Method of manufacturing a carbon fiber composite based aerodynamic pushrod head structure
By manufacturing the aerodynamic push rod head structure using carbon fiber composite materials, the problems of low carrying capacity and safety hazards of existing metal structures have been solved. This has resulted in structural weight reduction and cost reduction, and the structure is suitable for composite material molding processes, thereby improving the rocket's carrying capacity and safety.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- HUIZHOU HILONG MOULD & PLASTIC PRODUCE CO LTD
- Filing Date
- 2023-12-15
- Publication Date
- 2026-06-23
AI Technical Summary
Existing metal pneumatic push rod head structures have low overall carrying capacity, high launch costs, pose safety hazards, and are not suitable for composite material molding processes.
The pneumatic actuator head structure is made of carbon fiber composite material, which is divided into multiple parts and laid in multiple layers. It is cured and formed by autoclaving process, and has a thickened area and a silicone protective sleeve. The layup angle and ratio are optimized.
It achieves structural weight reduction, improves carrying capacity and safety, reduces launch costs, is suitable for composite material molding processes, and ensures product quality and mechanical properties.
Smart Images
Figure CN117698161B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of launch vehicle technology, and in particular to a method for manufacturing a pneumatic push rod head structure based on carbon fiber composite materials. Background Technology
[0002] With the continuous development of satellite communication and satellite internet technologies, the market demand for satellite launches is constantly growing, and the market demand for launch vehicles is also increasing. Currently, the domestic private commercial aerospace market is booming. For commercial aerospace, given a fixed engine thrust, reducing structural weight to increase the carrying capacity and reduce launch costs has always been a goal pursued by launch vehicle developers. Based on current commercial aerospace launch price calculations, every kilogram reduction in the launch vehicle's structure can generate approximately 60,000 to 80,000 yuan in economic benefits. Therefore, weight reduction is of great significance for launch vehicles. Composite materials, as an emerging material, have advantages over traditional metal materials, such as higher specific strength, higher specific stiffness, and better weather resistance. Under the premise of equal strength and stiffness, they can reduce weight by more than 30% compared to the original aluminum alloy structure and more than 40% compared to the original steel structure. Therefore, carbon fiber composite materials have been widely used in the aerospace field, with successful applications in areas such as launch vehicle fairings, interstage sections, engine casings, instrument bays, and satellite supports.
[0003] As a crucial component for rocket engine separation, the existing aerodynamic push rod head structure is still primarily constructed of aluminum alloy, such as... Figure 1 As shown, the existing metal pneumatic push rod head structure 1 is connected to the tail nozzle device 2 of the launch vehicle engine at its upper part and to the pneumatic push rod 3 at its lower part. The existing pneumatic push rod head structure 1 includes three parts formed by an integrated casting process: support surface 13, rib plate 12, and cylinder 11.
[0004] The existing metal pneumatic actuator head structure has the following defects:
[0005] (1) The single piece weighs 20 kg and has a load capacity of 10 tons. The total weight of all head structures of the separation mechanism (including multiple head structures) is as high as 200 kg, which reduces the overall carrying capacity and increases the launch cost.
[0006] (2) The engine tail nozzle device 2 that is in contact with the support surface 13 is made of copper. The hardness of aluminum alloy is greater than that of copper. When the pneumatic push rod 3 is working, it will instantly generate an impact load of about ten tons. Under the action of this impact load, the head structure 1 will scratch the copper surface of the tail nozzle device 2, which may affect the operation of the engine and poses a great safety hazard.
[0007] (3) The existing metal pneumatic push rod head structure is not suitable for the process requirements of composite material molding.
[0008] To solve this technical problem, we invented a manufacturing method for a pneumatic actuator head structure based on carbon fiber composite materials. Summary of the Invention
[0009] The purpose of this invention is to solve the problems of existing metal pneumatic push rod head structures, such as low overall carrying capacity, high launch cost, scratching the copper surface of the tail nozzle, affecting engine operation, posing significant safety hazards, and unsuitability for composite material molding processes. The specific solution is as follows:
[0010] A method for manufacturing a pneumatic actuator head structure based on carbon fiber composite materials includes:
[0011] The head structure is divided into five parts: a frustum-shaped upper shell, an inverted frustum-shaped lower shell, a support tube, a flange seat, and a frustum-shaped protective sleeve.
