Programmable gantry fiber three-dimensional fabric stitching apparatus and method for combined processing

Abstract

The present application belongs to the technical field of fiber three-dimensional fabric stitching, and discloses a program-controlled truss type fiber three-dimensional fabric stitching device and method for combined processing, which is composed of a frame body, a clamping needle stitching device, a movable clamp and a pressing device combination, a carbon fiber thread threading mechanism and a thread pulling mechanism. The clamping needle stitching device is arranged at the front end of the top of the frame body, the movable clamp and the pressing device combination are arranged below the clamping needle stitching device, the carbon fiber thread threading mechanism and the thread pulling mechanism are connected, the carbon fiber thread threading mechanism is located at the left side of the bottom end of the frame body, and the thread pulling mechanism is located at the front end of the carbon fiber thread threading mechanism. The present application provides a full-automatic truss type fiber three-dimensional fabric stitching device, which is controlled by a PLC industrial computer, adopts high-precision servo motors, high-precision linear guides and other components, realizes automatic connection of stitching needles and carbon fiber threads, has functions such as unmanned automatic sewing of the device, and realizes automatic sewing of regular fiber three-dimensional fabrics safely and efficiently.

Description

Technical Field

[0001] This invention belongs to the field of combined processing of non-textile materials, and particularly relates to a programmable truss-type fiber three-dimensional fabric sewing device and sewing method for combined processing. Background Technology

[0002] The development of modern science and technology is inseparable from composite materials, which play a vital role in its advancement. The depth of research, breadth of application, and speed and scale of production of composite materials have become important indicators of a country's scientific and technological advancement. Carbon / carbon composites, using materials such as pitch carbon, resin carbon, or pyrolytic carbon as the matrix and carbon fiber and its products as reinforcement, have become one of the most important aspects of advanced composite materials. Carbon fiber-reinforced composites possess characteristics such as being lightweight yet strong, lightweight yet rigid, high-temperature resistant, corrosion-resistant, fatigue-resistant, having good dimensional stability, high specific modulus, good design flexibility, and the ability to be integrally molded over large areas. The most common application of carbon fiber is as a reinforcement for resin materials. The resulting carbon fiber-reinforced resin matrix composites exhibit excellent comprehensive performance and have practical and potential applications in sixteen fields, including missiles, space platforms and launch vehicles, aircraft, advanced ships, rail transit vehicles, electric vehicles, trucks, wind turbine blades, fuel cells, power cables, pressure vessels, uranium enrichment ultra-high-speed centrifuges, special tubing, public infrastructure, medical and industrial equipment, sports and leisure products, and fashionable lifestyle products. Subsequently, the application of carbon fiber has grown rapidly towards high-end applications, exemplified by its use as a main structural material for aerospace vehicles.

[0003] Carbon fiber components often require multiple layers of carbon fiber fabric stacked and then sewn together to achieve the required product performance. Sewing technology, as a preform forming technique, is a new technology for producing carbon / carbon composite preforms, developed to address the shortcomings of traditional processes. It uses stitching threads to construct quasi-three-dimensional fabrics from two-dimensional or thin-layered three-dimensional fabrics, or to connect several separate pieces of fabric into a unified structure. The principle is that by sewing, stitching threads passing through the fabric's thickness direction reinforce the carbon fiber fabric in a direction perpendicular to the layup plane, thereby improving interlaminar fracture toughness and impact damage tolerance.

[0004] In the mid-1980s, NASA first used stitching technology to manufacture aircraft wings and conducted systematic tests on their mechanical properties, establishing a design database for stitched composite material wings. Additionally, the U.S. Air Force's Advanced Light Aircraft Airframe Structure Program (ALAFS program) also researched stitching technology, successfully replacing metal materials with stitched composite materials in the manufacture of fuselage, wings, and other components, significantly reducing their weight. Stitching technology has gained attention and is being studied worldwide.

[0005] Currently, carbon fiber fabrics are sewn manually, and the process is as follows:

[0006] a. First, manually clamp the carbon fiber fabrics that need to be sewn together.

[0007] b. Manually threading the suture needle and suture.

[0008] c. Use a suture needle to pierce the carbon fiber thread through the carbon fiber fabric from the front. Pull the suture needle and carbon fiber thread out from the back of the carbon fiber fabric. After tightening the carbon fiber thread, pierce it through from the back to the front again. Repeat this process to sew.

[0009] Because the product requires dense stitching, mass production necessitates a large workforce, resulting in substantial labor costs. Furthermore, the carbon fiber thread used for stitching is highly fragile, and the varying skill levels of sewing personnel contribute to low production efficiency and difficulty in controlling production progress. Additionally, the carbon fiber fabric and sheets used in prefabricated body production are extremely expensive. Manual operation cannot maintain consistent quality, leading to a high rate of waste and significant product defects. Therefore, there is an urgent need to invent an automated stitching device to improve both stitching quality and efficiency.

[0010] Based on the above analysis, the problems and shortcomings of the existing technology are as follows:

[0011] 1) A large workforce is required to complete the workload, resulting in huge labor costs;

[0012] 2) Due to the varying skill levels of sewing workers, production efficiency is low and production progress is difficult to control;

[0013] 3) The carbon fiber thread used for sewing is extremely fragile and the carbon fiber material cloth or board that needs to be sewn is extremely expensive. Due to the limited ability of the sewing personnel, manual operation cannot maintain a high degree of consistency, which easily leads to defective products and causes great waste, and cannot guarantee the consistency of product quality. Summary of the Invention

[0014] To address the problems existing in the prior art, this invention provides a programmable truss-type fiber three-dimensional fabric sewing equipment and sewing method for combined processing. It can realize the automatic connection between the sewing needle and the carbon fiber thread, and the unmanned automatic sewing of the equipment. Using the truss carbon fiber material sewing method, without considering other working conditions, the product specifications can be infinitely expanded. During the development, a specification that can cover all products at this time is adopted.

