic diagrams of the ultrasonic welding machine described in embodiments five and six;

[0081] Figure 7 These are schematic diagrams of the truss traction unit described in embodiments eight and nine;

[0082] Among them, 1 is the overall support structure; 2 is the longitudinal beam manufacturing unit; 3 is the secondary beam winding unit; 3-1 is the rod straightening manufacturing module; 3-1-1 is the bottom fixed support; 3-1-2 is the fixed base plate; 3-1-3 is the material box shell; 3-1-4 is the curved rod drum; 3-1-5 is the fastening and anti-loosening structure; 3-1-6 is the straightening heating block; 3-1-7 is the mold fixing plate; 3-1-8 is the straightening mold; 3-1-9 is the movable hinge; 3-1-10 is the heating ceramic; 3-1-11 is the 45° rotatable extruder head; 3-1-12 is the second rotary bearing; 3-2 is the first fixed support; 3-3 is the first rotary bearing; 3 -4 is the first slewing support, 3-5 is the large slewing structure, and 3-6 is the slewing gear; 4 is the ultrasonic welding unit, 4-1 is the support rib, 4-2 is the second fixed support, 4-3 is the micro-motion cam support, 4-4 is the drive gear, 4-5 is the second slewing support, 4-6 is the ultrasonic welder, 4-7 is the sliding double-sided fixed plate, 4-8 is the compression spring, and 4-9 is the stop bar; 5 is the truss traction unit, 5-1 is the drive motor, 5-2 is the preload wheel, 5-2 is the transmission shaft, 5-4 is the bevel gear, 5-5 is the center support, 5-6 is the adjustable slot, 5-7 is the chain drive with gripper design, and 5-8 is the double-sided transmission fixed plate. Detailed Implementation

[0083] 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.

[0084] Implementation Method 1. See [link / reference] Figure 1 This embodiment describes a continuous on-orbit manufacturing device based on pultrusion molding of coiled rods and continuous on-orbit manufacturing of coiled rod materials. The device includes an overall support structure 1, a longitudinal beam manufacturing unit 2, a secondary beam winding unit 3, an ultrasonic welding unit 4, and a truss traction unit 5.

[0085] The longitudinal beam manufacturing unit 2 is used to manufacture longitudinal beams and also to transport the longitudinal beams to the sub-beam winding unit 3;

[0086] The sub-beam winding unit 3 is used to output three rods, and also to adjust the curvature of the three rods. The adjusted three rods are used as sub-beams to wind around the longitudinal beam to form a crossbeam and an oblique beam. After winding, the rods are conveyed to the ultrasonic welding unit 4.

[0087] The ultrasonic welding unit 4 is used to weld the sub-beam to the longitudinal beam and to transport the welded sub-beam and longitudinal beam to the truss traction unit 5.

[0088] The truss traction unit 5 is used to pull the welded longitudinal beams;

[0089] The overall support structure 1 is used to support the longitudinal beam manufacturing unit 2, the sub-beam winding unit 3, the ultrasonic welding unit 4, and the truss traction unit 5.

[0090] In practical applications, this implementation method, such as Figure 1 As shown, the longitudinal beam manufacturing unit 2 manufactures a 4mm longitudinal beam and conveys it to the secondary beam winding unit 3. The secondary beam winding unit 3 outputs three rods and adjusts the curvature of the three rods. The adjusted three rods are then used as secondary beams and wound around the longitudinal beam to form a crossbeam and a diagonal beam. After winding, the beams are conveyed to the ultrasonic welding unit 4. The ultrasonic welding unit 4 welds the wound secondary beams and longitudinal beams and conveys the welded secondary beams and longitudinal beams to the truss traction unit 5. The truss traction unit 5 pulls the welded secondary beams and longitudinal beams in a pulling manner, so that the on-orbit manufacturing device enters the next winding and welding cycle, realizing continuous manufacturing.

