A rapid thermoplastic composite material forming system and method

Abstract

The application provides a thermoplastic composite material rapid forming system and method, and belongs to the technical field of composite material forming. The system comprises a laminated laying device, a three-dimensional positioning device, a rapid preheating device, a special-shaped stamping device and a cutting post-processing device arranged in sequence along the conveying direction of a conveying track. A planar base tray moving along the conveying track is arranged on the conveying track. The planar base tray comprises an edge frame and a central plane, and the central plane is spliced by a plurality of detachable skeleton rods. The three-dimensional positioning device comprises a clamping fixing strip and an up-down surface pre-tightening device. The special-shaped stamping device comprises an upper die and a lower die, and the upper die and the lower die are located above and below the conveying track respectively and can move towards each other. Rapid automatic forming is realized through the linkage design of the planar base tray, the conveying track and the special-shaped stamping device.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of composite material forming, and particularly relates to a rapid forming system and method of thermoplastic composite material. BACKGROUND

[0002] The information disclosed in this Background section is for the purpose of generally presenting the context of the application. The information disclosed in this Background section is not to be necessarily taken as an acknowledgement or any form of suggestion that this information forms part of the prior art already known to a person skilled in the art.

[0003] The plate and profiled material of high-performance fiber composite material are increasingly applied in the industrial fields of transportation, power facilities, oil exploitation, etc. The plate of thermosetting resin-based composite material can only be processed once due to the influence of the resin matrix characteristics, and the product cannot be recycled. Therefore, with the continuous research and development of the resin matrix of fiber composite material, the thermoplastic resin-based composite material is gradually recognized. The resin matrix can be repeatedly plasticized and formed, has the characteristics of fast forming processing speed, recyclability, excellent comprehensive mechanical properties, etc., and the product is increasingly applied in plate processing and profiled material forming.

[0004] The current forming of thermoplastic composite material mainly uses pre-impregnated material intermediate products for product processing. The process of the forming process has large discreteness, and has not yet formed a pipeline operation level. The product processing efficiency is lower than that of thermosetting composite material. SUMMARY

[0005] In view of the deficiencies in the prior art, the purpose of the present application is to provide a rapid forming system and method of thermoplastic composite material, to realize the continuous and integrated pipeline operation of the multiple processes of laying, positioning, preheating and rapid stamping, and to provide a technical basis for the rapid processing and preparation of thermoplastic fiber composite material.

[0006] In order to achieve the above-mentioned purpose, the technical scheme of the present application is as follows:

[0007] In a first aspect, a rapid forming system of thermoplastic composite material comprises a laminated laying device, a three-dimensional positioning device, a rapid preheating device, a profiled stamping device and a cutting post-processing device arranged in sequence along the conveying direction of a conveying track.

[0008] A planar base tray moving along the conveying track is arranged on the conveying track. The planar base tray comprises an edge frame and a central plane, and the central plane is composed of a plurality of detachable skeleton rods.

[0009] The stereoscopic positioning device comprises a clamping fixing strip and an upper and lower surface pre-tightening device, the clamping fixing strip can be clamped at the edge frame position of the planar substrate tray, and the upper and lower surface pre-tightening device covers and clamps at the central planar position of the planar substrate tray.

[0010] The special-shaped stamping device comprises an upper die and a lower die, the upper die and the lower die are located above and below the conveying track respectively and can move towards each other.

[0011] Optionally, the conveying track comprises a first track and a second track, the first track is sequentially connected with the laminated laying device, the stereoscopic positioning device, the rapid preheating device and the special-shaped stamping device, and the second track is connected with the special-shaped stamping device and the cutting post-processing device.

[0012] Optionally, the planar substrate tray moving along the conveying direction is arranged on the first track, and the lower die moving along the conveying direction is arranged on the second track.

[0013] Optionally, the laminated laying device comprises a first mechanical arm and a grabbing suction cup, and the grabbing suction cup is arranged at the end of the first mechanical arm.

[0014] Optionally, the rapid preheating device comprises an upper heating module, a lower heating module and a heat circulation device, the upper heating module is located above the conveying track, the lower heating module is located below the conveying track, and the heat circulation device is located at the side of the conveying track.