[0012] The first thickened area is set at the junction of the upper circular plane and the circumferential inclined surface of the upper shell, and the second thickened area is set at the junction of the first circular wall and the circumferential inclined surface of the upper shell.
[0013] A third thickened area is set at the junction of the second annular wall and the circumferential inclined surface of the lower shell, and a fourth thickened area is set at the junction of the lower circular plane and the circumferential inclined surface of the lower shell.
[0014] The entire area of the upper shell is covered with multiple layers of carbon fiber prepreg, and then multiple layers of carbon fiber prepreg are inserted into the multi-layer intervals of the first thickened area and the second thickened area for further covering. After the covering is completed, the upper shell product is sealed on the mold surface using a vacuum bag and cured and formed by autoclave process.
[0015] The entire area of the lower shell is covered with multiple layers of carbon fiber prepreg, and then multiple layers of carbon fiber prepreg are inserted into the multi-layer intervals of the third and fourth thickened areas for further covering. After the covering is completed, the lower shell product is sealed on the mold surface using a vacuum bag and cured and formed by autoclave process.
[0016] The support tube is laid in multiple layers using carbon fiber prepreg. After the laying is completed, the support tube product is sealed on the mold surface using a vacuum bag and cured by autoclave process.
[0017] With the center of the lower circular plane of the lower shell as the origin, a unified cylindrical coordinate system is established, and the ply angle is defined as follows: 0° direction is the axial direction of the head structure, and 90° direction is the circumferential direction of the head structure.
[0018] In a unified cylindrical coordinate system, all the layers of the upper shell, lower shell, and support tube are laid in an alternating pattern using four angles: 0°, ±45°, and 90°.
[0019] Furthermore, the method of using carbon fiber prepreg for multi-layer laying of the overall area of the upper shell is as follows: 10 to 35 layers of carbon fiber prepreg with a single layer thickness of 0.1 mm to 0.3 mm are laid together; the method of inserting multiple layers of carbon fiber prepreg into the multi-layer intervals of the first thickened area and the second thickened area is as follows: 5 to 15 layers of carbon fiber prepreg with a single layer thickness of 0.1 mm to 0.3 mm are inserted into the non-thickened area layer intervals to ensure the strength of the first thickened area and the second thickened area.
[0020] Furthermore, among all the layers of the upper shell, the 0° layer accounts for 40% to 60%, the ±45° layers account for 10% to 15% respectively, and the 90° layer accounts for 20% to 30%.
[0021] Optionally, the upper shell has a total of 16 layers, of which the 0° layers are P01, P03, P05, P07, P09, P11, P13 and P15, the 90° layers are P02, P08, P10 and P16, the 45° layers are P04 and P12, and the -45° layers are P06 and P14.
[0022] Furthermore, the method of using carbon fiber prepreg for multi-layer laying in the overall area of the lower shell is as follows: 20 to 60 layers of carbon fiber prepreg with a single layer thickness of 0.1 mm to 0.3 mm are laid; the method of inserting multiple layers of carbon fiber prepreg into the multi-layer intervals of the third thickened area and the fourth thickened area is as follows: 5 to 15 layers of carbon fiber prepreg with a single layer thickness of 0.1 mm to 0.3 mm are inserted into the non-thickened area layer intervals to ensure the strength of the third thickened area and the fourth thickened area.
[0023] Furthermore, among all the layers of the lower shell, the 0° layer accounts for 40% to 70%, the ±45° layers account for 10% to 15% respectively, and the 90° layer accounts for 10% to 30%.
[0024] Optionally, the lower shell has a total of 24 layers, of which the 0° layers are Q01, Q03, Q05, Q07, Q09, Q11, Q13, Q15, Q17, Q19, Q21 and Q23, the 90° layers are Q02, Q08, Q10, Q16, Q18 and Q24, the 45° layers are Q04, Q12 and Q20, and the -45° layers are Q06, Q14 and Q22.
[0025] Furthermore, the method of multi-layer laying of the support tube using carbon fiber prepreg is as follows: 10 to 35 layers of carbon fiber prepreg with a single layer thickness of 0.1 mm to 0.3 mm are laid; among all the laying layers of the support tube, the 0° layer accounts for 50% to 60%, the ±45° layers account for 10% to 12.5% respectively, and the 90° layer accounts for 20% to 25%.
[0026] Optionally, the support pipe has a total of 12 layers, of which the 0° layers are R01, R03, R05, R07 and R09, the 90° layers are R02, R08 and R10, the 45° layers are R04 and R11, and the -45° layers are R06 and R12.