[0091] Implementation Method 2. See also Figure 2 This embodiment is an example of a secondary beam winding unit 3 in a continuous on-rail manufacturing device based on pultrusion molding and coiled rod material as described in Embodiment 1. The secondary beam winding unit 3 includes three rod straightening manufacturing modules 3-1, a first fixed support 3-2, a first slewing bearing 3-3, a first slewing support 3-4, a large slewing structure 3-5, and a slewing gear 3-6.

[0092] The first fixed support 3-2 is fitted inside the first slewing bearing 3-3;

[0093] The first slewing bearing 3-3 is fixed to the large slewing structure 3-5 by the first slewing support 3-4;

[0094] The large slewing structure 3-5 is mounted on the slewing gear 3-6;

[0095] The three rod straightening manufacturing modules 3-1 are evenly fixed on the large rotary structure 3-5;

[0096] The three rod straightening manufacturing modules 3-1 are used to output three rods, adjust the curvature of the three rods, and use the adjusted three rods as secondary beams. Under the rotation of the rotary gear 3-6, the secondary beams are wound around the longitudinal beam to form a crossbeam and an oblique beam, thus completing the winding with the longitudinal beam.

[0097] The first slewing bearing 3-3 is used to drive the first fixed support 3-2 to generate different height differences.

[0098] In practical applications, this implementation method, such as Figure 1 As shown, the first fixed support 3-2 is fitted inside the first slewing bearing 3-3. The different height differences of the first fixed support 3-2, i.e., the three bottom fixed supports 3-1-1 with a height difference of 1mm, form three secondary beams with an adjacent cross-section center distance of 1mm. The first slewing bearing 3-3 is fixed to the large slewing structure 3-5 via the first slewing support 3-4. The large slewing structure 3-5 is fixed to the slewing gear 3-6. The three rod straightening manufacturing modules 3-1 are evenly fixed to the large slewing structure 3-5, allowing the three rod straightening manufacturing modules 3-1 to rotate 360 ​​degrees under the action of the slewing gear 3-6. In application, the three rod straightening manufacturing modules 3-1 simultaneously extend 1mm of secondary beams. The three secondary beams are wound onto the longitudinal beam according to a set winding procedure. During the winding process, the secondary beams form horizontal and diagonal beams, completing the winding with the longitudinal beam.

[0099] Implementation Method 3. See also Figure 3 and Figure 4 This embodiment illustrates the rod straightening manufacturing module 3-1 in a continuous on-rail manufacturing device based on rod pultrusion molding and coiled rod material as described in Embodiment 2. The rod straightening manufacturing module 3-1 includes a material box shell 3-1-3, a curved rod drum 3-1-4, a second rotary bearing 3-1-12, a straightening heating block 3-1-6, a mold fixing plate 3-1-7, a straightening mold 3-1-8, a heating ceramic 3-1-10, and a 45° rotatable extruder head 3-1-11.

[0100] The crank drum 3-1-4 is fixed inside the material box shell 3-1-3 by the second rotary bearing 3-1-12;

[0101] The straightening heating block 3-1-6 is disposed inside the outer shell 3-1-3 of the material box and fixed at the discharge end of the curved drum 3-1-4;

[0102] The straightening mold 3-1-8 is fixed to the discharge port of the straightening heating block 3-1-6 by the mold fixing plate 3-1-7;

[0103] The heating ceramic 3-1-10 is fixed at the discharge port of the straightening mold 3-1-8;

[0104] The 45° rotatable extruder head 3-1-11 is fixed on the heating ceramic 3-1-10;

[0105] The curved rod drum 3-1-4 is used to convey the coiled rod to the straightening heating block 3-1-6;

[0106] The straightening heating block 3-1-6 is used to straighten the curled rod and then convey it to the straightening mold 3-1-8;

[0107] The straightening mold 3-1-8 is used to convey the straightened rod to the heating ceramic 3-1-10;

[0108] The heating ceramic 3-1-10 is used to heat the received rod and convey it to the 45° rotatable extruder 3-1-11;

[0109] The 45° rotatable extruder 3-1-11 is used to process the bending angle of the rod to form a secondary beam, and then wraps the secondary beam around the longitudinal beam to form a crossbeam and a diagonal beam, thus completing the wrapping with the longitudinal beam.

