Novel aviation hot patching instrument system and method

Abstract

The invention discloses a novel aviation hot patching instrument system and method. The hot patching instrument system comprises a controller, and the controller and all elements form a temperature control system, a vacuum degree control system, an over-limit alarm system and a data input and output system. The temperature control system is composed of a controller, a temperature sensor, a temperature acquisition module, a power module and an AD / DA module. The vacuum degree control system is composed of a controller, a vacuum pump, a pressure sensor and an AD / DA module. The over-limit alarm system is composed of a controller, an AD / DA module, an audible and visual alarm and an emergency protection switch. The heating rate, the heating process, the temperature maintaining time and the cooling rate required by vacuum curing are designed according to operation requirements, meanwhile, an ideal vacuum state is provided, and accurate pressure inspection and adjustment are carried out. And the curing of the resin is controlled and completed by a set program, so that the quality and efficiency of repairing work of the composite material can be ideally ensured.

Description

Technical Field

[0001] The invention relates to the technical field of aviation maintenance equipment, and in particular to a novel aviation hot repair instrument system and method. Background Art

[0002] Aircraft will inevitably suffer various types of structural damage during their service, such as damage caused by falling tools, runway gravel, bird strikes and hail, and military aircraft may also suffer combat damage. When aircraft composite structures are damaged, their load-bearing capacity will be reduced, and repairs must be carried out to restore their functional use and structural integrity. In addition, aircraft composite structures will inevitably have manufacturing defects or damage during the manufacturing process, and timely repairs must be carried out to reduce the scrap rate of parts in production, improve the intact rate of parts, and reduce the cost of using composite materials while ensuring safety.

[0003] The hot patching instrument is the most critical equipment among the repair equipment and tools for composite materials. The hot patching instrument is a comprehensive composite material repair equipment that integrates heating, vacuum, temperature process control and vacuum process control. It mainly provides the necessary high temperature curing temperature and vacuum environment for the curing of resin-based composite prepregs and resin adhesives. It can design the heating rate, heating process, temperature maintenance time and cooling rate required for vacuum curing according to operational needs, while providing an ideal vacuum state and performing precise pressure inspection and adjustment. However, the current hot patching instrument can only repair one composite material at a time, and the existing hot patching instrument cannot accurately control the process of hot patching, making the mechanical properties of the material after hot patching unstable. Summary of the invention

[0004] The technical problem to be solved by the present invention is to provide a novel aviation thermal patching instrument system and method, which can perform precise process control during the thermal patching of aviation composite materials.

[0005] In order to solve the above technical problems, the technical solution adopted by the present invention is: A new type of aviation thermal patching instrument system, the thermal patching instrument system includes a controller, the controller and various components form a temperature control system, a vacuum control system, an over-limit alarm system and a data input and output system; The temperature control system consists of a controller, a temperature sensor, a temperature acquisition module, a power module and an AD / DA module; The vacuum control system consists of a controller, a vacuum pump, a pressure sensor and an AD / DA module; The over-limit alarm system consists of a controller, AD / DA module, sound and light alarm and emergency protection switch.

[0006] The above-mentioned data input and output system is composed of a controller, a touch display screen and a data transmission module.

[0007] The temperature sensors mentioned above are multiple thermocouples.

[0008] The vacuum pump mentioned above is a built-in electric vacuum pump.

[0009] The above-mentioned temperature control system, vacuum control system, over-limit alarm system and data input and output system are connected to multiple sets by the controller respectively, so as to control the heat patching at multiple locations at the same time.

[0010] The control method of the novel aviation thermal repair instrument system mentioned above includes temperature monitoring, vacuum monitoring, temperature control program, vacuum control program and over-limit alarm program.