[0027] Furthermore, the protective sleeve is a silicone protective sleeve, which is made of AIRCAST3700A / B material. The AIRCAST3700 silicone system is mixed in a ratio of A:B = 100:12, stirred evenly, and then poured into a silicone protective sleeve molding mold. It is then cured and molded at room temperature for 24 hours or at 60°C for 3 hours.
[0028] In summary, the technical solution of the present invention has the following beneficial effects:
[0029] This solution addresses the problems of existing metal pneumatic push rod head structures, such as low overall carrying capacity, high launch cost, scratching the copper surface of the tail nozzle, affecting engine operation, posing significant safety hazards, and unsuitability for composite material molding processes. This solution employs an integral separation mechanism, which offers the following advantages:
[0030] (1) Based on the load-bearing capacity requirements of the head structure and the stress state of each component, the present invention has carried out a reasonable optimization design of the prepreg layup angle, layup sequence and layup ratio to ensure that the load-bearing requirements of the head structure are met and to achieve overall weight reduction of the structure.
[0031] (2) The pneumatic push rod head structure of carbon fiber composite material designed in this invention is suitable for carbon fiber composite material autoclave molding process. The prepreg is easy to lay, the molding process is mature and reliable, the product quality is stable, and the mechanical properties are excellent.
[0032] (3) The carbon fiber composite aerodynamic pusher head structure manufactured using this method reduces the weight of the original metal aerodynamic pusher head structure from 20 kg per unit to 6-8 kg per unit. The overall separation mechanism of this method can achieve a weight reduction of 120-140 kg, improving the rocket's carrying capacity and increasing the load-bearing capacity of the original metal aerodynamic pusher head structure from 10 tons to 15-20 tons. This reduces the rocket's launch cost and can create significant economic benefits.
[0033] (4) This solution is equipped with a silicone protective sleeve, which gives the pneumatic push rod head structure surface a buffering capacity, so that it will not cause impact damage to the copper surface of the tail spray device under impact load, thus eliminating safety risks. Attached Figure Description
[0034] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments of the present invention will be briefly introduced below. Obviously, the accompanying drawings described below are only a part of the embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.
[0035] Figure 1 This is a cross-sectional view of the existing metal pneumatic actuator head structure in the background art;
[0036] Figure 2 This is an exploded view of the pneumatic actuator head structure based on carbon fiber composite material of the present invention;
[0037] Figure 3 This is a schematic diagram of the upper shell layer of the present invention;
[0038] Figure 4 for Figure 3 Enlarged view of area A in the image;
[0039] Figure 5 for Figure 3 Enlarged view of area B in the image;
[0040] Figure 6 This is a schematic diagram of the lower shell layer of the present invention;
[0041] Figure 7 for Figure 6 Enlarged view of area C in the image;
[0042] Figure 8 for Figure 6 Enlarged view of area D in the image;
[0043] Figure 9 This is a schematic diagram of the support tube layer of the present invention;
[0044] Figure 10 for Figure 9 Enlarged view of area E in the image.
[0045] Explanation of reference numerals in the attached figures:
[0046] 1- Existing metal pneumatic push rod head structure, 2- Tail spray device, 3- Pneumatic push rod, 11- Cylindrical, 12- Rib plate, 13- Support surface, 31- Front frustum, 41- Protective sleeve, 42- Upper shell, 43- Lower shell, 44- Support tube, 45- Flange seat, 411- Circular window, 421- First thickened area, 422- Second thickened area, 423- First air hole, 424- Rivet hole, 425- First circular hole, 426- First annular wall, 431- Third thickened area, 432- Fourth thickened area, 433- Second air hole, 435- Third circular hole, 436- Second annular wall, 437- Axis axis, 441- First circular platform, 442- Second circular hole, 451- Upper convex tube, 452- Second circular platform, 453- Threaded hole. Detailed Implementation
[0047] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.
[0048] like Figures 2 to 10 As shown, the manufacturing method of the pneumatic actuator head structure based on carbon fiber composite material includes: dividing the head structure into five parts: a frustum-shaped upper shell 42, an inverted frustum-shaped lower shell 43, a support tube 44, a flange seat 45, and a frustum-shaped protective sleeve 41.
