Multi-angle automatic winding control system and method for prefabricated body with complex molded surface

Abstract

The invention discloses a multi-angle automatic winding control system and method for a complex molded surface preform, and belongs to the technical field of textile. According to different winding modes of a complex profile preform, a rotating shaft R for controlling the preform to rotate, a longitudinal shaft Y for controlling winding fibers to move in the axial direction of the preform and a radial shaft X for controlling the winding fibers to advance and retreat in the radial direction of fabric are established, and winding path movement is controlled through the linear synchronous or nonlinear cam coupling relation of the R shaft and the Y shaft; through an X-axis and Y-axis gradient regulation and control method, profiling winding of the winding fibers is achieved. The method is suitable for rapid development of large-size, multi-variety, complex and special-shaped three-dimensional fabrics; constant-tension multi-angle winding of the complex special-shaped fabric is achieved, it is guaranteed that fabric winding fiber lines are not loose, and the product quality requirement is met; low-cost, efficient and high-precision winding preparation of the three-dimensional fabric is achieved, the requirement for uniform winding grids of the fabric with the complex contour is met, and technical guarantee is provided for diversity development of the three-dimensional fabric.

Description

Technical Field

[0001] The invention belongs to the field of textile technology, and in particular relates to a multi-angle automatic winding control system and method for a complex profile preform. Background Art

[0002] With the development of aerospace technology, in order to adapt to the working requirements in complex environments, the demand for the diversity of preform structures is also increasing. Preforms used as composite material reinforced skeletons are developing in the direction of large size, complex and special shapes, high-precision profiling, fast and low-cost preparation. In the process of preform preparation, winding is a key process, which plays a role in maintaining shape and increasing volume density. Therefore, in the preparation process of complex and special-shaped preforms, the fiber bundle winding effect directly determines the quality of the fabric. The traditional manual winding method has problems such as low control accuracy, large uniformity fluctuations, and low efficiency.

[0003] The invention patent with patent number 202410082764.3 discloses a needle-punched rotating preform laying, winding and piercing integrated forming method, by evenly arranging a number of nail columns at both ends of the rotating core mold, so as to realize spiral winding and annular winding; the invention patent with patent number 202311790626.2 discloses a fiber winding device and a fiber winding method, which obtains the outer dimensions of the model through a laser sensor, and controls the fiber winding in combination with a predetermined target pressure value to ensure the control of the internal pressure of the model; the utility model patent with patent number 202221411179.6 discloses a compaction and winding integrated device for the casing preform, which ensures that the tension force of the preform continues to maintain the required winding, thereby controlling the curvature of the fiber wound around the preform and improving the stiffness and strength of the composite casing.

[0004] Most of the existing winding technologies are only applicable to regular-shaped preforms. When dealing with special-shaped preforms, it is necessary to manually add nails to assist in the realization. This method is difficult to meet the needs of large-size, complex and special-shaped, high-precision profiling, fast and low-cost development. Therefore, it is necessary to propose a complex surface multi-angle automatic winding control system and method, which can realize automatic winding in the preparation process of complex special-shaped fabrics, ensure the internal quality of the product and improve the preparation efficiency. Summary of the invention

[0005] The purpose of the present invention is to solve the problems raised in the background technology and to provide a multi-angle automatic winding control system and method for complex surface preforms, which meet the requirements of high grid uniformity, strong adaptability, fast preparation efficiency and low cost.

[0006] In order to achieve the purpose of the present invention, the present invention discloses a multi-angle automatic winding control method for a complex profile preform, comprising the following steps:

[0007] Step 1, set the complex profile preform motion control device as the rotation axis R, the winding fiber radial motion control device along the preform as the radial axis X, and the winding fiber axial motion control device along the preform as the longitudinal axis Y, and control the preform rotational motion to the initial position with the rotation axis R, the initial position is the starting point of the first oblique winding curve, and this is set as the zero point of the rotation axis R; based on the initial position of the preform, the position of the bottom of the preform is set as the zero point of the longitudinal axis Y, and the position within 1 cm close to the preform profile is set as the zero point of the radial axis X, and the origin of the three-axis coordinate system for the winding motion of the complex profile preform is established;

[0008] Step 2: According to the winding molding process of the complex surface preform, the winding mode is selected, and the setting values ​​of the winding fiber line tension F and the tension deviation ±ΔF are input;