[0015] The present invention is implemented as follows: a programmable truss-type three-dimensional fiber fabric sewing equipment for combined processing, comprising a frame, a needle clamping sewing device, a combination of a movable clamp and a pressing device, a carbon fiber threading mechanism, and a thread pulling mechanism. The needle clamping sewing device is located at the front of the top of the frame, the combination of the movable clamp and the pressing device is located below the needle clamping sewing device, the carbon fiber threading mechanism and the thread pulling mechanism are connected, the carbon fiber threading mechanism is located on the left side of the bottom of the frame, and the thread pulling mechanism is located at the front end of the carbon fiber threading mechanism.

[0016] Furthermore, standard I-beams are used for welding, all system axes use servo systems with ball screw mechanisms, the guide uses linear guide mechanisms, the needle insertion mechanism uses an electric cylinder module with a servo system, the needle clamping uses a gripper cylinder, the clamping system uses a pneumatic cylinder, the needle feeding system uses an electric cylinder module with a servo system, the glue injection system uses a servo system with a ball screw mechanism, the guide uses a linear guide mechanism, the detection system uses a camera, the wire feeding system uses an electric cylinder module with a servo system, and the rotating parts use a swing cylinder with adjustable swing angle.

[0017] Furthermore, the needle clamping sewing device mainly consists of a moving device, a needle clamping and puncturing mechanism, and a tray moving device. The needle clamping and puncturing mechanism realizes the sewing of carbon fiber fabrics and the needle clamping technology. The needle clamping and puncturing mechanism is mainly composed of a rotary cylinder, a gripper cylinder, a SCHUNK gripper, a servo motor, a water spray assembly, and other components, all mounted on the frame to realize the sewing of carbon fiber fabrics and the needle clamping technology.

[0018] The system employs SCHUNK grippers made of rigid material, utilizing a combination of a 180° rotating cylinder and a gripper cylinder. The gripper cylinder clamps the needle, the needle clamping assembly releases and shifts, the rotating cylinder rotates to change the needle's direction, the needle clamping assembly clamps it again, and the needle tip is rotated 180° to continue sewing. A servo motor is used for simultaneous displacement and torque control. A water spray component is added to the needle clamping assembly to spray deionized water to lubricate the non-woven thread. The suture thread length is determined according to process requirements, and the suture thread is replaced before wear.

[0019] Furthermore, the moving clamp and clamping device assembly is composed of a mold base, a mold frame, main and auxiliary molds, main and auxiliary mold clamping cylinders, left and right positioning cylinders, a bottom mold moving mechanism, and a clamping component motion mechanism. Ribs are added to the outside of the mold frame, and the mold core plate is made of titanium alloy with staggered holes. The mold base and mold frame are made of stainless steel, and the base has a water receiving trough. The mold is configured as a main mold and an auxiliary mold. The main mold is reinforced with ribs as a reference, and the auxiliary mold is installed on top of the main mold for easy operation.

[0020] Furthermore, the carbon fiber threading mechanism includes fully automatic threading, needle loading, needle picking, fully automatic needle-thread connection, and glue dispensing functions. It mainly consists of a worktable, a spool assembly, a thread feeding assembly, a needle picking assembly, a glue dispensing assembly, a thread feeding assembly, a needle holder assembly, a scissor assembly, a needle loading assembly, and a material supply assembly.

[0021] The suture needle is made of hot-rolled steel wire. The suture needle is ground to a sharp point and the tail is punched with electric spark. The connection between the suture thread and the suture needle is made with an adhesive groove 3mm beyond the tail. After the adhesive is applied, it is integrated into the front and rear cavities to prevent the adhesive from coming out of the suture needle and affecting the suturing process.

[0022] The carbon fiber thread enters the thread output assembly through the spool assembly. The thread feeding assembly's gripper cylinder actuates to clamp the thread and pass it through the thread tube. At this time, the needle mounting assembly and the thread feeding assembly move simultaneously through the servo electric cylinder to automatically feed the thread into the suture needle. Then, a water spray assembly is added to lubricate the carbon fiber thread.

[0023] The needle-picking assembly is used to clamp the needles in the needle box with a gripper and place them on the needle holder assembly under the drive of a servo motor, thus completing the needle-picking function. The scissor assembly is used to cut the carbon fiber thread to the appropriate length according to the process requirements. The glue dispensing assembly is used to press the glue tube with a servo-controlled pressure head after the needle and thread are threaded, control the stroke, and dispense a certain amount of glue to the joint of the needle and thread. The glue cures within the process time, bonding the needle and thread together.

[0024] Furthermore, two types of cylinders are used for clamping: one side uses a 100mm diameter cylinder as a reference, and the other side uses an 80mm diameter cylinder for clamping. The cylinder extension is adjusted according to the process requirements. The clamping assembly slides freely on a linear guide rail and is moved by a top servo system. After the stitching is in place, the pressure block assembly is moved. Positioning cylinders are added on the left and right sides, with conical holes for positioning. A double-sided mirror station is used for simultaneous sewing.

[0025] Another object of the present invention is to provide a method for sewing programmable truss-type three-dimensional fiber fabrics for combined processing using the aforementioned programmable truss-type three-dimensional fiber fabric sewing equipment, comprising:

[0026] S1, Lay carbon fiber material on the mold;

[0027] S2, lifting mold;

[0028] S3, hoist the mold onto the transfer device;

[0029] S4, the movable component extends;

[0030] S5, the transfer device moves toward the moving component and transports the mold onto the moving component;

[0031] S6, the transfer device transports the mold to the moving component, retracts, and prepares for the installation of the other mold;

[0032] S7, the moving component with mold returns to the initial position, the clamping cylinder clamps the core plate, and the sewing component begins to sew from bottom to top;

[0033] S8, according to the stitching position, the clamping cylinders are adjusted respectively, and the moving component moves forward to stitch in sequence;

[0034] S9, suture end;

[0035] S10, after sewing is completed, the moving component extends, the mold is lifted, and the product is taken out.

[0036] First, this invention is used for carbon fiber sewing, which can realize automatic needle picking, automatic needle threading, automatic connection between sewing needle and carbon fiber thread, and automatic sewing of three-dimensional fiber fabric. It has tensile strength detection and can adjust the torque of the thread pulling, replacing manual sewing, improving work efficiency, improving product quality, and fully realizing fully automated sewing.