[0049] The first thickened area 421 is set at the junction of the upper circular plane and the peripheral inclined surface of the upper shell 42, and the second thickened area 422 is set at the junction of the first annular wall 426 and the peripheral inclined surface of the upper shell 42.
[0050] The third thickened area 431 is set at the junction of the second annular wall 436 of the lower shell 43 and the circumferential inclined surface, and the fourth thickened area 432 is set at the junction of the lower circular plane of the lower shell 43 and the circumferential inclined surface.
[0051] The entire area of the upper shell 42 is covered with multiple layers of carbon fiber prepreg, and then multiple layers of carbon fiber prepreg are inserted into the multi-layer intervals of the first thickened area 421 and the second thickened area 422 respectively for further covering; after the covering is completed, the upper shell product is sealed on the mold surface using a vacuum bag and cured and formed by autoclave process.
[0052] The lower shell 43 is covered with multiple layers of carbon fiber prepreg, and then multiple layers of carbon fiber prepreg are inserted into the multi-layer intervals of the third thickened area 431 and the fourth thickened area 432 for further coverage. After coverage, the lower shell product is sealed on the mold surface using a vacuum bag and cured by autoclave process.
[0053] The support tube 44 is laid with multiple layers of carbon fiber prepreg. After the laying is completed, the support tube product is sealed on the mold surface using a vacuum bag and cured by autoclave process.
[0054] Using the center of the lower circular plane of the lower shell 43 as the origin, a unified cylindrical coordinate system is established to define the ply angles: the 0° direction is the axis 437 direction of the head structure, and the 90° direction is the circumferential direction of the head structure.
[0055] In a unified cylindrical coordinate system, all the paving layers of the upper shell 42, lower shell 43, and support tube 44 are laid in an alternating manner using four angles: 0°, ±45°, and 90°.
[0056] Specifically, the overall area of the upper shell 42 is constructed using a multi-layer carbon fiber prepreg method: 10 to 35 layers of carbon fiber prepreg with a single layer thickness of 0.1 mm to 0.3 mm are laid. The method of inserting multiple layers of carbon fiber prepreg into the multi-layer intervals of the first thickened area 421 and the second thickened area 422 is as follows: 5 to 15 layers of carbon fiber prepreg with a single layer thickness of 0.1 mm to 0.3 mm are inserted into the non-thickened area layer intervals to ensure the strength of the first thickened area 421 and the second thickened area 422.
[0057] Specifically, among all the layers of the upper shell 42, the 0° layer accounts for 40% to 60%, the ±45° layers account for 10% to 15% respectively, and the 90° layer accounts for 20% to 30%.
[0058] Specifically, the lower shell 43 is constructed using a multi-layer carbon fiber prepreg method: 20 to 60 layers of carbon fiber prepreg with a single layer thickness of 0.1 mm to 0.3 mm are laid. The method for inserting multiple layers of carbon fiber prepreg into the multi-layer intervals of the third thickened zone 431 and the fourth thickened zone 432 is as follows: 5 to 15 layers of carbon fiber prepreg with a single layer thickness of 0.1 mm to 0.3 mm are inserted into the non-thickened zone layer intervals to ensure the strength of the third thickened zone 431 and the fourth thickened zone 432.
[0059] Specifically, among all the layers of the lower shell 43, the 0° layer accounts for 40% to 70%, the ±45° layers account for 10% to 15% respectively, and the 90° layer accounts for 10% to 30%.
[0060] Specifically, the support tube 44 is constructed using a multi-layer carbon fiber prepreg method: 10 to 35 layers of carbon fiber prepreg with a single layer thickness of 0.1 mm to 0.3 mm are laid. Of all the layers laid on the support tube 44, the 0° layer accounts for 50% to 60%, the ±45° layers each account for 10% to 12.5%, and the 90° layer accounts for 20% to 25%.
[0061] Specifically, the protective sleeve 41 is a silicone protective sleeve made of AIRCAST3700A / B material. The AIRCAST3700 silicone system is mixed in a ratio of A:B = 100:12, stirred evenly, and then poured into a silicone protective sleeve molding mold. It is then cured and molded at room temperature for 24 hours or at 60°C for 3 hours. The protective sleeve 41 has a circular opening 411.