[0011] The above-mentioned temperature monitoring includes receiving the digital signal output after analog-to-digital conversion by the AD / DA module, converting it into a real-time temperature value, and then outputting it to the touch screen for display, so as to realize the real-time temperature monitoring of the thermal compensation instrument system; Vacuum degree monitoring includes converting the digital signal after analog-to-digital conversion by the AD / DA module into real-time vacuum pressure value, and then outputting it to the touch screen for display, so as to realize the real-time vacuum degree monitoring of the hot filling instrument system; The temperature control program uses the fuzzy PID algorithm to control the temperature according to the real-time temperature monitored and the temperature parameters set by the user, and outputs digital temperature control instructions to the power module in the temperature control system to adjust the heating power and realize temperature control; The vacuum control program uses the PID algorithm to control the vacuum according to the real-time vacuum pressure monitored and the vacuum pressure parameters set by the user, and outputs digital vacuum pressure control instructions to the vacuum control system to achieve vacuum control; The over-limit alarm program determines whether each parameter is out of limit based on the monitored temperature and vacuum pressure values. If so, on the one hand, it outputs a digital signal to the sound and light alarm to make it sound an alarm, and on the other hand, it outputs the corresponding program control parameters to the management subsystem of the touch screen to make it issue a corresponding program alarm on the screen.

[0012] The fuzzy PID algorithm in the above temperature control program first fuzzifies the input temperature deviation e and the deviation change rate ec to obtain E and EC, and then finds the three parameters K of PID P , K I , K d ; K d The fuzzy relationship between the deviation E and the deviation change rate EC is determined by real-time detection of E and EC during operation, and the three parameters are modified online according to the fuzzy control principle to meet different requirements for control parameters under different E and EC.

[0013] In the above-mentioned fuzzy PID algorithm, the controller obtains the precise value of the controlled quantity through sampling, compares the precise value with the given value to obtain the error signal e, and fuzzifies the precise value of the error signal into a fuzzy quantity to obtain a subset E of the fuzzy language set of the error e; then the decision is made by the e fuzzy control rule R, that is, the fuzzy relationship, and the synthesis rule to obtain the fuzzy control quantity u=EoR, where u is the fuzzy quantity; the fuzzy quantity u is converted into a digital quantity, converted by D / A, and sent to the actuator to realize closed-loop control of the temperature.

[0014] The invention provides a novel aviation hot repair instrument system and method, which can design the heating rate, heating process, temperature maintenance time and cooling rate required for vacuum curing according to the operation requirements, and provide an ideal vacuum state and perform precise pressure inspection and adjustment. The curing of the resin is completed by the set program control, which can ideally ensure the quality and efficiency of the composite material repair work. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The present invention will be further described below in conjunction with the accompanying drawings and embodiments: Figure 1 It is a schematic diagram of the hardware structure of the novel aviation thermal repair instrument system of the present invention; Figure 2 This is a control structure diagram of the novel aviation thermal compensation instrument system of the present invention; Figure 3 It is a PID fuzzy control flow chart of the temperature control of the heat compensation instrument of the present invention; Figure 4 This is a schematic diagram of a display screen operation monitoring interface in an embodiment of the present invention; Figure 5 This is a schematic diagram of a display screen parameter setting interface in an embodiment of the present invention; Figure 6 This is a flow chart of the working principle of the heat repair instrument in the embodiment of the present invention; Figure 7 Schematic diagram of the panel of the thermal repair instrument in the embodiment of the present invention. DETAILED DESCRIPTION

[0016] The technical solution of the present invention is described in detail below in conjunction with the accompanying drawings and embodiments.

[0017] Embodiment 1: A new type of aviation thermal patching instrument system, the thermal patching instrument system includes a controller, the controller and various components form a temperature control system, a vacuum control system, an over-limit alarm system and a data input and output system; The temperature control system consists of a controller, a temperature sensor, a temperature acquisition module, a power module and an AD / DA module; The vacuum control system consists of a controller, a vacuum pump, a pressure sensor and an AD / DA module; The over-limit alarm system consists of a controller, AD / DA module, sound and light alarm and emergency protection switch.

[0018] The above-mentioned data input and output system is composed of a controller, a touch display screen and a data transmission module.

[0019] The temperature sensors mentioned above are multiple thermocouples.

[0020] The vacuum pump mentioned above is a built-in electric vacuum pump.

[0021] The above-mentioned temperature control system, vacuum control system, over-limit alarm system and data input and output system are connected to multiple sets by the controller respectively, so as to control the heat patching at multiple locations at the same time.

[0022] The control method of the novel aviation thermal repair instrument system mentioned above includes temperature monitoring, vacuum monitoring, temperature control program, vacuum control program and over-limit alarm program.