[0110] In practical applications, this implementation method, such as Figure 3 and Figure 4 As shown, the curved rod drum 3-1-4 contains a coiled rod, which is fixed inside the material box shell 3-1-3 by the second slewing bearing 3-1-12. A straightening heating block 3-1-6 is disposed inside the material box shell 3-1-3 and fixed at the outlet of the curved rod drum 3-1-4, allowing the bent rod exiting the drum 3-1-4 to enter the straightening heating block 3-1-6. The straightening heating block 3-1-6 straightens the bent rod during heating and then conveys the straightened rod to the heating ceramic 3-1-10 via the straightening die 3-1-8. The heating ceramic 3-1-10 further heats the rod and then conveys it to the 45° rotatable extruder 3-1-11. The 45° rotatable extruder adjusts the angle of the heated rod to accommodate changes in the winding schedule.

[0111] Implementation Method Four. See also Figure 3 and Figure 4 This embodiment is an example of the rod straightening manufacturing module 3-1 in the continuous on-rail manufacturing device based on rod pultrusion molding and coiled rod material as described in Embodiment 3. The rod straightening manufacturing module 3-1 also includes a fastening and anti-loosening structure 3-1-5, a movable hinge 3-1-9, a bottom fixed support 3-1-1, and a fixed base plate 3-1-2.

[0112] The fastening and anti-loosening structure 3-1-5 is installed inside the outer shell of the material box 3-1-3 and fixed between the straightening heating block 3-1-6 and the discharge port of the curved rod drum 3-1-4 to prevent the rod from falling off.

[0113] The movable hinge 3-1-9 is fixed on the upper and lower sides of the straightening mold 3-1-8 to accommodate the angular change of the rod during the winding process;

[0114] The bottom fixed support 3-1-1 is fixed to the material box shell 3-1-3 by the fixed base plate 3-1-2, and is used to support the material box shell 3-1-3;

[0115] The bottom fixed support 3-1-1 is fixed on the large rotating structure 3-5.

[0116] In practical applications, this implementation method, such as Figure 3 and Figure 4 As shown, the fastening and anti-loosening structure 3-1-5 is installed inside the material box shell 3-1-3 and fixed between the straightening heating block 3-1-6 and the discharge port of the curved rod drum 3-1-4 to prevent the rod from falling off. The movable hinge 3-1-9 is fixed on the upper and lower sides of the straightening mold 3-1-8 to accommodate the angle change of the rod during the winding process; the bottom fixed support 3-1-1 is fixed to the material box shell 3-1-3 through the fixed base plate 3-1-2 to support the material box shell 3-1-3.

[0117] Implementation Method 5. See also Figure 5 and Figure 6 This embodiment is described in the example of the ultrasonic welding unit 4 in the continuous on-rail manufacturing device based on pultrusion molding and coiled rod material described in Embodiment 1. The ultrasonic welding unit 4 includes a second fixed support 4-2, a micro-movement cam support 4-3, a drive gear 4-4, a second rotary support 4-5, an ultrasonic welder 4-6, a sliding double-sided fixed plate 4-7, and a stop bar 4-9.

[0118] The second fixed support 4-2 is fixed to one side of the micro-cam support 4-3;

[0119] The drive gear 4-4 is connected to the micro-motion cam support 4-3;

[0120] The second rotary support 4-5 is fixed to the other side of the micro-cam support 4-3.