[0062] Flange seat 45 is made of aluminum alloy by CNC machining. The main function of flange seat 45 is to connect support tube 44 and lower shell 43, and to connect lower shell 43 and pneumatic push rod 3 (see Figure 1 The connection shown is provided with internal threads to facilitate the assembly of the head structure and the pneumatic push rod 3. The upper end of the flange 45 is an upward-facing tube 451, and the lower end is a second circular platform 452. The second circular platform 452 has a plurality of evenly spaced threaded holes 453. The flange 45 is a hollow metal part. (The front end frustum 31 of the pneumatic push rod 3 has a plurality of screw holes that match the threaded holes 453, which are not shown in the figure.)
[0063] Example:
[0064] Optionally, the upper shell has a total of 16 layers, of which the 0° layers are P01, P03, P05, P07, P09, P11, P13 and P15, the 90° layers are P02, P08, P10 and P16, the 45° layers are P04 and P12, and the -45° layers are P06 and P14.
[0065] Optionally, the lower shell has a total of 24 layers, of which the 0° layer is Q01, Q03, Q05, Q07, Q09, Q11, Q13, Q15, Q17, Q19, Q21 and Q23, the 90° layer is Q02, Q08, Q10, Q16, Q18 and Q24, the 45° layer is Q04, Q12 and Q20, and the -45° layer is Q06, Q14 and Q22.
[0066] Optionally, the support pipe has a total of 12 layers, of which the 0° layer is R01, R03, R05, R07 and R09, the 90° layer is R02, R08 and R10, the 45° layer is R04 and R11, and the -45° layer is R06 and R12.
[0067] After manufacturing the upper shell 42, lower shell 43, support tube 44, and flange seat 45 according to the above embodiments, the present invention is then assembled according to the following steps:
[0068] 1. Bond the support pipe 44 to the flange seat 45 with adhesive;
[0069] 2. Attach the bonded support components to the lower shell 43;
[0070] 3. Based on the positioning of the threaded hole 453 of the flange seat 45, drill the third circular hole 435 in the lower shell 43;
[0071] 4. Drill holes for rivet holes 424 on the first annular wall 426 of the upper shell 42;
[0072] 5. Drill a hole 425 in the first circular hole on the upper shell 42;
[0073] 6. Simultaneously bond the upper surface of the first circular platform 441 of the upper shell 42 and the support tube 44, the first circular wall 426 of the upper shell 42 and the second circular wall 436 of the lower shell 43;
[0074] 7. Using the pre-drilled rivet holes 424 on the upper shell 42 as a reference, complete the drilling of the rivet holes 424 on the second annular wall 436 of the lower shell 43;
[0075] 8. Using the first round hole 425 drilled in the upper shell 42 as a positioning point, complete the drilling of the second round hole 442 on the first round platform 441 of the support tube 44;
[0076] 9. Secure the upper shell 42 to the support tube 44 and the upper shell 42 to the lower shell 43 with rivets respectively;
[0077] 10. Complete the drilling of the first air hole 423 of the upper shell 42 and the second air hole 433 of the lower shell 43 respectively; (The main function of the first air hole 423 and the second air hole 433 is to form a communication channel with the inner cavity of the head structure to facilitate the airflow when the head structure impacts the tail nozzle device 2, and to prevent the formation of a pressure difference between the tail nozzle device 2 and the head structure during the impact process, so as to bring additional air pressure load to the structure.)
[0078] 11. Attach the upper shell 42 to the protective sleeve 41 to complete the assembly of the head structure. (The first circular hole 425 and the first air hole 423 are located within the circular opening 411 of the protective sleeve 41)
[0079] The carbon fiber composite material referred to in this invention is a composite material made of epoxy resin as the matrix and continuous fibers as the reinforcing fibers. Carbon fiber prepreg: refers to a sheet-like preformed material in which treated resin and fibers are compounded to obtain resin in a semi-cured state, with a thickness typically between 0.1 mm and 0.6 mm.