[0015] Optionally, the upper heating module, the lower heating module and the heat circulation device are located in a preheating cavity, and the conveying track passes through the preheating cavity.

[0016] Optionally, the cutting post-processing device comprises a second mechanical arm and a cutting device, and the cutting device is arranged at the end of the second mechanical arm.

[0017] Optionally, the cutting device is a water jet cutter.

[0018] Optionally, the upper die and the lower die are arranged in a heat preservation box, and a heating device is arranged in the heat preservation box.

[0019] Optionally, the cutting post-processing device is located in an operation room.

[0020] In a second aspect, a rapid forming method of thermoplastic composite material based on the above-mentioned rapid forming system of thermoplastic composite material comprises the following steps:

[0021] S1, the laminated laying device lays the prepreg fabric above the planar substrate tray, and the planar substrate tray moves along the conveying track to the stereoscopic positioning device.

[0022] S2, in the stereotactic device, the clamping fixed strip clamps the prepreg fabric located at the edge frame position, the upper and lower surface pre-tightening device clamps the prepreg fabric at the center plane position and then loosens, and the plane base tray is moved to the rapid preheating device;

[0023] S3, in the rapid preheating device, the prepreg fabric is heated to a preheating temperature, and the plane base tray is moved to the profile stamping device;

[0024] S4, in the profile stamping device, the prepreg fabric is moved from the upper surface of the plane base tray to the upper surface of the lower die, the stamping forming is completed by the upper die, the clamping fixed strip is removed, and the lower die supports the to-be-cut stamping product and moves to the cutting post-processing device;

[0025] S5, in the cutting post-processing device, the stamping formed thermoplastic prepreg is cut into a product.

[0026] Optionally, in S1, in the laminated deposition device, the size-cut single-layer thermoplastic prepreg fabric is fixed by the multi-point suction cup and then pushed to the surface of the plane base tray by the first mechanical hand, the mechanical hand repeatedly grabs and pushes according to the set layering sequence to obtain the set layering structure.

[0027] Optionally, in S2, the upper and lower pre-tightening devices loosen after synchronously realizing the exhaust and pre-tightening fixation process of the prepreg fabric in a pulse pressure relief manner.

[0028] Optionally, in S4, the skeleton rod body of the plane base tray is separated from the plane base tray to form an empty slot at the center plane position, and the lower die is raised from the empty slot at the center plane to the height level with the edge frame.

[0029] Optionally, in S5, the second mechanical hand cuts along the edge of the lower die by using a water jet.

[0030] Optionally, in S2, the fastening work of the clamping fixed strip at the edge frame position, the separation work of the skeleton rod body of the plane base tray in S4, the removal work of the clamping fixed strip, and the installation work of the skeleton rod body are manually completed by an operator.

[0031] The beneficial effects of the present application are:

[0032] The application provides a kind of thermoplastic composite rapid forming equipment, specifically includes: laminated laying device, three-dimensional positioning device, rapid preheating device, profile punching device and cutting post-processing device five parts. Among them, the plane base tray includes detachable skeleton rod body, the skeleton rod body is positioned by edge frame and clamping fixed strip after disassembly, the cavity position appeared after disassembly of the skeleton rod body can be used for the die of upper die and lower die, the product transformed by pre-impregnated fabric after die closing is transferred to lower die and continues to be transported. The relative position of plane base tray, conveying track and profile punching device is designed and the linkage design between each other is realized to realize rapid automatic forming. BRIEF DESCRIPTION OF DRAWINGS

[0033] The drawings constituting a part of the specification of the application are used to provide further understanding of the application, the illustrative embodiments of the application and the description thereof are used to explain the application, and do not constitute undue limitation on the application.

[0034] Figure 1 is the structure schematic diagram of plane base tray in embodiment 1 of the application.

[0035] Figure 2 is the structure schematic diagram of plane base tray in embodiment 1 of the application.

[0036] Figure 3 is the structure schematic diagram of conveying track in embodiment 1 of the application.