[0023] The above-mentioned temperature monitoring includes receiving the digital signal output after analog-to-digital conversion by the AD / DA module, converting it into a real-time temperature value, and then outputting it to the touch screen for display, so as to realize the real-time temperature monitoring of the thermal compensation instrument system; Vacuum degree monitoring includes converting the digital signal after analog-to-digital conversion by the AD / DA module into real-time vacuum pressure value, and then outputting it to the touch screen for display, so as to realize the real-time vacuum degree monitoring of the hot filling instrument system; The temperature control program uses the fuzzy PID algorithm to control the temperature according to the real-time temperature monitored and the temperature parameters set by the user, and outputs digital temperature control instructions to the power module in the temperature control system to adjust the heating power and realize temperature control; The vacuum control program uses the PID algorithm to control the vacuum according to the real-time vacuum pressure monitored and the vacuum pressure parameters set by the user, and outputs digital vacuum pressure control instructions to the vacuum control system to achieve vacuum control; The over-limit alarm program determines whether each parameter is out of limit based on the monitored temperature and vacuum pressure values. If so, on the one hand, it outputs a digital signal to the sound and light alarm to make it sound an alarm, and on the other hand, it outputs the corresponding program control parameters to the management subsystem of the touch screen to make it issue a corresponding program alarm on the screen.

[0024] The fuzzy PID algorithm in the above temperature control program is as follows Figure 3 As shown in , firstly, the input temperature deviation e and the deviation change rate ec are fuzzyized to obtain E and EC, and then the three parameters K of PID are found. P , K I , K d ; K dThe fuzzy relationship between the deviation E and the deviation change rate EC is determined by real-time detection of E and EC during operation, and the three parameters are modified online according to the fuzzy control principle to meet different requirements for control parameters under different E and EC.

[0025] In the above-mentioned fuzzy PID algorithm, the controller obtains the precise value of the controlled quantity through sampling, compares the precise value with the given value to obtain the error signal e, and fuzzifies the precise value of the error signal into a fuzzy quantity to obtain a subset E of the fuzzy language set of the error e; then the decision is made by the e fuzzy control rule R, that is, the fuzzy relationship, and the synthesis rule to obtain the fuzzy control quantity u=EoR, where u is the fuzzy quantity; the fuzzy quantity u is converted into a digital quantity, converted by D / A, and sent to the actuator to realize closed-loop control of the temperature.

[0026] Embodiment 2: From the design perspective of the heat patching device, the ideas for forming the heat patching device include: The design of the thermal patching instrument focuses on two main functions: temperature control and creating a vacuum environment. It also comprehensively considers normal operating procedures and abnormal situation handling, and combines the performance optimization design plan of the instrument and equipment to form a military composite material thermal patching instrument product with independent intellectual property rights.

[0027] According to the above functional requirements, the design of the thermal patching instrument includes two parts: hardware design and software design.

[0028] 1. Hardware design The hardware system of the thermal patching instrument consists of a PLC controller, display screen, temperature module, pressure module, vacuum pump system, data input and output module, AD data acquisition system, power amplifier module, heating power control module, alarm protection module and power supply module. The above hardware mainly constitutes the four major systems of the thermal patching instrument: temperature control system, vacuum control system, over-limit alarm system and data input and output system, such as Figure 1 shown.

[0029] 1.1 Temperature control system The temperature control system consists of a PLC controller, a temperature sensor (thermocouple), a temperature acquisition module, a power regulation module and a DA module, forming an automatic closed-loop temperature control system that can accurately control the temperature (control the heating rate, heating history, temperature maintenance time and cooling rate, etc.).

[0030] 1.2 Vacuum control system The vacuum control system consists of a PLC controller, a built-in electric vacuum pump, a pressure sensor, an AD / DA module, etc., forming an automatic closed-loop control system that can create a vacuum environment and accurately control the vacuum degree.

[0031] 1.3. Over-limit alarm system The over-limit alarm system consists of a PLC controller, AD / DA module, sound and light alarm, emergency protection switch, etc. When the temperature and pressure monitored by the thermal compensation instrument PLC controller exceed the limit, an sound and light alarm can be issued and emergency protection operations can be performed.