[0080] Autoclave molding process: This involves layering prepreg onto a mold surface to achieve the designed number of layers. A vacuum bag is then used to seal the product between the mold and the vacuum bag. A vacuum pump is used to remove air from between the mold and the vacuum bag, creating a vacuum. Atmospheric pressure is then used to compact the prepreg and the mold. An autoclave, a special pressure vessel capable of precisely applying temperature and uniform positive pressure, is then used to heat and pressurize the prepreg mold, curing it. Typically, an autoclave provides 6 to 9 atmospheres of positive pressure to the product. This allows the resin to be heated to its flowable temperature, further impregnating the fiber in the product and expelling excess air bubbles, resulting in a high-quality composite material. This process is characterized by uniform pressure and accurate temperature control. Composite products molded using this process have low porosity and good mechanical property stability. This process is widely used in the molding of load-bearing structures in the aerospace field. For example, the curing process of this solution is briefly described as follows: The mold with the prepreg applied is sealed in a vacuum bag. Then, a vacuum pump is used to extract air from the vacuum bag until the internal negative pressure reaches -0.98 MPa. The vacuum bag and mold are then placed in an autoclave. The autoclave is heated to 60°C at a rate of 2°C / min. Then, a positive pressure of 0.6 MPa is injected into the autoclave using an air compressor. Once the pressure is reached, the temperature is further increased to 125°C at a rate of 2°C / min. This temperature is then maintained for 2 hours. After the maintenance time is reached, the temperature is reduced to 60°C at a rate of 2°C / min. The autoclave is then depressurized to standard atmospheric pressure, and the door is opened to complete the curing process. Demolding is then performed: the cured product is separated from the mold, yielding the upper shell 42, lower shell 43, and support tube 44.
[0081] In summary, the technical solution of the present invention has the following beneficial effects:
[0082] This solution addresses the problems of existing metal pneumatic push rod head structures, such as low overall carrying capacity, high launch cost, scratching the copper surface of the tail nozzle, affecting engine operation, posing significant safety hazards, and unsuitability for composite material molding processes. This solution employs an integral separation mechanism, which offers the following advantages:
[0083] (1) Based on the load-bearing capacity requirements of the head structure and the stress state of each component, the present invention has carried out a reasonable optimization design of the prepreg layup angle, layup sequence and layup ratio to ensure that the load-bearing requirements of the head structure are met and to achieve overall weight reduction of the structure.
[0084] (2) The pneumatic push rod head structure of carbon fiber composite material designed in this invention is suitable for carbon fiber composite material autoclave molding process. The prepreg is easy to lay, the molding process is mature and reliable, the product quality is stable, and the mechanical properties are excellent.
[0085] (3) The carbon fiber composite aerodynamic pusher head structure manufactured using this method reduces the weight of the original metal aerodynamic pusher head structure from 20 kg per unit to 6-8 kg per unit. The overall separation mechanism of this method can achieve a weight reduction of 120-140 kg, improving the rocket's carrying capacity and increasing the load-bearing capacity of the original metal aerodynamic pusher head structure from 10 tons to 15-20 tons. This reduces the rocket's launch cost and can create significant economic benefits.
[0086] (4) This solution is equipped with a silicone protective sleeve, which gives the pneumatic push rod head structure surface a buffering capacity, so that it will not cause impact damage to the copper surface of the tail spray device under impact load, thus eliminating safety risks.
[0087] The embodiments described above do not constitute a limitation on the scope of protection of this technical solution. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the above embodiments should be included within the scope of protection of this technical solution.
Claims
1. A method for manufacturing a pneumatic actuator head structure based on carbon fiber composite materials, characterized in that, include: The head structure is divided into five parts: a frustum-shaped upper shell, an inverted frustum-shaped lower shell, a support tube, a flange seat, and a frustum-shaped protective sleeve. The first thickened area is set at the junction of the upper circular plane and the circumferential inclined surface of the upper shell, and the second thickened area is set at the junction of the first circular wall and the circumferential inclined surface of the upper shell. A third thickened area is set at the junction of the second annular wall and the circumferential inclined surface of the lower shell, and a fourth thickened area is set at the junction of the lower circular plane and the circumferential inclined surface of the lower shell. The entire area of the upper shell is covered with multiple layers of carbon fiber prepreg, and then multiple layers of carbon fiber prepreg are inserted into the multi-layer intervals of the first thickened area and the second thickened area for further covering. After the covering is completed, the upper shell product is sealed on the mold surface using a vacuum bag and cured and formed by autoclave process. The entire area of the lower shell is covered with multiple layers of carbon fiber prepreg, and then multiple layers of carbon fiber prepreg are inserted into the multi-layer intervals of the third and fourth thickened areas for further covering. After the covering is completed, the lower shell product is sealed on the mold surface using a vacuum bag and cured and formed by autoclave process. The support tube is laid in multiple layers using carbon fiber prepreg. After the laying is completed, the support tube product is sealed on the mold surface using a vacuum bag and cured by autoclave process. With the center of the lower circular plane of the lower shell as the origin, a unified cylindrical coordinate system is established, and the ply angle is defined as follows: 0° direction is the axial direction of the head structure, and 90° direction is the circumferential direction of the head structure. In a unified cylindrical coordinate system, all the layers of the upper shell, lower shell, and support tube are laid in an alternating pattern using four angles: 0°, ±45°, and 90°.