[0037] Figure 4 is the structure schematic diagram of laminated laying device in embodiment 1 of the application.

[0038] Figure 5 is the structure schematic diagram of rapid preheating device in embodiment 1 of the application.

[0039] Figure 6 is the structure schematic diagram of profile punching device in embodiment 1 of the application.

[0040] Figure 7 is the structure schematic diagram of cutting post-processing device in embodiment 1 of the application.

[0041] Wherein: 1, prepreg fabric; 2, flat substrate tray; 21, sliding block; 22, edge frame; 23, central plane; 231, skeleton rod body; 3, punched product; 4, first mechanical arm; 5, grabbing suction cup; 6, second mechanical arm; 7, clamping fixing strip; 71, clamping positioning guide rail; 8, cutting device; 9, upper surface pre-tightening device; 91, pre-tightening hydraulic power system; 10, lower surface pre-tightening device; 101, pre-tightening suction cup; 11, first track; 12, second track; 13, upper heating module; 131, preheating cavity; 14, lower heating module; 15, thermal cycle device; 16, operation room; 17, lower mold; 18, upper mold; 19, heat preservation box; 20, forming heating device. DETAILED DESCRIPTION

[0042] It should be noted that the following detailed description is exemplary in nature and is intended to provide further description of the application. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs.

[0043] It is to be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments consistent with the present application. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises" and / or "comprising," when used in this specification, specify the presence of stated features, steps, operations, elements, components, and / or groups thereof, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof.

[0044] Example 1

[0045] A thermoplastic composite material rapid forming system comprises a laminated laying device, a three-dimensional positioning device, a rapid preheating device, a special-shaped punching device and a cutting post-processing device arranged in sequence along the conveying direction of a conveying track.

[0046] The conveying track comprises a first track 11 and a second track 12, the first track 11 is connected in sequence with the laminated laying device, the three-dimensional positioning device, the rapid preheating device and the special-shaped punching device, and the second track 12 is connected with the special-shaped punching device and the cutting post-processing device.

[0047] As Figure 1As shown in the figure, the conveying track is provided with a planar substrate tray 2 moving along the conveying track; each side of the planar substrate tray 2 is provided with a first track 11, the planar substrate tray 2 is slidably connected to the first track 11 through a plurality of sliders 21 on both sides, and can move along the direction of the first track 11; the planar substrate tray 2 comprises an edge frame 22 and a central plane 23, the central plane 23 is spliced by a plurality of extractable skeleton rods 231, the upper surfaces of the plurality of skeleton rods 231 form the central plane 23, and the central plane 23 has a matrix arrangement of upper and lower through holes, and the skeleton rods 231 can be extracted from the planar substrate tray 2;

[0048] As shown in the figure, Figure 2 The first track 11 is provided with a planar substrate tray 2 moving along the conveying direction, and the second track 12 is provided with a lower mold 17 moving along the conveying direction; in the special-shaped stamping device, the moving ranges of the first track 11 and the second conveying track 12 coincide, so that the planar substrate tray 2 and the lower mold 17 can coincide in the up-down direction, Figure 1 After a plurality of skeleton rods 231 of the planar substrate tray 2 in the figure are extracted, the central plane 23 becomes a cavity, so that Figure 2 The lower mold 17 in the figure can be lifted to the height level with the edge frame 22 from the central plane 23, so that the pre-impregnated fabric 1 is moved from the upper surface of the planar substrate tray 2 to the upper surface of the lower mold 17 at this time.

[0049] As shown in the figure, Figure 3 The laminated deposition device comprises a first manipulator 4 and a grabbing suction cup 5, the grabbing suction cup 5 is arranged at the end of the first manipulator 4, when the empty planar substrate tray 2 moves to the laminated deposition device along the first track 11, the single-layer thermoplastic pre-impregnated fabric of a set size is fixed by the grabbing suction cup 5 at multiple points and then pushed to the surface of the planar substrate tray 2 by the first manipulator 4, the first manipulator 4 repeatedly grabs and pushes according to the set layering sequence to obtain the pre-impregnated fabric 1 with the set layering structure.