[0032] 1.4 Data input and output system The data input and output system consists of a PLC controller, a touch screen, a data transmission module, etc. Various control parameters can be input in this system (touch screen keyboard input) and the entire process of hot patching can be monitored in real time through the touch screen. The required data can also be output through USB as needed.

[0033] 2. Software Design The software design is mainly divided into two parts: display management and PLC controller control. The schematic diagram is as follows Figure 2 as shown in .

[0034] 2.1. Display screen management subsystem The main function of the display management subsystem is to display various information monitored by the thermal patch instrument on the touch screen with an intuitive user graphic and text interface and provide control input for user operation. The main software modules include: (1) Real-time monitoring data display module - This module can display the real-time temperature monitored by all thermocouples in the four partitions and the real-time vacuum pressure monitored by the pressure sensor. The real-time temperature includes the single value monitored by each thermocouple, the average value / maximum value / minimum value of all or some thermocouples. When a monitored parameter exceeds the limit, the alarm status indicator of the module turns red and flashes to warn of the limit. (2) Temperature curve image display module - This module can display the real-time temperature curve monitored by the program, where the real-time temperature curve can come from a single value monitored by each thermocouple, or the average value / maximum value / minimum value of all or some thermocouples; (3) Pressure curve image display module: This module can display the vacuum curve of the repair area actually monitored; (4) Control parameter setting module - In this module, users can set the following parameters: (a) Heating rate, target temperature, holding time, cooling rate, end temperature, and upper temperature alarm limit; (b) Vacuum pressure upper limit, vacuum pressure lower limit, vacuum pressure alarm value.

[0035] (5) Process program calling module: In this module, users can directly select and modify the preset process programs stored in the system to realize quick process program compilation; after the preset process program is modified, users can save the customized program for easy calling next time; (6) Data transmission and output: In this module, select the data to be transmitted (such as process program, temperature / vacuum history data, etc.) and perform the transmission operation.

[0036] Control interface such as Figure 4 and Figure 5 As shown in the figure, taking zone I control as an example.

[0037] 2.2 PLC control program (1) After receiving the digital signals monitored by each sensor monitoring module and converting them into corresponding parameter values ​​(temperature, pressure, etc.) and curve graphs, they are output to the touch screen for display, so as to realize the monitoring of various types of information by the thermal compensation instrument system; (2) Accept the control parameters or process procedures set by the user on the touch screen, and combine the real-time signals of each sensor monitored, perform control algorithm calculations, and then output digital control signals to the heating system, vacuum system and over-limit alarm system of the thermal compensation instrument for closed-loop control to achieve temperature control, vacuum control and over-limit alarm. The main software modules include: (a) Temperature monitoring - receiving the digital signal output by the temperature module after analog-to-digital conversion by the AD module, converting it into a real-time temperature value through a program, and then outputting it to the touch screen for display, so as to realize the real-time temperature monitoring of the thermal compensation instrument system; (b) Vacuum degree monitoring - receiving the digital signal output by the vacuum pressure module after analog-to-digital conversion by the AD module, converting it into a real-time vacuum pressure value through a program, and then outputting it to the touch screen for display, so as to realize the real-time vacuum degree monitoring of the thermal patching instrument system; (c) Temperature control program: Based on the real-time temperature monitored and the temperature parameters set by the user, the fuzzy PID algorithm is used for temperature control, and digital temperature control instructions are output to the heat compensation instrument module to adjust the heating power to achieve temperature control; (d) Vacuum control program: Based on the monitored real-time vacuum pressure and the vacuum pressure parameters set by the user, the PID algorithm is used to control the vacuum degree, and the digital vacuum pressure control command is output to the vacuum system of the thermal compensation instrument to achieve vacuum control; (e) Over-limit alarm program - Based on the monitored temperature and vacuum pressure values, determine whether each parameter is over-limit. If so, on the one hand, output a digital signal to the sound and light alarm to make it sound an alarm, and on the other hand, output the corresponding program control parameters to the display screen management subsystem to make it sound a corresponding program alarm on the display screen.