2. The manufacturing method of the pneumatic actuator head structure based on carbon fiber composite material according to claim 1, characterized in that, The method of using carbon fiber prepreg for multi-layer laying of the overall area of the upper shell is as follows: 10 to 35 layers of carbon fiber prepreg with a single layer thickness of 0.1 mm to 0.3 mm are laid. The method of inserting multiple layers of carbon fiber prepreg into the multi-layer intervals of the first thickened area and the second thickened area is as follows: 5 to 15 layers of carbon fiber prepreg with a single layer thickness of 0.1 mm to 0.3 mm are inserted into the non-thickened area layer intervals to ensure the strength of the first thickened area and the second thickened area.
3. The manufacturing method of the pneumatic actuator head structure based on carbon fiber composite material according to claim 2, characterized in that: Of all the layers laid on the upper shell, the 0° layer accounts for 40% to 60%. The ±45° layers account for 10%–15%, and the 90° layers account for 20%–30%.
4. The manufacturing method of the pneumatic actuator head structure based on carbon fiber composite material according to claim 3, characterized in that: The upper shell has a total of 16 layers, of which the 0° layers are P01, P03, P05, P07, P09, P11, P13 and P15, the 90° layers are P02, P08, P10 and P16, the 45° layers are P04 and P12, and the -45° layers are P06 and P14.
5. The manufacturing method of the pneumatic actuator head structure based on carbon fiber composite material according to claim 1, characterized in that, The method of using carbon fiber prepreg for multi-layer laying of the overall area of the lower shell is as follows: 20 to 60 layers of carbon fiber prepreg with a single layer thickness of 0.1 mm to 0.3 mm are laid. The method of inserting multiple layers of carbon fiber prepreg into the multi-layer intervals of the third and fourth thickened areas is as follows: 5 to 15 layers of carbon fiber prepreg with a single layer thickness of 0.1 mm to 0.3 mm are inserted into the non-thickened area layer intervals to ensure the strength of the third and fourth thickened areas.
6. The manufacturing method of the pneumatic actuator head structure based on carbon fiber composite material according to claim 5, characterized in that, Of all the layers laid in the lower shell, the 0° layer accounts for 40% to 70%. The ±45° layers account for 10% to 15% of the total, and the 90° layers account for 10% to 30%.
7. The manufacturing method of the pneumatic actuator head structure based on carbon fiber composite material according to claim 6, characterized in that: The lower shell has a total of 24 layers, of which the 0° layers are Q01, Q03, Q05, Q07, Q09, Q11, Q13, Q15, Q17, Q19, Q21 and Q23, the 90° layers are Q02, Q08, Q10, Q16, Q18 and Q24, the 45° layers are Q04, Q12 and Q20, and the -45° layers are Q06, Q14 and Q22.
8. The manufacturing method of the pneumatic actuator head structure based on carbon fiber composite material according to claim 1, characterized in that, The method of multi-layer laying of the support tube using carbon fiber prepreg is as follows: 10 to 35 layers of carbon fiber prepreg with a single layer thickness of 0.1 mm to 0.3 mm are laid. Among all the laying layers of the support tube, the 0° layer accounts for 50% to 60%, the ±45° layers account for 10% to 12.5% respectively, and the 90° layer accounts for 20% to 25%.
9. The manufacturing method of the pneumatic actuator head structure based on carbon fiber composite material according to claim 8, characterized in that: The support pipe has a total of 12 layers, of which the 0° layers are R01, R03, R05, R07 and R09, the 90° layers are R02, R08 and R10, the 45° layers are R04 and R11, and the -45° layers are R06 and R12.
10. The manufacturing method of the pneumatic actuator head structure based on carbon fiber composite material according to claim 1, characterized in that: The protective sleeve is a silicone protective sleeve, which is made of AIRCAST3700A / B material. The AIRCAST3700 silicone system is mixed in a ratio of A:B=100:
12. After being stirred evenly, it is poured into a silicone protective sleeve molding mold and cured at room temperature for 24 hours or at 60°C for 3 hours.