[0037] 1) To address the problem that existing technologies require a large amount of labor to complete the workload and result in huge labor costs, this invention designs a fully automatic truss fiber three-dimensional fabric sewing equipment. It adopts PLC industrial control computer control, high-precision servo motor, high-precision linear guide rail and other components to realize the automatic connection between the sewing needle and carbon fiber thread, and the unmanned automatic sewing of the equipment. It can safely and efficiently realize the automatic sewing of regular non-woven fabrics.

[0038] 2) To address the problem of low production efficiency and difficulty in controlling production progress caused by varying skill levels among sewing personnel, the present invention adopts PLC industrial control technology. The automatic sewing equipment for carbon fiber three-dimensional fabric trusses is characterized by high efficiency, fast speed, and good stability. Each set of equipment is equivalent to the production of 4-6 people and has stable quality.

[0039] 3) To address the issue that existing technologies cannot guarantee product quality consistency, this invention employs innovative stitching needle clamping technology, mold clamping technology, and automatic needle threading technology. By controlling a high-precision servo motor with a PLC industrial control computer, displacement control and torque control are performed simultaneously to complete the stitching with high quality and ensure product quality consistency.

[0040] Secondly, this invention possesses the technical advantage of rapid needle threading. The innovative carbon fiber threading mechanism enables fully automatic threading, needle insertion, needle removal, fully automatic needle-thread connection, and glue application. It boasts high stability and high threading efficiency, and the glue application function effectively solves the needle-thread connection problem.

[0041] This invention offers highly efficient and stable sewing technology. It innovatively designs a needle-clamping sewing device, achieving canvas sewing and needle clamping through a needle-clamping and puncture mechanism. A servo motor is used, with simultaneous displacement and torque control to precisely control the sewing tension, preventing incomplete sewing or breakage of the carbon fiber thread. A water spray component is added to the needle clamping assembly to spray deionized water, lubricating the carbon fiber thread and effectively solving the problem of carbon fiber thread wear, thus significantly increasing the stability of the stretched thread.

[0042] This invention features a unique mold clamping technology that clamps and positions the main and auxiliary molds, effectively solving the product deformation problem and achieving the effect of automatic repositioning of the pressure block during the sewing process.

[0043] This invention features double-sided sewing, resulting in high efficiency. It employs a double-sided mirrored workstation for simultaneous sewing, meaning both sides of the product are equipped with identical needle clamping and sewing devices and threading mechanisms, allowing for simultaneous sewing on both sides, significantly improving efficiency compared to previous methods.

[0044] Third, the technical solution of this invention fills a technological gap in the industry both domestically and internationally: This invention innovatively employs a truss method to achieve three-dimensional fiber fabric sewing technology, filling a technological gap in truss sewing both domestically and internationally. The truss method offers advantages such as high needle-threading positioning accuracy, large sewing area, and high speed. Using the truss carbon fiber sewing method, without considering other working conditions, the carbon cloth specifications can be infinitely expanded, and a specification suitable for covering all products at that time can be adopted during development.

[0045] The technical solution of this invention solves a long-standing technical problem that people have long desired to solve but have been unable to achieve: This invention solves the technical problem of automatic needle threading by using a threading mechanism to achieve fully automatic threading, needle insertion, needle removal, fully automatic needle-thread connection, and glue application. It completely eliminates the problem of manual needle threading and glue application.

[0046] Fourth, the significant technological advancements of the programmable truss-type three-dimensional fiber fabric sewing equipment provided by this invention are mainly reflected in the following aspects:

[0047] 1. High degree of automation and intelligence:

[0048] The equipment uses a servo system, ball screw mechanism, and linear guide mechanism to achieve high-precision movement and positioning of each component, which greatly improves the automation level of the sewing process.

[0049] The detection system, which combines camera recording and lighting, enables the equipment to monitor the sewing process in real time, intelligently identify abnormalities and take corresponding measures, significantly improving production efficiency and product quality.

[0050] 2. Precise clamping and positioning:

[0051] The needle clamping sewing device uses a gripper cylinder, which can stably hold the sewing needle, ensuring accurate movement and positioning of the needle during the sewing process, reducing errors and the generation of defective products.

[0052] The mold system, consisting of a mold base, mold frame, main mold, and auxiliary mold, along with the mold moving mechanism and clamping component movement mechanism, achieves precise support and positioning of the fabric, improving the accuracy and stability of sewing.

[0053] 3. Flexible adjustment and adaptability:

[0054] The equipment uses a swing cylinder as the rotating part, and the swing angle is adjustable, which allows the equipment to adapt to the sewing needs of different angles and shapes, thus improving the flexibility and adaptability of the equipment.

[0055] The slide rail platform, propulsion cylinder, needle holder lifting cylinder and other components are responsible for precisely controlling the movement and positioning of each component. They can be quickly adjusted according to different sewing requirements, improving the versatility and production efficiency of the equipment.

[0056] 4. Highly efficient wire feeding and dispensing system:

[0057] The thread feeding system uses an electric cylinder module and a servo system to ensure that the suture thread can be delivered smoothly and accurately to the threading mechanism, thereby improving suturing efficiency.

[0058] The glue injection system uses a servo system to precisely control the amount and location of glue injection, ensuring sufficient strength and stability at the seam while avoiding glue waste.

[0059] 5. Convenient maintenance and operation:

[0060] The equipment platform is welded from standard I-beams, making it robust and easy to maintain, which reduces equipment failure rate and maintenance costs.

[0061] The equipment is simple and convenient to operate. Through the control system, various parameters and settings can be easily adjusted, which improves operating efficiency and user experience.