[0121] The ultrasonic welding machine 4-6 is used to be fixed on the second rotary support 4-5 by the sliding double-sided fixing plate 4-7;

[0122] The ultrasonic welding machine 4-6 is slidably connected to the slidable double-sided fixing plate 4-7;

[0123] The stop bar 4-9 is connected to the trigger end of the ultrasonic welding machine 4-6;

[0124] The micro-motion cam support 4-3 is used to achieve reciprocating motion through the drive gear 4-4, thereby driving the second rotary support 4-5 to achieve reciprocating motion;

[0125] The outer edge profile of the micro-motion cam support 4-3 is used to trigger the ultrasonic welding machine 4-6 via the stop bar 4-9.

[0126] In practical applications, this implementation method, such as Figure 5 and Figure 6 As shown, the micro-motion cam support 4-3 is connected to the driving gear 4-4 via gears, enabling the micro-motion cam support 4-3 to reciprocate under the action of the driving gear 4-4. The two sides of the micro-motion cam support 4-3 are respectively equipped with a second fixed support 4-2 and a second rotary support 4-5. The ultrasonic welder 4-6 is fixed to the second rotary support 4-5 via the slidable double-sided fixed plate 4-7. The stop rod 4-9 is connected to the trigger end of the ultrasonic welder 4-6, allowing the micro-motion cam support 4-3 to reciprocate while simultaneously triggering the ultrasonic welder 4-6 to complete the welding process of three sub-beams and longitudinal beams through the outer contour of the cam of the micro-motion cam support 4-3 and the stop rod 4-9. The micro-motion cam support 4-3 is designed with a predetermined cam trajectory to ensure close contact between the stop rod and the outer contour, achieving the downward stroke and welding stroke. Simultaneously, the ultrasonic welder 4-6 moves slowly upward along the slidable double-sided fixed plate 4-7, reducing the impact force during the return stroke.

[0127] Implementation Method Six. See also Figure 6 This embodiment is described by way of example of the ultrasonic welding unit 4 in the continuous on-rail manufacturing device based on pultrusion molding and coiled rod material described in Embodiment 5. The ultrasonic welding unit 4 also includes compression springs 4-8.

[0128] The compression spring 4-8 interacts with the outer shell of the ultrasonic welding machine 4-6 to achieve the return process.

[0129] In practical applications, this implementation method, such as Figure 6 As shown, the compression spring 4-8 interacts with the housing of the integrated ultrasonic welding machine 4-6 to achieve the return process and fit the outer contour of the cam.

[0130] Implementation Method Seven. See also Figure 5This embodiment is described by way of example of the ultrasonic welding unit 4 in the continuous on-rail manufacturing device based on pultrusion molding and coiled rod material described in Embodiment 5. The ultrasonic welding unit 4 also includes a support rib plate 4-1.

[0131] The supporting rib 4-1 is fixed on the second fixed support 4-2 to provide support.

[0132] In practical applications, this implementation method, such as Figure 5 As shown, the support rib 4-1 is fixed on the second fixed support 4-2 to achieve the support function.

[0133] Implementation Method 8. See also Figure 7 This embodiment is an example of a truss traction unit 5 in a continuous on-rail manufacturing device based on pultrusion molding and coiled rod material as described in Embodiment 1. The truss traction unit 5 includes two drive shafts 5-3, two bevel gears 5-4, a central support 5-5, and three sets of traction modules.

[0134] The three sets of traction modules are used to achieve a star-shaped connection through the central support 5-5;

[0135] The three sets of traction modules are used to achieve series transmission through the two drive shafts 5-3 and the two bevel gears 5-4;

[0136] The traction module is used to pull the welded longitudinal beam.

[0137] In practical applications, this implementation method, such as Figure 7 As shown, the three sets of traction modules are used to pull the three welded longitudinal beams, and the three sets of traction modules are connected in a star shape through the central support 5-5. The three sets of traction modules are connected in series through the two drive shafts 5-3 and the two bevel gears 5-4, which drive the three sets of traction modules to rotate simultaneously.