[0050] As shown in the figure, Figure 4As shown, the stereotactic device includes clamping fixed bar 7, upper surface pre-tightening device 9 and lower surface pre-tightening device 10, clamping fixed bar 7 can be clamped at the edge frame 22 position of the planar base tray 2, clamping fixed bar 7 is moved to the set position by clamping positioning guide rail 71, and then it is top-tightened by pre-tightening spring to ensure the edge clamping force; the upper surface pre-tightening device 9 and the lower surface pre-tightening device 10 can cover and clamp at the center plane 23 position of the planar base tray 2; the upper surface of the lower surface pre-tightening device 10 is provided with a plurality of pre-tightening suction cups 101, the pre-tightening suction cups 101 pass through the holes in the center plane 23 from top to bottom, and provide the pre-tightening force of the lower surface of the prepreg fabric 1 in a vacuum adsorption manner; the upper surface pre-tightening device 9 is driven by pre-tightening hydraulic power system 91, the hydraulic power system can drive the square pressure head of the upper surface pre-tightening device 9 to apply an adjustable pre-tightening force of 0.1-1.0 MPa to the prepreg fabric 1 below, and the whole upper and lower pre-tightening device can realize the synchronization of the exhaust and pre-tightening fixing process between the layers of the prepreg fabric 1 in a pulse plus pressure relief manner.

[0051] As shown in Figure 5 The rapid preheating device includes upper heating module 13, lower heating module 14 and heat circulation device 15, the upper heating module 13 is located above the conveying track 1, the lower heating module 14 is located below the first track 11, and the heat circulation device 15 is located at the side of the first conveying track 1; and the upper heating module 13, the lower heating module 14 and the heat circulation device 15 are located in the preheating cavity 131, and the first track 1 passes through the preheating cavity 131; the upper and lower heating modules include infrared radiation heating elements for heating the prepreg fabric 1 in the preheating cavity 131 to a set preheating temperature, and the heat circulation device 15 is used to ensure that the temperatures at various positions in the preheating cavity 131 are relatively uniform; the heat circulation device 15 is a blast heat circulation device, and the blast direction avoids blowing air into the layers of the prepreg fabric 1.

[0052] As shown in Figure 6 The special-shaped stamping device includes upper die 18 and lower die 17, the upper die 18 is located above the second track 12, the lower die 17 can move along the second track 12, and the upper die 18 and the lower die 17 can move towards each other to complete the die closing action, so that the prepreg fabric 1 clamped between the upper die 18 and the lower die 17 is converted into the stamping product 3 to be cut, the upper die 18 and the lower die 17 are arranged in the heat preservation box 19, and the heat preservation box 19 is provided with a forming heating device 20, because the die closing action has a large force, the lower die 17 is provided below with a supporting device connected with the ground, which is used to limit the position of the lower die 17, after the stamping is completed, the lower die 17 is separated from the supporting device and moves along the second track 12 to the cutting post-processing device.

[0053] The upper die 18 and the lower die 17 are closed and molded in the cavity position of the center plane 23, and then the clamping fixing strip 7 on the planar base tray 2 is removed; the formed pre-impregnated fabric 1 is completely separated from the planar base tray 2, and since Figure 2 the edge frame 22 of the planar base tray 2 in the opening Figure 2 on the upper side of the edge frame 22 continues to move in the direction of the second conveying track 12, the lower die 17 is not blocked from moving out of the cavity of the center plane 23.

[0054] As shown in Figure 7 , the post-cutting processing device includes a second robot 6 and a cutting device 8, the cutting device 8 is arranged at the end of the second robot 6, and the post-cutting processing device is located in the operation room 16; the cutting device 8 is a water jet cutter for cutting along the edge of the lower die 17 to obtain the cut stamping product 3.