[0062] The programmable truss-type fiber three-dimensional fabric sewing equipment provided by this invention has achieved significant technological progress in terms of automation, intelligence, precision, flexibility, efficiency, and operation and maintenance, providing a more efficient and stable solution for the sewing production of fiber three-dimensional fabrics. Attached Figure Description

[0063] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the embodiments of the present invention will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0064] Figure 1 This is a schematic diagram of the truss non-textile material sewing equipment provided in an embodiment of the present invention;

[0065] Figure 2 This is a schematic diagram of the needle clamping and sewing device provided in an embodiment of the present invention;

[0066] Figure 3 This is a schematic diagram of the needle clamping puncture mechanism provided in an embodiment of the present invention;

[0067] Figure 4 This is a schematic diagram of the combination of the moving clamp and the clamping device provided in an embodiment of the present invention;

[0068] Figure 5 This is a schematic diagram of the carbon fiber threading mechanism provided in an embodiment of the present invention;

[0069] Figure 6 This is a schematic diagram of a hot-rolled steel wire grinding and sewing needle provided in an embodiment of the present invention;

[0070] Figure 7 This is a schematic diagram of the outgoing cable assembly provided in an embodiment of the present invention;

[0071] Figure 8 This is a schematic diagram of the wire feeding assembly provided in an embodiment of the present invention;

[0072] Figure 9 This is a schematic diagram of the pin holder assembly provided in an embodiment of the present invention;

[0073] Figure 10 This is a schematic diagram of the needle retrieval assembly provided in an embodiment of the present invention;

[0074] Figure 11 This is a schematic diagram of the dispensing assembly provided in an embodiment of the present invention;

[0075] Figure 12 This is a schematic diagram of the fiber three-dimensional fabric sewing process provided in an embodiment of the present invention;

[0076] In the diagram: 1. Frame; 2. Needle-clamping sewing device; 3. Combination of moving clamp and clamping device; 4. Carbon fiber thread threading mechanism; 5. Thread pulling mechanism; 6. Moving device; 7. Needle-clamping piercing mechanism; 8. Pallet moving device; 9. Rotary cylinder; 10. Clamping cylinder; 11. SCHUNK clamping jaw; 12. Servo motor; 13. Water spray assembly; 14. Mold base; 15. Mold frame; 16. Main mold; 17. Secondary mold; 18. Clamping cylinder; 19. Positioning cylinder; 20. Mold moving mechanism; 21. Clamping assembly motion mechanism; 22. Worktable; 23. Reel assembly; 24. Wire feed assembly; 25. Needle pick-up assembly; 26. Glue dispensing assembly; 27. Wire feeding assembly; 28. Needle holder assembly; 29. ​​Scissors assembly; 30. Needle loading assembly; 31. Feeding assembly; 32. Frame; 33. Wire guide roller; 34. Water injection needle assembly; 35. Wire feed roller; 36. Wire guide assembly; 37. Electric cylinder; 38. Gripper; 39. Slide rail platform; 40. Push cylinder; 41. Needle holder lifting cylinder; 42. Needle holder plate; 43. Up and down moving cylinder; 44. Back and forth moving cylinder; 45. Servo displacement mechanism; 46. Lighting. Detailed Implementation

[0077] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0078] This invention provides a programmable truss-type three-dimensional fiber fabric sewing device, characterized in that the device includes a frame 1, a needle clamping sewing device 2, a combination of a movable clamp and a pressing device 3, a carbon fiber threading mechanism 4, a thread pulling mechanism 5, a rotary cylinder 9, a servo motor 12, a mold base 14, a main mold 16, and a secondary mold 17. The needle clamping sewing device 2 is located at the top front of the frame 1, and the combination of the movable clamp and the pressing device 3 is located below the needle clamping sewing device 2. The carbon fiber threading mechanism 4 and the thread pulling mechanism 5 are connected, with the carbon fiber threading mechanism 4 located on the bottom left side of the frame 1, and the thread pulling mechanism 5 located at the front end of the carbon fiber threading mechanism 4. The rotary cylinder 9 is used to control the rotation of the needle clamp, the servo motor 12 is responsible for the precise position control of the drive system shaft, and the mold base 14 is used to fix the main mold 16 and the secondary mold 17 for sewing operations.

[0079] The equipment also includes a water spray assembly 13, a mold moving mechanism 20, a thread feeding assembly 27, and a lighting lamp 46. The water spray assembly 13 is used to wet the material during the sewing process. The mold moving mechanism 20 is responsible for the precise movement and positioning of the main mold 16 and the auxiliary mold 17 on the mold base 14. The thread feeding assembly 27 is responsible for smoothly feeding the sewing thread to the threading mechanism through an electric cylinder module and a servo system. The lighting lamp 46 provides sufficient light so that the operator can clearly observe the sewing process.

[0080] The equipment's system axis uses a servo system plus a ball screw mechanism, the guide uses a linear guide mechanism, the carbon fiber thread insertion mechanism uses an electric cylinder module plus a servo system, the detection system uses camera imaging, and the rotating part uses a swing cylinder with adjustable swing angle to achieve precise position control and stable motion performance, as well as real-time monitoring of the sewing process, ensuring sewing quality and meeting the needs of different sewing angles.

[0081] Example 1: Automated Carbon Fiber 3D Fabric Sewing Production Line

[0082] In this embodiment of the automated carbon fiber 3D fabric sewing production line, the equipment adopts a programmable truss design to improve production efficiency and product quality. The frame 1, serving as the main support structure, is welded from standard I-beams to ensure stability and durability. The needle-clamping sewing device 2 is installed at the front top of the frame and performs the sewing operation, while the moving clamp and pressing device combination 3 is located below the needle-clamping sewing device to fix and adjust the position of the carbon fiber 3D fabric to ensure sewing accuracy. The carbon fiber thread threading mechanism 4 and the thread-pulling mechanism 5 are connected and located on the left side of the bottom of the frame, responsible for feeding and tensioning the sewing thread. In this embodiment, the servo motor 12 precisely controls the ball screw mechanism to achieve high-precision positioning and movement of the needle-clamping sewing device, thereby improving sewing efficiency and quality.

[0083] Example 2: Intelligent Controlled Fiber Three-Dimensional Fabric Repair Device

[0084] In this embodiment of the intelligent-controlled fiber 3D fabric repair device, the device is specifically designed for precise repair of damaged fiber 3D fabrics. The device is also based on a programmable truss architecture, including a precision needle-clamping and piercing mechanism 7 and a tray moving device 8 for precise positioning and suturing of the damaged area. A rotary cylinder 9 and a SCHUNK gripper 11 work together to provide flexible operating angles and stable material clamping for needle-clamping. Furthermore, the device is equipped with a water spray assembly 13 to moisten the material during the suturing process, preventing additional damage due to dryness. Through a mold moving mechanism 20 and a clamping assembly movement mechanism 21, the device can precisely move and adjust the mold to adapt to repair tasks of different shapes and sizes. This embodiment is particularly suitable for the repair of high-value fiber 3D fabrics, ensuring high efficiency and quality through an intelligent control system and high-precision mechanical structure.