[0009] Step 3, the radial axis X frame is equipped with a laser position sensor, which moves with the longitudinal axis Y and remains unchanged relative to the radial axis X origin. The laser position sensor does not move with the radial axis X and is arranged in front of the winding yarn outlet to detect changes in the thickness of the preform surface in advance;

[0010] Step 4: Establish a gradient control method for the radial axis X displacement to follow the longitudinal axis Y displacement, so as to control the winding fiber and the preform to be wound closely in real time, while avoiding interference between the winding device and the preform surface;

[0011] Step 5, when the circumferential winding mode is selected, a linear synchronization relationship between the rotation axis R and the longitudinal axis Y is established according to the circumferential spacing winding requirements; when the oblique winding mode is selected, a nonlinear cam coupling relationship between the rotation axis R and the longitudinal axis Y is established according to the grid spacing winding requirements, and the control curves of the constant speed rotation of the preform and the variable speed reciprocating motion of the winding fiber are determined, and the movement of the rotation axis R and the longitudinal axis Y is controlled to achieve the equal grid control requirements of the variable angle oblique winding of the complex surface preform;

[0012] Step 6: When the oblique winding mode is selected, a multi-curve continuous winding control method is established according to the number of winding curves, the starting point and the end point of each curve, so as to realize the continuous movement of all oblique winding curves and improve the winding efficiency and the consistency of the grid;

[0013] Step 7. When all winding tasks are completed, the radial axis X automatically returns to the origin position. After the return is completed, the longitudinal Y axis and the rotation axis R return to the starting coordinate point and wait for the next winding task.

[0014] Furthermore, in step 4, based on the thickness variation of the preform surface, a gradient control method of "gradient radial feed" is adopted to establish a control method in which the radial axis X position follows the longitudinal axis Y position variation, so as to realize the gradient radial feed adjustment of the winding fiber, so as to control the fiber and the preform to be wound close to each other in real time;

[0015] D=K*L*h / H

[0016]

[0017] Where D is the radial axis X positioning target position; L is the detection position of the laser position sensor, L min is the minimum value, L max is the maximum value; h is the longitudinal axis Y position; H is the total height of the preform; K is the gradient coefficient, ranging from 0.1 to K max .

[0018] Further, in step 5, in the hoop winding mode, the linear synchronization relationship between the rotation axis R and the longitudinal axis Y is established by the synchronization coupling coefficient k, and the synchronization coupling coefficient k is:

[0019] k=a*36*ρ

[0020] Wherein, a is the directional coefficient. When a=-1, the rotation axis R is synchronized in the opposite direction with the longitudinal axis Y; when a=1, the rotation axis R is synchronized in the positive direction with the longitudinal axis Y. By controlling the movement direction of the rotation axis R by a, the yarn output positions of the two adjacent layers are opposite, which meets the force requirements of the top of the preform in different unit layers; ρ is the circumferential winding grid spacing, and the unit is root / cm.

[0021] Further, in step 5, in the oblique winding mode, the preform rotation axis R is taken as the main axis, which moves at a constant speed, and the winding fiber longitudinal movement axis Y is taken as the slave axis, which follows the movement of the main axis, and a nonlinear cam coupling relationship between the angle of the preform rotation axis R and the absolute position of the winding fiber longitudinal movement axis Y is established. By establishing the angle θ of the rotation axis R ij The position h with respect to the longitudinal axis Y ij The coordinate points (θ ij ,h ij ) forms N oblique winding cam coupling curves, and realizes the oblique reciprocating winding of N winding fibers from bottom to top and from top to bottom along the axial direction of the preform, as follows:

[0022] (1) Based on the requirements of the preform oblique winding grid spacing d, determine the total number of preform oblique winding fibers N, the starting angle α of each oblique winding fiber at the bottom of the preform i , i is the number of obliquely wound fibers, i∈[1,N];

[0023] (2) Each oblique winding cam coupling curve starts from the zero point of the longitudinal axis Y, the total height of the preform is H, and the height of the non-winding area at the top of the preform is H 0To avoid the accumulation of winding fibers on the top of the preform, the first winding curve is used as the reference line at the top, and the remaining N-1 curves are wound at the top with a step height s; the preform is divided into longitudinal sections along the longitudinal axis Y according to the height Δh i Divide, Δh i ∈1,2.5]mm to ensure that the winding angle does not change suddenly; combined with the cross-sectional perimeter of the preform, determine the angle θ of the rotation axis R ij The position h with respect to the longitudinal axis Y ij The calculation method is:

[0024]

[0025] Where M i is the number of winding points of the i-th oblique winding cam curve; l p is the preform at p*Δh i The cross-sectional perimeter at the height; j is the jth winding point on the i-th oblique winding cam curve, 1≤j≤M i .