[0038] 3. Working principle The most basic function of the hot patching instrument is to set the heating rate, heating process, temperature maintenance time and cooling rate required for vacuum curing according to the needs of the repair operation, while providing an ideal vacuum state and performing precise temperature and pressure inspection and adjustment. Figure 6 as shown in .

Claims

1. A new type of aviation thermal compensation instrument system, characterized in that: The thermal patching instrument system includes a controller, which together with various components forms a temperature control system, a vacuum control system, an over-limit alarm system and a data input and output system; The temperature control system consists of a controller, a temperature sensor, a temperature acquisition module, a power module and an AD / DA module; The vacuum control system consists of a controller, a vacuum pump, a pressure sensor and an AD / DA module; The over-limit alarm system consists of a controller, AD / DA module, sound and light alarm and emergency protection switch.

2. A novel aviation thermal compensation instrument system according to claim 1, characterized in that: The data input and output system is composed of a controller, a touch display screen and a data transmission module.

3. A novel aviation thermal compensation instrument system according to claim 2, characterized in that: The temperature sensors are multiple thermocouples.

4. A novel aviation thermal compensation instrument system according to claim 3, characterized in that: The vacuum pump is a built-in electric vacuum pump.

5. A novel aviation thermal compensation instrument system according to claim 4, characterized in that: The temperature control system, vacuum control system, over-limit alarm system and data input and output system are connected to multiple sets by the controller respectively, so as to control the heat repair at multiple locations at the same time.

6. A control method for a novel aviation thermal compensation instrument system using claim 5, characterized in that: The control method includes temperature monitoring, vacuum monitoring, temperature control program, vacuum control program and over-limit alarm program.

7. The control method of a novel aviation thermal compensation instrument system according to claim 6 is characterized in that: The temperature monitoring includes receiving the digital signal output after analog-to-digital conversion by the AD / DA module, converting it into a real-time temperature value, and then outputting it to the touch screen for display, so as to realize the real-time temperature monitoring of the thermal compensation instrument system; Vacuum degree monitoring includes converting the digital signal after analog-to-digital conversion by the AD / DA module into real-time vacuum pressure value, and then outputting it to the touch screen for display, so as to realize the real-time vacuum degree monitoring of the hot filling instrument system; The temperature control program uses the fuzzy PID algorithm to control the temperature according to the real-time temperature monitored and the temperature parameters set by the user, and outputs digital temperature control instructions to the power module in the temperature control system to adjust the heating power and realize temperature control; The vacuum control program uses the PID algorithm to control the vacuum according to the real-time vacuum pressure monitored and the vacuum pressure parameters set by the user, and outputs digital vacuum pressure control instructions to the vacuum control system to achieve vacuum control; The over-limit alarm program determines whether each parameter is out of limit based on the monitored temperature and vacuum pressure values. If so, on the one hand, it outputs a digital signal to the sound and light alarm to make it sound an alarm, and on the other hand, it outputs the corresponding program control parameters to the management subsystem of the touch screen to make it issue a corresponding program alarm on the screen.

8. The control method of a novel aviation thermal compensation instrument system according to claim 7 is characterized in that: The fuzzy PID algorithm in the temperature control program first fuzzifies the input temperature deviation e and the deviation change rate ec to obtain E and EC, and then finds the three parameters K of PID. P , K I , K d ; K d The fuzzy relationship between the deviation E and the deviation change rate EC is determined by real-time detection of E and EC during operation, and the three parameters are modified online according to the fuzzy control principle to meet different requirements for control parameters under different E and EC.

9. The control method of a novel aviation thermal compensation instrument system according to claim 8 is characterized in that: In the fuzzy PID algorithm, the controller obtains the precise value of the controlled quantity through sampling, compares the precise value with the given value to obtain the error signal e, and fuzzifies the precise value of the error signal into a fuzzy quantity to obtain a subset E of the fuzzy language set of the error e; then the decision is made by the e fuzzy control rule R, that is, the fuzzy relationship, and the synthesis rule to obtain the fuzzy control quantity u=EoR, where u is the fuzzy quantity; the fuzzy quantity u is converted into a digital quantity, converted by D / A, and sent to the actuator to realize closed-loop control of the temperature.

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