[0085] These two examples demonstrate the application potential of programmable truss-type fiber 3D fabric sewing equipment in automated production and intelligent repair. Through sophisticated mechanical design and intelligent control, these devices not only improve production efficiency and product quality but also provide more flexible and efficient solutions for the processing and repair of fiber 3D fabrics.

[0086] To address the problems existing in the prior art, the present invention provides a programmable truss-type fiber three-dimensional fabric sewing device and sewing method for combined processing. The present invention will be described in detail below with reference to the accompanying drawings.

[0087] The present invention provides a programmable truss-type fiber three-dimensional fabric sewing device for combined processing, involving a sophisticated component layout and installation relationship to ensure the high efficiency and stability of the equipment. First, the needle-clamping sewing device 2 is installed at the top front of the frame 1, directly responsible for sewing the fiber three-dimensional fabric. Next, a combination of a moving clamp and a pressing device 3 is arranged below the needle-clamping sewing device. This combination not only fixes the fiber three-dimensional fabric but also works with the needle-clamping sewing device to complete the sewing work. To achieve precise control and guidance of the sewing thread, a carbon fiber threading mechanism 4 is placed on the bottom left side of the frame and connected to it via a thread-pulling mechanism 5, located at the front end of the carbon fiber threading mechanism, responsible for controlling the tension of the sewing thread.

[0088] In the design of this device, the combination of rotary cylinder 9, gripper cylinder 10, and SCHUNK gripper 11 not only optimizes the flexibility and precision of the needle clamping mechanism but also ensures the stability and stitching effect of the three-dimensional fiber fabric. The introduction of servo motor 12 further enhances the control precision of the system axis. In conjunction with the ball screw mechanism and linear guide mechanism, it achieves high-precision position control and smooth movement during the stitching process.

[0089] Furthermore, the layout and function of the mold system are also highlights of this invention. The mold base 14, mold frame 15, main mold 16, and auxiliary mold 17 together constitute the core working area of ​​the sewing equipment. The main and auxiliary molds are installed inside the mold frame and fixed to the mold base, achieving precise positioning and movement through the mold moving mechanism 20. The clamping cylinder 18 and positioning cylinder 19 are responsible for clamping and positioning the mold, respectively, ensuring high efficiency and stability during the sewing process.

[0090] The present invention provides a programmable truss-type three-dimensional fiber fabric sewing equipment for combined processing. Through a standardized welded I-beam frame, a high-precision servo system, and flexible and reliable cylinder and electric cylinder modules, it achieves efficient sewing of three-dimensional fiber fabrics. The equipment design not only emphasizes ease of operation and flexibility but also considers the stability and accuracy of the sewing process, showcasing a new advancement in modern textile equipment technology. The automatic sewing project for three-dimensional fiber fabrics is a truss-type three-dimensional fiber fabric sewing equipment, which can achieve automatic connection between the sewing needle and carbon fiber thread, and unmanned automatic sewing functions.

[0091] The working principle of the programmable truss-type three-dimensional fiber fabric sewing equipment used for combined processing is as follows: The entire equipment is built on a standard H-beam welded equipment platform 22, ensuring the stability and load-bearing capacity of the equipment. The system axis adopts a servo system plus a ball screw mechanism, ensuring precise position control and stable motion performance. The guide adopts a linear guide mechanism, which allows each component to move smoothly along a straight line.

[0092] The needle-clamping sewing device 2 is located at the top front of the frame 1 and is the core component in the sewing process. When sewing is required, the needle-clamping sewing device 2 is activated, precisely controlling the movement trajectory and speed of the needle through the coordinated work of the electric cylinder module and servo system such as the servo motor 12. The needle clamping device uses a gripper cylinder 10, which can stably hold the sewing needle and ensure the smooth progress of the sewing process.

[0093] The movable clamp and clamping device assembly 3 is located below the needle clamping sewing device 2. Its main function is to fix the non-textile material to be sewn. The movable clamp can be moved to a designated position as needed, and then the clamping device clamps the fibrous three-dimensional fabric through a cylinder such as the clamping cylinder 18 to prevent it from moving or deforming during the sewing process.

[0094] The carbon fiber threading mechanism 4 and the thread-pulling mechanism 5 are connected, and together they are responsible for threading the suture through the three-dimensional fiber fabric. The carbon fiber threading mechanism 4 is located on the bottom left side of the frame 1, and through a precise mechanical structure and control system, it accurately guides the suture to the position where it needs to be sewn. The thread-pulling mechanism 5 is located at the front end of the carbon fiber threading mechanism 4 and is responsible for pulling the suture to sew.

[0095] During the stitching process, the glue injection system (such as glue dispensing component 26) comes into play. It uses a servo system and ball screw mechanism to precisely control the amount and position of glue injection, ensuring that the stitch has sufficient strength and stability.

[0096] The detection system uses a camera to record images and provides auxiliary lighting (illumination lamp 46) to monitor the suturing process and quality in real time. If any abnormality is detected, the system will immediately issue an alarm and take appropriate action.

[0097] The thread feeding system, such as the thread feeding assembly 27, uses an electric cylinder module and a servo system to smoothly deliver the suture thread to the threading mechanism.

[0098] The rotating part uses a swing cylinder, such as a rotary cylinder 9, with an adjustable swing angle, which allows the equipment to adapt to different sewing angle requirements.

[0099] The mold base 14, mold frame 15, main mold 16, and auxiliary mold 17 work together to provide stable support and positioning for the sewing process. The mold moving mechanism 20 is responsible for the precise movement and positioning of the mold.

[0100] The water spray assembly 13 is used to spray water during the sewing process to meet specific process requirements.