[0026] Furthermore, in step 6, in the oblique winding mode, based on the requirements of large wrap angle and small fiber waste, a method for automatically connecting multiple fiber winding curves without slippage is established to improve the oblique winding efficiency and the consistency of winding quality;

[0027] (1) After the end point of the i-th oblique winding cam curve passes through the δ wrap angle, the number of cam coupling curves that have completed oblique winding, r, r∈[0,N], is counted, and the allowable angle β for automatic connection to the next oblique winding without slippage is determined. i :

[0028] r=r+1

[0029]

[0030] In the formula, θ i is the end point angle of the rotation axis R when completing the i-th oblique winding cam curve; δ is the wrap angle between different oblique winding cam curves without slippage and automatic connection, δ∈[90,270].

[0031] (2) β i The starting angle α of the remaining Nr oblique winding cam curves m Compare them one by one until the deviation Δ im , when Δ im When the value is the smallest, it indicates that the oblique winding starting angle α of the mth oblique winding cam curve m With β i The closest, that is, the next time the mth oblique winding cam curve is wound, the m number is assigned to i;

[0032] Δ im =|β i -α m |1≤i,m≤N and i≠m

[0033] Furthermore, during the winding process, the yarn tension F is detected in real time using a tension sensor. 1 It is compared with the control input tension F, and the torque motor is used to control the fiber winding tension in an online closed loop. It is compared with the expected value F in real time to ensure that the error between the detected tension and the expected tension is within the range of ±ΔF.

[0034] In order to achieve the purpose of the present invention, the present invention also discloses a multi-angle automatic winding control system for complex profile preforms, including a winding fiber yarn tube, a complex profile preform motion control device, a winding fiber axial motion control device along the preform, a winding fiber radial motion control device along the preform, a winding fiber tension control and state monitoring module, and a winding motion centralized control module;

[0035] Winding fiber yarn bobbin: installed on the winding fiber radial movement control device along the preform;

[0036] Complex profile preform motion control device: used to control the rotational motion of complex profile preform;

[0037] A device for controlling the axial movement of the winding fiber along the preform: used to control the axial movement of the winding fiber along the complex profile preform to match the rotational movement of the complex profile preform;

[0038] Winding fiber radial movement control device along the preform: installed on the winding fiber axial movement control device along the preform, used to control the winding fiber radial movement along the complex surface preform, so that the winding fiber is close to the fabric surface;

[0039] Winding fiber tension control and status monitoring module: connected to the winding fiber yarn drum, installed on the winding fiber axial motion control device along the preform, including a tension control module, a tension detection sensor, a yarn break detection sensor, and a position sensor, which detects the yarn tension and yarn breakage status of the winding process in different winding modes in real time, and the distance between the winding fiber radial motion control device and the complex surface preform, and controls the fiber winding tension in an online closed loop according to the expected tension value;

[0040] Winding motion centralized control module: connected with the complex surface preform motion control device, the winding fiber axial motion control device along the preform, the winding fiber radial motion control device along the preform, the winding fiber tension control and state monitoring module respectively, to establish the motion relationship between the complex surface preform and the winding fiber.

[0041] Furthermore, the winding motion centralized control module adopts a PLC supporting motion control functions as the CPU, and supports multi-axis servo synchronization and cam curve coupled motion under CANopen or Ethercat bus communication status; the CPU obtains the yarn tension and position in real time during the yarn winding process through the analog input module; the CPU controls the torque motor to adjust the yarn tension through the analog output module; the CPU receives the yarn break detection sensor signal through the digital input module, and if the yarn breaks, the distance between the winding fiber along the radial motion control device of the preform and the complex surface preform at the yarn break, the yarn tension, and the output value of the torque motor are recorded, and the winding mechanism movement is paused, and a yarn break warning is output.