[0055] The thermoplastic composite rapid forming method based on the thermoplastic composite rapid forming system of the embodiment includes the following steps:

[0056] S1, as shown in Figure 3 , in the laminated laying device, the single-layer thermoplastic pre-impregnated fabric cut to size is fixed by the multi-point suction cup 5, and then pushed to the surface of the planar base tray 2 by the first robot 4, the first robot 4 repeatedly grabs and pushes according to the set laying sequence, and the pre-impregnated fabric 1 with the set laying structure is obtained, and the planar base tray 2 moves to the three-dimensional positioning device along the first track 11;

[0057] S2, as shown in Figure 4 , in the three-dimensional positioning device, the clamping fixing strip 7 clamps the pre-impregnated fabric 1 located at the edge frame 22 position, and the upper and lower surface pre-tightening device clamps the pre-impregnated fabric 1 located at the center plane 23 position, and the upper and lower pre-tightening devices are synchronized to realize the pre-impregnated fabric 1 exhaust and pre-tightening fixation process in the form of pulse plus pressure relief, and then loosen, and the planar base tray 2 carrying the clamping fixing strip 7 moves to the rapid preheating device;

[0058] S3, as shown in Figure 5 , in the rapid preheating device, the pre-impregnated fabric 1 is heated to a preheating temperature by the upper heating module 13 and the lower heating module 14 in the preheating cavity 131, and the planar base tray 2 moves to the profile stamping device;

[0059] S4, as shown in Figure 6As shown, in the irregular stamping device, the lower die 17 moves to the position below the center plane 23 of the planar base tray 2, the skeleton rod body 231 of the planar base tray 2 is separated from the planar base tray 2 to form an empty space at the center plane 23, and the lower die 17 is raised to the height level with the edge frame 22 from the empty space of the center plane 23. At this time, the prepreg fabric 1 is moved from the upper surface of the planar base tray 2 to the upper surface of the lower die 17, and the upper die 18 and the lower die 17 are closed in the empty space of the center plane 23 to form the stamping product 3 to be cut. Then, the clamping fixing strip 7 on the edge frame 22 is removed, and the upper die 17 is separated from the stamping product 3. The lower die 17 supports the formed stamping product 3 to move along the second track 12 to the post-cutting processing device.

[0060] S5, as shown in Figure 7 As shown, in the post-cutting processing device, the second mechanical arm 6 cuts along the edge of the lower die 17 by using a water jet to cut the thermoplastic prepreg after stamping into the stamping product 3.

[0061] In S4, after the prepreg fabric 1 is moved from the upper surface of the planar base tray 2 to the upper surface of the lower die 17, the planar base tray 2 is moved along the first track 11 back to the laminated deposition device, and the skeleton rod body 231 is installed to form the center plane 23, and the next product forming work is continued.

[0062] In S2, the fastening work of the clamping fixing strip 7 on the position of the edge frame 22, the separation work of the skeleton rod body 231 of the planar base tray 2, the removal work of the clamping fixing strip 7 and the installation work of the skeleton rod body 231 are completed manually by the operator.

[0063] Example 2

[0064] The method for rapid forming of thermoplastic composite material by using the rapid forming system of thermoplastic composite material of Example 1 is different from Example 1 in that in S2, the upper pre-tightening device applies a pre-tightening force of 1 MPa, and in S4, the lower die 17 and the upper die are closed at a pressure of 10 MPa to complete the stamping processing for 10 s.

[0065] And because the deformation degree of the stamping product 3 in this embodiment is large, the clamping fixing strip 7 is manually removed first in S4, and then the die is closed.

[0066] Example 3

[0067] The method for rapid forming of thermoplastic composite material by using the rapid forming system of thermoplastic composite material of Example 1 is different from Example 1 in that in S2, the upper pre-tightening device applies a pre-tightening force of 0.5 MPa, and in S4, the lower die 17 and the upper die are closed at a pressure of 5 MPa to complete the stamping processing for 12 s.

[0068] Example 4

[0069] The method for rapid forming of thermoplastic composite material by using the thermoplastic composite material rapid forming system of Example 1 is different from that of Example 1 in that in S2, the upper pre-tightening device applies a pre-tightening force of 0.9 MPa, and in S4, the lower die 17 and the upper die are closed at a pressure of 4 MPa, and the stamping process is completed in 7 s.