[0101] The components, including the spool assembly 23, thread delivery assembly 24, needle take-up assembly 25, needle holder assembly 28, scissor assembly 29, needle loading assembly 30, and feed assembly 31, each perform their specific functions, such as providing suture thread, picking up and placing suture needles, and trimming excess thread ends, working together to ensure the smooth progress of the sewing process. The frame 32 is the supporting structure for the entire equipment, ensuring the stable installation and operation of all components.

[0102] Auxiliary components such as the thread guide roller 33, water-filling needle assembly 34, thread feed roller 35, and thread guide assembly 36 are responsible for the transmission and guidance of the suture thread, ensuring its smooth flow. Actuators such as the electric cylinder 37 and gripper 38 are responsible for precisely controlling the movement and position of each component.

[0103] The slide rail platform 39, propulsion cylinder 40, needle holder lifting cylinder 41, needle holder plate 42, up-and-down moving cylinder 43, forward-and-backward moving cylinder 44, and servo displacement mechanism 45 are responsible for precisely controlling the movement and positioning of each component, ensuring the accuracy and stability of the sewing process. Throughout the sewing process, all components and mechanisms work together, achieving rapid, efficient, and precise sewing of three-dimensional fiber fabrics through a precise control system and mechanical structure. The programmable truss-type three-dimensional fiber fabric sewing equipment for combined processing, through its unique device structure and control system, achieves automated sewing of three-dimensional fiber fabrics, greatly improving production efficiency and quality.

[0104] Using the truss fiber three-dimensional fabric sewing method, without considering other working conditions, the product specifications can be expanded indefinitely, and the specifications used during development can cover all products at this time.

[0105] The equipment in this practical case can accommodate products up to 2030mm x 1200mm in size. Due to the large size of the truss stitching mold, automatic clamping and automatic repositioning of the pressure blocks during the stitching process are employed to prevent deformation of the mold core plate.

[0106] This equipment mainly consists of the following parts: 1. frame, 2. needle clamping and sewing device, 3. combination of moving clamp and pressing device, 4. carbon fiber threading mechanism, and 5. thread pulling mechanism. Figure 1 These components are fixedly installed according to their relative positions and operate in conjunction with each other by issuing commands through the control system.

[0107] The technical requirements for this equipment are shown in the table below:

[0108]

[0109]

[0110] The equipment platform is welded with standard I-beams, ensuring stable and reliable strength. All system axes use servo systems with ball screw mechanisms, and the guides use linear guide mechanisms, ensuring stable, reliable, and high-precision control. The needle insertion mechanism for carbon fiber threads uses an electric cylinder 37 module with a servo system, ensuring stable and reliable control. The needle clamping system uses a gripper cylinder, providing large clamping force and stable operation. The clamping system uses a pneumatic cylinder for clamping, with adjustable stroke and stable pressure.

[0111] The needle feeding system uses a 37-module electric cylinder plus a servo system, ensuring stable and reliable control; the glue injection system uses a servo system plus a ball screw mechanism, and the guide uses a linear guide mechanism, ensuring stable and reliable control with high precision; the detection system uses a camera for video recording, ensuring high precision and convenient control; the wire feeding system uses a 37-module electric cylinder plus a servo system, ensuring stable and reliable control, and the rotating part uses a swing cylinder with adjustable swing angle, high speed, and high repeatability.

[0112] It uses professional programming software for automatic program control, providing powerful logic control and motion logic functions; it can complete input / output logic control and mathematical operations, as well as high-speed counting and timing. It also allows editing of linear, rotational, and other motion functions of parts, as well as complex motions of components, and supports automatic saving of manually adjusted positions.

[0113] It supports multiple motion controls and uses G-code programming, which is convenient for operators to edit and develop. It also supports stable and safe functions in prohibited areas.

[0114] It has complete manual operation functions. In addition to the basic functions, the control system also provides manual operation for each component, such as: supporting inching function and individual positioning function for each part, which facilitates the alignment and debugging of each component; and supporting manual single-step debugging according to the process trajectory.

[0115] 2. Key technological solutions, their implementation process, and their effects

[0116] 2.1 Suture needle clamping technique

[0117] This invention innovatively designs a needle clamping sewing device 2 (see...) Figure 2 It mainly consists of a moving device 6, a needle clamping and puncturing mechanism 7, and a tray moving device 8. The needle clamping and puncturing mechanism 7 realizes the sewing of three-dimensional fiber fabrics and the needle clamping technique.

[0118] The needle-clamping puncture mechanism 7 mainly consists of a rotary cylinder 9, a gripper cylinder 10, a SCHUNK gripper 11, a servo motor 12, a water spray assembly 13, and other components, all mounted on the frame 32. Figure 3 This enables the stitching of three-dimensional fiber fabrics and the needle clamping technique.

[0119] The SCHUNK gripper 11 is used, which has reliable clamping force and stability; the gripper 38 is made of rigid material, which has the advantages of strong clamping force and steel needles are not easy to fall off; this solution can effectively solve the problem of clamping force of suture needles.

[0120] The system employs a 180° rotating cylinder and a clamping cylinder 10. The clamping cylinder 10 clamps the needle, the needle clamping assembly loosens and shifts, the rotating cylinder rotates to change the direction of the needle, the needle clamping assembly clamps the needle, and the needle tip is rotated 180° to continue suturing. This solution can effectively solve the problem of needle reversal and continuous operation.

[0121] It adopts 12 servo motors, and simultaneously controls displacement and torque to precisely control the sewing tension and prevent incomplete sewing or breakage of carbon fiber threads;

[0122] Adding a water spray component 13 to the needle clamp assembly to spray deionized water and lubricate the carbon fiber thread can effectively solve the problem of carbon fiber thread wear; determine the suture length according to process requirements and replace the suture before wear occurs; this solution can effectively solve the problem of suture stability.