[0138] Implementation Method Nine. See also... Figure 7 This embodiment is an example of a traction module in a continuous on-rail manufacturing device based on pultrusion molding and coiled rod material as described in Embodiment 8. The traction module includes an upper traction transmission module and a lower traction transmission module.

[0139] The upper traction transmission module is connected to the central support 5-5;

[0140] The lower traction transmission module is equipped with a chain drive 5-7 with a gripper design;

[0141] The upper traction transmission module is used to connect with the lower traction transmission module through the chain transmission 5-7 with clamp design to pull the welded longitudinal beam.

[0142] The transmission fixing plate 5-8 is used to fix the transmission chain of the lower traction transmission module;

[0143] The preload wheel 5-2 is used to adjust the tension of the transmission chain;

[0144] The adjustable slot 5-6 is used to adjust the connection position between the upper traction transmission module and the central support 5-5.

[0145] In practical applications, this implementation method, such as Figure 7 As shown, the traction module includes an upper traction drive module and a lower traction drive module. The upper traction drive module is connected to the lower traction drive module via a chain drive 5-7 with a gripper design, enabling the truss to move forward 100mm. During rotation, the preload wheel 5-2 is connected to the adjustable slot 5-6 through several connecting plates. By changing the position of the adjustable slot 5-6, tension is applied outward from the center, tightening the chain and thus clamping the truss structure, applying preload, and moving it forward.

[0146] Implementation Method 10. This implementation method provides a continuous on-rail manufacturing method based on pultrusion molding of coiled rods and coiled rod material. The manufacturing method is implemented using any one of the implementation methods 1 to 10, and the manufacturing method is as follows:

[0147] Step 1: After stretching the longitudinal beam to 700mm using the longitudinal beam manufacturing unit, it is then conveyed to the secondary beam winding unit;

[0148] Step 2: Use the secondary beam winding unit to output three rods, and adjust the curvature of the three rods before using them as secondary beams to wind around the longitudinal beam;

[0149] Step 3: Use an ultrasonic welding unit to weld the sub-beam to the longitudinal beam;

[0150] Step 4: After welding is completed, the welded longitudinal beam is pulled by the truss traction unit, and the secondary beam winding unit rotates 360° to enter the next winding welding cycle, thus realizing continuous manufacturing.

[0151] In practical application, this embodiment involves installing the longitudinal beam material box onto the interface of the longitudinal beam manufacturing unit. After stretching the longitudinal beam by approximately 700mm using a mold, the longitudinal beam manufacturing unit is connected to the support rib plate. Simultaneously, a rod roll is installed, the mold and straightening module are heated, and the sub-beam is stretched to its initial position. After the three sets of longitudinal beam manufacturing units form the longitudinal beam members, they are welded to the sub-beam at the initial position by the ultrasonic welding unit, completing the welding. After welding, the sub-beam winding unit rotates 360°, the longitudinal beam manufacturing unit manufactures the longitudinal beam members, and pulls them a specified distance. At the same time, the sub-beam winding unit rotates by a corresponding angle, and the truss traction unit, after clamping with the truss node through the grippers, continues to pull the truss. After completing the set pulling distance, it continues winding 360°, entering the next winding and welding cycle, thus achieving continuous manufacturing.

[0152] 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.

[0153] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are 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.