[0042] Compared with the prior art, the significant progress of the present invention lies in: 1) relative to the existing winding technology, it provides a low-cost, fast-response multi-angle automatic winding control method, which is more suitable for the rapid development of large-size, multi-variety, complex and special-shaped three-dimensional fabrics; 2) by utilizing tension detection and adjustment, the fiber winding tension is controlled in an online closed-loop manner to achieve constant tension multi-angle winding of complex and special-shaped fabrics, ensuring that the fabric winding fiber lines are not loose and meeting product quality requirements; 3) the present invention can achieve low-cost, efficient and high-precision winding preparation of three-dimensional fabrics, can meet the requirements of uniform winding grids for complex contour fabrics, and provide technical guarantee for the diversified development of three-dimensional fabrics.

[0043] In order to more clearly illustrate the functional characteristics and structural parameters of the present invention, further description is given below in conjunction with the accompanying drawings and specific implementation methods. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] The drawings described herein are used to provide a further understanding of the present invention and constitute a part of this application. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0045] Figure 1 This is a structural diagram of a multi-angle automatic winding control system for a complex profile preform of the present invention;

[0046] Figure 2 A schematic diagram of the control parameters of the oblique winding of a complex profile preform of the present invention;

[0047] Figure 3 It is a structural schematic diagram of a multi-angle automatic winding control device for a complex profile preform of the present invention;

[0048] Figure 4 It is a schematic diagram of a cam coupling curve for automatic oblique winding of a complex profile preform of the present invention;

[0049] Figure 5 It is a schematic diagram of an automatic hoop-wound preform of the present invention;

[0050] Figure 6 The present invention is a schematic diagram of the overall process of a method for automatically winding a complex-shaped preform at multiple angles. DETAILED DESCRIPTION

[0051] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments; based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0052] Combination Figure 1 , a multi-angle automatic winding control system for large-size, variable-section complex and special-shaped preform fabrics, including a winding fiber yarn tube, a complex-shaped preform motion control device, a winding fiber axial motion control device along the preform, a winding fiber radial motion control device along the preform, a winding fiber tension control and state monitoring module, and a winding motion centralized control module, as follows:

[0053] The winding fiber yarn bobbin is installed on a device for controlling the radial movement of the winding fiber along the preform;

[0054] The complex profile preform motion control device is used to control the rotational motion of the complex profile preform;

[0055] The device for controlling the axial movement of the winding fiber along the preform is used to control the axial movement of the winding fiber along the complex profile preform to match the rotational movement of the complex profile preform;

[0056] The device for controlling the radial movement of the winding fibers along the preform is installed on the device for controlling the axial movement of the winding fibers along the preform, and is used to control the radial movement of the winding fibers along the complex-shaped preform, so that the winding fibers are close to the fabric surface;

[0057] The winding fiber tension control and state monitoring module is connected to the winding fiber yarn drum and installed on the winding fiber axial motion control device along the preform. It includes a tension control module, a tension detection sensor, a yarn break detection sensor, and a position sensor. It detects the yarn tension, yarn breakage status, and the distance between the winding fiber radial motion control device and the complex surface preform in real time during the winding process under different winding modes. According to the expected tension value, the fiber winding tension is controlled in an online closed loop.

[0058] The winding motion centralized control module is respectively connected with the complex surface preform motion control device, the winding fiber axial motion control device along the preform, the winding fiber radial motion control device along the preform, and the winding fiber tension control and state monitoring module to establish the motion relationship between the complex surface preform and the winding fiber.

[0059] The motion control device for complex surface preforms uses Delta A3 series servo driver ASD-A3-1521-M supporting CANOpen communication and servo motor ECMC-EW1315SS with absolute encoder to control the movement of the rotating axis R, driving the complex surface preform to rotate at a certain speed. The fabric can be a special-shaped rotating body or a standard rotating body;

[0060] The winding fiber axial motion control device along the preform uses Delta's servo driver ASD-A3-0721-M that supports CANOpen communication and the servo motor ECM-A3L-CA0807SS1 with an absolute encoder to control the longitudinal axis X movement, meeting the actuator's longitudinal winding motion requirements along the fabric;

[0061] The radial motion control device for the winding fiber along the preform uses Delta's servo driver ASD-A3-0421-M that supports CANOpen communication and the servo motor ECM-A3L-CA0604SS1 with an absolute encoder to control the radial Y-axis movement and the gradient horizontal follow-up to meet the winding requirements of variable diameter special-shaped preforms;