[0123] 2.2 Research and development of mold clamping technology

[0124] This invention innovatively designs a combination of a moving clamp and a pressing device 3 (see...) Figure 4 It is assembled from a mold base 14, a mold frame 15, main and auxiliary molds, main and auxiliary mold clamping cylinders 18 (the main mold 16 uses a 100mm diameter cylinder as a reference, and the auxiliary mold 17 uses an 80mm diameter cylinder for clamping), left and right positioning cylinders 19, a bottom mold moving mechanism 20, and a clamping component movement mechanism 21. This unique innovation solves the problems of mold clamping and displacement, and effectively addresses the issue of automatic repositioning of the pressure block.

[0125] Adding stiffening plates to the outside of the mold frame 15 strengthens the tooling; using titanium alloy plates for the mold core plate increases its strength; staggered holes are made in the core plate openings to further enhance its strength; this solution effectively addresses the tooling strength issue.

[0126] The mold base 14 and mold frame 15 are made of stainless steel. The base is designed as a water collection trough so that water can be drained, thus solving the problem of mold corrosion.

[0127] The mold is set as a main mold 16 and a secondary mold 17. The main mold 16 is reinforced with ribs and serves as a reference. The secondary mold 17 is installed on the main mold 16, which facilitates operation after differentiation. This solves the problem of laying and assembling three-dimensional fiber fabrics.

[0128] 2.3 Automatic needle threading technology

[0129] This invention innovatively designs a carbon fiber threading mechanism 4 (see...) Figure 5This device can automatically perform functions such as threading, needle loading, needle removal, automatic needle-thread connection, and glue dispensing. The mechanism mainly consists of a worktable 22, a winding drum assembly 23, a thread feeding assembly 24, a needle picking assembly 25, a glue dispensing assembly 26, a thread feeding assembly 27, a needle holder assembly 28, a scissor assembly 29, a needle loading assembly 30, and a material feeding assembly 31.

[0130] 1) Regarding the problem of using glue for needle-thread connection, the present invention has proven through experiments that using a specially selected brand of glue to bond the needle and carbon fiber thread can effectively solve the problem of needle-thread connection.

[0131] We sought out professional manufacturers to develop specialized suture needles based on production process requirements, conducted comparative experiments on needle-thread bonding processes, and selected the best suture needles.

[0132] During the development of the suture needle, GCr6 steel was selected as the material due to its high hardness, high wear resistance, certain corrosion resistance, and a certain degree of toughness and impact resistance. Initially, five manufacturing processes for the suture needle were selected, categorized by manufacturing method as steel plate rolling and hot-rolled steel wire grinding. The final experimental suture needle made from hot-rolled steel wire (see...) Figure 6 To meet production needs, the suture needle is ground to a sharp point and the tail is perforated by electrical discharge machining. The processing technology is complex, but it has excellent toughness and impact resistance during the suturing process. The connection between the suture and the suture needle is made with an adhesive groove 3mm away from the tail. After the adhesive is applied, it can be smoothly integrated into the front and rear cavities, preventing the adhesive from coming out of the suture needle and affecting the suturing process.

[0133] 2) Develop a dedicated wire feeding mechanism, where the wire enters the wire output assembly 24 through the drum assembly 23. Figure 7 ), wire feeding assembly 27 ( Figure 8 The gripper cylinder 10 clamps the suture and passes the carbon fiber thread through the threading tube. At this time, the needle holder assembly 28 ( Figure 9 The suture thread is automatically fed into the suture needle by the simultaneous movement of the suture feeding assembly 27 and the servo electric cylinder 37. Next, the water spray assembly 13 is added to lubricate the carbon fiber thread and prevent wear.

[0134] Needle extraction assembly 25 ( Figure 10 The clamp 38 is used to hold the needles in the needle box and place them on the needle holder assembly 28 under the drive of the servo cylinder 37, thus completing the needle picking function. The scissor assembly 29 is used to cut the carbon fiber thread to the appropriate length according to the process requirements.

[0135] 3) Develop a dedicated dispensing assembly 26 ( Figure 11 Once the needle and thread are threaded, the servo-controlled pressure head presses the glue tube, controls the stroke, and dispenses a fixed amount of glue. The glue is applied to the joint between the needle and thread, and then cures within the processing time, bonding the needle and thread together.

[0136] 2.4 Truss mold positioning and clamping technology

[0137] Two types of cylinders are used for clamping: one side uses a 100mm diameter cylinder as a reference, and the other side uses an 80mm diameter cylinder for clamping (see...). Figure 4 The cylinder extension dimension is determined and adjusted according to process requirements; this solution can effectively solve the problem of clamping amount control.

[0138] The clamping assembly slides freely on a linear guide rail and is moved by a top servo system. After the stitching is in place, the clamping block assembly moves. This solution effectively solves the problem of automatic clamping block repositioning (see...). Figure 4 ).

[0139] Left and right positioning cylinders 19 are added, with conical holes for positioning to improve alignment accuracy (see...). Figure 4 ).

[0140] In addition, the truss fiber three-dimensional fabric sewing equipment of the present invention adopts a double-sided mirror workstation for simultaneous sewing, which increases the efficiency by nearly 100% compared to the original method.

[0141] 3. Production operation flow of the equipment of this invention

[0142] The process of the device for sewing fiber material according to this invention is as follows (see...) Figure 12 ):

[0143] ① Lay the three-dimensional fiber fabric on the mold

[0144] ② Lifting mold

[0145] ③ Hoist the mold onto the transfer device

[0146] ④ The moving component extends

[0147] ⑤ The transfer device moves towards the moving assembly, transporting the mold onto the moving assembly.

[0148] ⑥ The transfer device transports the mold to the moving component, then retracts to prepare for the installation of the other mold.

[0149] ⑦ The moving component with mold returns to its initial position, the clamping cylinder clamps the core plate, and the sewing component begins sewing from bottom to top.

[0150] ⑧ Adjust the clamping cylinders according to the stitching position, and move the moving assembly forward to sew sequentially.

[0151] ⑨ Suture end

[0152] ⑩ After sewing is completed, the movable component extends, the mold is lifted, and the product is taken out.

[0153] According to the technical solution of the present invention, a programmable truss fiber three-dimensional fabric sewing equipment has been manufactured. This equipment can cover the sewing of carbon cloth with a thickness of 2160mm x 1200mm. It can realize automatic needle picking, automatic needle threading (conveying length 2800mm), automatic connection of sewing needle and carbon fiber thread, and automatic sewing of fiber three-dimensional fabric. It has tensile force detection and adjustable thread torque. It can replace manual sewing, improve work efficiency, improve product quality, and fully realize fully automated sewing.