[0154] 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, improvements, etc., 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. A continuous on-orbit manufacturing device based on pultrusion molding of coiled rods and continuous on-orbit manufacturing of coiled rod materials, characterized in that, The device includes an overall support structure (1), a longitudinal beam manufacturing unit (2), a secondary beam winding unit (3), an ultrasonic welding unit (4), and a truss traction unit (5). The longitudinal beam manufacturing unit (2) is used to manufacture longitudinal beams and also to transport the longitudinal beams to the sub-beam winding unit (3). The sub-beam winding unit (3) is used to output three rods, and also to adjust the curvature of the three rods. The adjusted three rods are used as sub-beams to wind around the longitudinal beam to form a transverse beam and an oblique beam. After winding, the rods are delivered to the ultrasonic welding unit (4). The sub-beam winding unit (3) includes three rod straightening manufacturing modules (3-1), a first fixed support (3-2), a first slewing bearing (3-3), a first slewing support (3-4), a large slewing structure (3-5), and a slewing gear (3-6). The first fixed support (3-2) is fitted inside the first slewing bearing (3-3); The first slewing bearing (3-3) is fixed to the large slewing structure (3-5) by the first slewing support (3-4); The large slewing structure (3-5) is mounted on the slewing gear (3-6); The three rod straightening manufacturing modules (3-1) are evenly fixed on the large rotating structure (3-5); The three rod straightening manufacturing modules (3-1) are used to output three rods, adjust the curvature of the three rods, and use the adjusted three rods as secondary beams. Under the rotation of the rotary gear (3-6), the secondary beams are wound around the longitudinal beam to form a crossbeam and an oblique beam, thus completing the winding with the longitudinal beam. The first slewing bearing (3-3) is used to drive the first fixed support (3-2) to generate different height differences; The rod straightening manufacturing module (3-1) includes a material box shell (3-1-3), a curved rod drum (3-1-4), a second rotary bearing (3-1-12), a straightening heating block (3-1-6), a mold fixing plate (3-1-7), a straightening mold (3-1-8), a heating ceramic (3-1-10), and a 45° rotatable extruder (3-1-11). The crank drum (3-1-4) is fixed inside the material box shell (3-1-3) by the second slewing bearing (3-1-12); The straightening heating block (3-1-6) is disposed inside the outer shell of the material box (3-1-3) and fixed at the discharge end of the curved drum (3-1-4); The straightening mold (3-1-8) is fixed to the discharge port of the straightening heating block (3-1-6) by the mold fixing plate (3-1-7); The heating ceramic (3-1-10) is fixed at the discharge port of the straightening mold (3-1-8); The 45° rotatable extruder (3-1-11) is fixed on the heating ceramic (3-1-10); The curved rod drum (3-1-4) is used to convey the coiled rod to the straightening heating block (3-1-6). The straightening heating block (3-1-6) is used to straighten the coiled rod and then convey it to the straightening mold (3-1-8). The straightening mold (3-1-8) is used to convey the straightened rod to the heating ceramic (3-1-10). The heating ceramic (3-1-10) is used to heat the received rod and feed it to the 45° rotatable extruder (3-1-11). The 45° rotatable extruder (3-1-11) is used to process the bending angle of the rod to form a secondary beam, and then the secondary beam is wound around the longitudinal beam to form a crossbeam and a diagonal beam, thus completing the winding with the longitudinal beam; The rod straightening manufacturing module (3-1) also includes a fastening and anti-loosening structure (3-1-5), a movable hinge (3-1-9), a bottom fixed support (3-1-1), and a fixed base plate (3-1-2). The fastening and anti-loosening structure (3-1-5) is installed inside the outer shell of the material box (3-1-3) and fixed between the straightening heating block (3-1-6) and the discharge port of the curved rod drum (3-1-4) to prevent the rod from falling off; The movable hinge (3-1-9) is fixed on the upper and lower sides of the straightening mold (3-1-8) to accommodate the angular change of the rod during the winding process; The bottom fixed support (3-1-1) is fixed to the outer shell of the material box (3-1-3) by the fixed base plate (3-1-2) to support the outer shell of the material box (3-1-3). The bottom fixed support (3-1-1) is fixed to the large rotation structure (3-5); The ultrasonic welding unit (4) is used to weld the sub-beam to the longitudinal beam and to transport the welded sub-beam and longitudinal beam to the truss traction unit (5). The truss traction unit (5) is used to pull the welded longitudinal beams; The overall support structure (1) is used to support the longitudinal beam manufacturing unit (2), the sub-beam winding unit (3), the ultrasonic welding unit (4), and the truss traction unit (5).