[0062] The winding motion centralized control module uses Delta DVP15MC-11T which supports motion control function as CPU, supports multi-axis servo synchronization and cam curve coupling motion under CANopen or Ethercat bus communication state; and expands 1 analog input and output module DVP06XA-S;

[0063] The tension sensor uses Jinnuo JZHL-M1 series tension sensor with a detection range of 0-20N; the position detection unit uses Shendawei SW-LDS20DB high-precision ranging laser displacement sensor with a measuring distance of 0.2-20m; and the detection signal is transmitted to the integrated motion controller DVP15MC-11T through the analog module DVP06XA-S to achieve radial axis Y gradient following, and control the Oriental Motor TM series torque motor to close the loop to adjust the yarn winding tension.

[0064] The winding motion centralized control module DVP15MC-11T establishes the synchronization and cam interpolation relationship between the rotation axis R and the longitudinal axis Y of the three-coordinate joint control unit, with the rotation axis R as the main axis and the longitudinal axis Y as the slave axis. Taking the winding of a large-sized complex surface preform as an example, this example also provides a multi-angle automatic winding control method for a complex surface preform, such as Figure 6 As shown, the specific steps are as follows:

[0065] Step 1, set the complex profile preform motion control device as the rotation axis R, the winding fiber radial motion control device along the preform as the radial axis X, and the winding fiber axial motion control device along the preform as the longitudinal axis Y, and control the preform rotational motion to the initial position with the rotation axis R, the initial position is the starting point of the first oblique winding curve, and this is set as the zero point of the rotation axis R; based on the initial position of the preform, the position of the bottom of the preform is set as the zero point of the longitudinal axis Y, and the position within 1 cm close to the preform profile is set as the zero point of the radial axis X, and the origin of the three-axis coordinate system for the winding motion of the complex profile preform is established;

[0066] Step 2: According to the winding molding process of the complex surface preform, the winding mode is selected, and the setting values ​​of the winding fiber line tension F and the tension deviation ±ΔF are input;

[0067] Step 3, the radial axis X frame is equipped with a laser position sensor, which moves with the longitudinal axis Y and remains unchanged relative to the radial axis X origin. The laser position sensor does not move with the radial axis X and is arranged in front of the winding yarn outlet to detect changes in the thickness of the preform surface in advance;

[0068] Step 4: Establish a gradient control method for the radial axis X displacement to follow the longitudinal axis Y displacement, so as to control the winding fiber and the preform to be wound closely in real time, while avoiding interference between the winding device and the preform surface;

[0069] Step 5, when the circumferential winding mode is selected, a linear synchronization relationship between the rotation axis R and the longitudinal axis Y is established according to the circumferential spacing winding requirements; when the oblique winding mode is selected, a nonlinear cam coupling relationship between the rotation axis R and the longitudinal axis Y is established according to the grid spacing winding requirements, and the control curves of the constant speed rotation of the preform and the variable speed reciprocating motion of the winding fiber are determined, and the movement of the rotation axis R and the longitudinal axis Y is controlled to achieve the equal grid control requirements of the variable angle oblique winding of the complex surface preform;

[0070] Step 6: When the oblique winding mode is selected, a multi-curve continuous winding control method is established according to the number of winding curves, the starting point and the end point of each curve, so as to realize the continuous movement of all oblique winding curves and improve the winding efficiency and the consistency of the grid;

[0071] Step 7. When all winding tasks are completed, the radial axis X automatically returns to the origin position. After the return is completed, the longitudinal Y axis and the rotation axis R return to the starting coordinate point and wait for the next winding task.

[0072] The linear synchronization relationship between the rotation axis R and the longitudinal axis Y is established by the synchronization coupling coefficient k, which is:

[0073] k=a*36*ρ

[0074] Wherein, a is the directional coefficient. When a=-1, the rotation axis R is synchronized in the opposite direction with the longitudinal axis Y; when a=1, the rotation axis R is synchronized in the positive direction with the longitudinal axis Y. By controlling the movement direction of the rotation axis R by a, the yarn output positions of the two adjacent layers are opposite, which meets the force requirements of the top of the preform in different unit layers; ρ is the circumferential winding grid spacing, and the unit is root / cm.