[0070] Example 5

[0071] The method for rapid forming of thermoplastic composite material by using the thermoplastic composite material rapid forming system of Example 1 is different from that of Example 1 in that in S2, the upper pre-tightening device applies a pre-tightening force of 0.8 MPa, and in S4, the lower die 17 and the upper die are closed at a pressure of 6 MPa, and the stamping process is completed in 8 s.

[0072] The above only describes the preferred embodiments of the present application and is not intended to limit the present application. Various modifications and changes can be made by those skilled in the art based on the principles and spirit of the present application. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. A thermoplastic composite rapid forming system, characterized by, The laminated deposition device, the stereoscopic positioning device, the rapid preheating device, the special-shaped stamping device and the cutting post-processing device are arranged in sequence along the conveying direction of the conveying track. A planar substrate tray moving along the conveying track is arranged on the conveying track. The stereoscopic positioning device comprises a clamping fixed strip and an upper and lower surface pre-tightening device. The upper die and the lower die are located above and below the conveying track respectively and can move towards each other.

2. The thermoplastic composite rapid forming system of claim 1, wherein, The conveying track comprises a first track and a second track.

3. The thermoplastic composite rapid forming system of claim 2, wherein, The planar substrate tray moving along the conveying direction is arranged on the first track, and the lower die moving along the conveying direction is arranged on the second track.

4. The thermoplastic composite rapid forming system of claim 1, wherein, The laminated deposition device comprises a first mechanical hand and a grabbing suction cup.

5. The thermoplastic composite rapid forming system of claim 1, wherein, The rapid preheating device comprises an upper heating module, a lower heating module and a heat circulation device.

6. The thermoplastic composite rapid forming system of claim 5, wherein, The upper heating module, the lower heating module and the heat circulation device are located in a preheating cavity, and the conveying track passes through the preheating cavity.

7. The thermoplastic composite rapid forming system of claim 1, wherein, The cutting post-processing device comprises a second mechanical hand and a cutting device.

8. The thermoplastic composite rapid forming system of claim 7, wherein, The cutting device is a water jet.

9. The thermoplastic composite rapid forming system of claim 7, wherein, The cutting post-processing device is located in an operation room.

10. The thermoplastic composite rapid forming system of claim 1, wherein, The upper die and the lower die are arranged in a heat preservation box, and a heating device is arranged in the heat preservation box.

11. A method of rapid prototyping of thermoplastic composite material based on the system of rapid prototyping of thermoplastic composite material according to any one of claims 1 to 10, characterized in that, The laminated deposition device deposits prepreg fabric above the planar substrate tray, and the planar substrate tray moves along the conveying track to the stereoscopic positioning device. In the stereoscopic positioning device, the clamping fixed strip clamps the prepreg fabric located in the edge frame position, and the upper and lower surface pre-tightening device clamps the prepreg fabric in the center plane position and then loosens. In the rapid preheating device, the prepreg fabric is heated to a preheating temperature, and the planar substrate tray moves to the special-shaped stamping device. In the special-shaped stamping device, the prepreg fabric is moved from the upper surface of the planar substrate tray to the upper surface of the lower die, and the stamping forming is completed by the upper die. In the cutting post-processing device, the thermoplastic prepreg after stamping forming is cut into products.

12. The rapid forming method of the thermoplastic composite material according to claim 11, wherein ​ In S1, the single layer of thermoplastic pre-impregnated fabric of a set size is fixed by a multi-point suction cup in the laminated laying device, and then pushed to the surface of the flat base tray by the first mechanical hand. The mechanical hand repeats the process of grabbing and pushing according to the set laying sequence to obtain the set laying structure.

13. The method of claim 11, wherein the thermoplastic composite is formed by a process selected from the group consisting of extrusion, pultrusion, injection molding, compression molding, and combinations thereof. In S2, the upper and lower pre-tightening devices are loosened after synchronously realizing the exhaust and pre-tightening fixation process of the pre-impregnated fabric in a pulse pressure relief mode.

14. The method of claim 11, wherein the thermoplastic composite rapid forming method is characterized by, In S4, the skeleton rod body of the flat base tray is separated from the flat base tray, and then an empty space is formed at the center plane position. The lower mold is raised to the height level with the edge frame from the empty space at the center plane.

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