2. The device for continuous on-rail manufacturing of coiled rods based on pultrusion molding and coiled rod material according to claim 1, characterized in that, The ultrasonic welding unit (4) includes a second fixed support (4-2), a micro-motion cam support (4-3), a drive gear (4-4), a second rotary support (4-5), an ultrasonic welder (4-6), a sliding double-sided fixed plate (4-7), and a stop bar (4-9). The second fixed support (4-2) is fixed to one side of the micro-motion cam support (4-3); The drive gear (4-4) is connected to the micro-motion cam support (4-3) gear; The second rotary support (4-5) is fixed to the other side of the micro-motion cam support (4-3). The ultrasonic welding machine (4-6) is used to be fixed on the second rotary support (4-5) by means of the sliding double-sided fixing plate (4-7); The ultrasonic welding machine (4-6) is slidably connected to the slidable double-sided fixing plate (4-7); The stop bar (4-9) is connected to the trigger end of the ultrasonic welding machine (4-6); The micro-motion cam support (4-3) is used to achieve reciprocating motion through the drive gear (4-4), thereby driving the second rotary support (4-5) to achieve reciprocating motion; The outer edge profile of the micro-motion cam support (4-3) is used to trigger the ultrasonic welding machine (4-6) via the stop bar (4-9).

3. The device for continuous on-rail manufacturing of coiled rods based on pultrusion molding and coiled rod material according to claim 2, characterized in that, The ultrasonic welding unit (4) also includes a compression spring (4-8). The compression spring (4-8) interacts with the housing of the ultrasonic welding machine (4-6) to achieve the return process.

4. The device for continuous on-rail manufacturing of coiled rods based on pultrusion molding and coiled rod material according to claim 2, characterized in that, The ultrasonic welding unit (4) also includes a support rib (4-1). The supporting rib (4-1) is fixed on the second fixed support (4-2) to provide support.

5. The device for continuous on-rail manufacturing of coiled rods based on pultrusion molding and coiled rod material according to claim 1, characterized in that, The truss traction unit (5) includes two drive shafts (5-3), two bevel gears (5-4), a central support (5-5), and three sets of traction modules; The three sets of traction modules are used to achieve a star-shaped connection through the central support (5-5); The three sets of traction modules are used to achieve series transmission through the two drive shafts (5-3) and the two bevel gears (5-4); The traction module is used to pull the welded longitudinal beam.

6. The device for continuous on-rail manufacturing of coiled rods based on pultrusion molding and coiled rod material according to claim 5, characterized in that, The traction module includes an upper traction drive module and a lower traction drive module; The upper traction transmission module is connected to the central support (5-5); The lower traction transmission module is equipped with a chain drive with a gripper design (5-7). The upper traction transmission module is used to connect with the lower traction transmission module through the chain transmission with gripper design (5-7) to pull the welded longitudinal beam. The transmission fixing plate (5-8) is used to fix the transmission chain of the lower traction transmission module; The preload wheel (5-2) is used to adjust the tension of the drive chain; The adjustable slot (5-6) is used to adjust the connection position between the upper traction transmission module and the central support (5-5).

7. A method for continuous on-orbit manufacturing of coiled rods based on pultrusion molding and coiled rod material, characterized in that, The manufacturing method is based on a continuous on-rail manufacturing device for pultrusion molding and coiled rod material as described in any one of claims 1-6, and the manufacturing method is as follows: Step 1: After stretching the longitudinal beam to 700mm using the longitudinal beam manufacturing unit, it is then conveyed to the secondary beam winding unit; Step 2: Use the secondary beam winding unit to output three rods, and adjust the curvature of the three rods before using them as secondary beams to wind around the longitudinal beam; Step 3: Use an ultrasonic welding unit to weld the sub-beam to the longitudinal beam; Step 4: After welding is completed, the welded longitudinal beam is pulled by the truss traction unit, and the secondary beam winding unit rotates 360° to enter the next winding welding cycle, thus realizing continuous manufacturing.

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