[0154] The embodiments of this invention have demonstrated significant advantages over existing technologies through testing. In terms of needle threading, needle pushing force, and suturing speed, they exhibit the following positive effects and advantages:

[0155]

[0156] In the description of this invention, unless otherwise stated, "a plurality of" means two or more; the terms "upper," "lower," "left," "right," "inner," "outer," "front end," "rear end," "head," "tail," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," "third," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0157] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any modifications, equivalent substitutions, and improvements made by those skilled in the art within the scope of the technology disclosed in the present invention, and within the spirit and principles of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A programmable truss-type three-dimensional fiber fabric sewing device for combined processing, characterized in that, It includes a frame, a needle-clamping sewing device, a combination of a movable clamp and a pressing device, a carbon fiber threading mechanism, and a thread-pulling mechanism; the needle-clamping sewing device is located at the front of the top of the frame, the combination of the movable clamp and the pressing device is located below the needle-clamping sewing device, the carbon fiber threading mechanism and the thread-pulling mechanism are connected, the carbon fiber threading mechanism is located on the left side of the bottom of the frame, and the thread-pulling mechanism is located at the front of the carbon fiber threading mechanism. The equipment platform of the programmable truss-type three-dimensional fiber fabric sewing equipment used for combined processing is welded with standard I-beams. All system axes adopt servo systems and ball screw mechanisms, and the guide adopts linear guide mechanism. The needle insertion carbon fiber threading mechanism adopts electric cylinder module and servo system. The needle clamping adopts claw cylinder. The clamping device adopts cylinder clamping. The needle feeding system adopts electric cylinder module and servo system. The glue injection system adopts servo system and ball screw mechanism, and the guide adopts linear guide mechanism. The detection system adopts camera imaging. The thread feeding system adopts electric cylinder module and servo system. The rotating part adopts swing cylinder with adjustable swing angle. The equipment includes a carbon fiber threading mechanism, which has fully automatic threading, needle loading, needle picking, fully automatic needle-thread connection and glue dispensing functions. It consists of a worktable, a spool assembly, a thread output assembly, a needle picking assembly, a glue dispensing assembly, a thread feeding assembly, a needle holder assembly, a scissor assembly, a needle loading assembly, and a material supply assembly. Carbon fiber thread enters the thread output assembly through the spool assembly. The gripper cylinder of the thread feeding assembly clamps the thread and passes it through the threading tube. At this time, the needle holder assembly and the thread feeding assembly move simultaneously via servo electric cylinders, automatically feeding the thread into the suture needle. In addition, the equipment is equipped with a water spray assembly to keep the carbon fiber thread lubricated during the sewing process. The needle pick-up assembly is used to pick up the suture needle from the needle box and place it on the needle holder assembly under the drive of the servo motor. The scissors assembly is used to cut the carbon fiber thread to the appropriate length according to process requirements. After the needle and thread are threaded, the glue dispensing assembly uses the servo system to control the pressure head to press the glue tube and control the pressure stroke to dispense a certain amount of glue. The glue is then applied to the needle and thread joint, allowing it to cure within the process time and firmly bond the needle and thread together.

2. The programmable truss-type three-dimensional fiber fabric sewing equipment for combined processing as described in claim 1, characterized in that, The needle clamping sewing device consists of a moving device, a needle clamping and puncturing mechanism, and a tray moving device. The needle clamping and puncturing mechanism realizes the sewing of three-dimensional fiber fabrics and the needle clamping technology. The needle clamping and puncturing mechanism is composed of a rotary cylinder, a gripper cylinder, a gripper, a servo motor, and a water spray assembly, all mounted on the frame. The device employs a rigid gripper, utilizing a 180° rotating cylinder and a gripper cylinder. The gripper cylinder clamps the needle, the needle clamping assembly releases and shifts, the rotating cylinder rotates to change the needle's direction, the needle clamping assembly clamps it again, the needle tip is rotated 180°, and suturing continues. A servo motor is used for simultaneous displacement and torque control. A water spray component is added to the needle clamping assembly to spray deionized water to lubricate the carbon fiber thread. The suture length is determined according to process requirements, and the suture is replaced before wear.

3. The programmable truss-type three-dimensional fiber fabric sewing equipment for combined processing as described in claim 1, characterized in that, The moving clamp and clamping device assembly consists of a mold base, a mold frame, main and auxiliary molds, main and auxiliary mold clamping cylinders, left and right positioning cylinders, a bottom mold moving mechanism, and a clamping component motion mechanism. The mold frame is reinforced with stiffening plates, and the mold core plate is made of titanium alloy with staggered holes. The mold base and mold frame are made of stainless steel, and the base has a water collection trough. The molds are divided into a main mold and an auxiliary mold. The main mold is reinforced with stiffening plates to serve as a reference, and the auxiliary mold is installed on top of the main mold for easy operation.

4. The programmable truss-type three-dimensional fiber fabric sewing equipment for combined processing according to claim 1, characterized in that, The suture needle is made of hot-rolled steel wire. The tip of the suture needle is ground and the tail is punched with electrical discharge machining. The connection between the suture thread and the suture needle has an adhesive groove processed 3mm beyond the tail. After applying adhesive, it is integrated into the front and rear cavities to achieve a stable needle-thread connection.

5. The programmable truss-type three-dimensional fiber fabric sewing equipment for combined processing according to claim 3, characterized in that, The clamping device of the equipment uses two cylinders with different diameters for clamping. One side uses a 100mm diameter cylinder as a reference, and the other side uses an 80mm diameter cylinder for clamping. The extension of the cylinders is adjusted according to process requirements to ensure appropriate clamping amount. The clamping assembly can slide freely on a linear guide rail and its movement is controlled by a servo system at the top. After the stitching is in place, the clamping block assembly moves accordingly. In addition, the equipment is also equipped with left and right positioning cylinders with tapered hole designs to achieve simultaneous stitching at double-sided mirror workstations.

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