[0075] like Figure 2 , 3 As shown in 4, in the oblique winding mode, the preform rotation axis R is the main axis, which moves at a constant speed, and the winding fiber longitudinal movement axis Y is the slave axis, which follows the movement of the main axis. A nonlinear cam coupling relationship is established between the angle of the preform rotation axis R and the absolute position of the winding fiber longitudinal movement axis Y. By establishing the angle θ of the rotation axis R ij The position h with respect to the longitudinal axis Y ij The coordinate points (θ ij ,h ij ) forms N oblique winding cam coupling curves, and realizes the oblique reciprocating winding of N winding fibers from bottom to top and from top to bottom along the axial direction of the preform, as follows:

[0076] (1) Based on the requirements of the preform oblique winding grid spacing d, determine the total number of preform oblique winding fibers N, the starting angle α of each oblique winding fiber at the bottom of the preform i , i is the number of obliquely wound fibers, i∈[1,N];

[0077] (2) Each oblique winding cam coupling curve starts from the zero point of the longitudinal axis Y, the total height of the preform is H, and the height of the non-winding area at the top of the preform is H 0 To avoid the accumulation of winding fibers on the top of the preform, the first winding curve is used as the reference line at the top, and the remaining N-1 curves are wound at the top with a step height s; the preform is divided into longitudinal sections along the longitudinal axis Y according to the height Δh i Divide, Δh i ∈1,2.5]mm to ensure that the winding angle does not change suddenly; combined with the cross-sectional perimeter of the preform, determine the angle θ of the rotation axis R ij The position h with respect to the longitudinal axis Y ij The calculation method is:

[0078]

[0079]

[0080] Where M i is the number of winding points of the i-th oblique winding cam curve; l p is the preform at p*Δh iThe cross-sectional perimeter at the height; j is the jth winding point on the i-th oblique winding cam curve, 1≤j≤M i .

[0081] like Figure 4 , 5 As shown, based on the thickness variation of the preform surface, a gradient control method of "gradient horizontal feeding" is adopted, and a control method of the radial axis X position following the longitudinal axis Y position change is established to realize the gradient radial feeding adjustment of the winding fiber, so as to control the fiber and the preform to be wound close to each other in real time;

[0082] D=K*L*h / H

[0083]

[0084] Where D is the radial axis X positioning target position; L is the detection position of the laser position sensor, L min is the minimum value, L max is the maximum value; h is the longitudinal axis Y position; H is the total height of the preform; K is the gradient coefficient, ranging from 0.1 to K max .

[0085] like Figure 2 , 3 As shown in Figure 4, in the oblique winding mode, based on the requirements of large wrap angle and small fiber waste, a method for automatically connecting multiple fiber winding curves without slippage is established to improve the oblique winding efficiency and the consistency of winding quality;

[0086] (1) After the end point of the i-th oblique winding cam curve passes through the δ wrap angle, the number of cam coupling curves that have completed oblique winding, r, r∈[0,N], is counted, and the allowable angle β for automatic connection to the next oblique winding without slippage is determined. i :

[0087] r=r+1

[0088]

[0089] In the formula, θ i is the end point angle of the rotation axis R when completing the i-th oblique winding cam curve; δ is the wrap angle between different oblique winding cam curves without slippage and automatic connection, δ∈[90,270].

[0090] (2) β i The starting angle α of the remaining Nr oblique winding cam curves m Compare them one by one until the deviation Δ im , when Δ im When the value is the smallest, it indicates that the oblique winding starting angle α of the mth oblique winding cam curve m With β iThe closest, that is, the next time the mth oblique winding cam curve is wound, the m number is assigned to i;

[0091] Δ im =|β i -α m |1≤i,m≤N and i≠m

[0092] The multi-angle automatic winding control system and method of a complex-shaped preform of the present invention provides a low-cost, fast-response automatic winding control method compared to the existing winding technology, and is more suitable for the rapid development of multi-variety, complex and special-shaped three-dimensional fabrics; by utilizing tension detection and adjustment, the fiber winding tension is controlled in an online closed loop to achieve constant tension winding of the complex-shaped preform, ensuring that the fabric winding fiber line is not loose and meeting product quality requirements; the present invention can achieve low-cost, efficient and high-precision winding preparation of three-dimensional fabrics, can meet the demand for uniform winding grids of complex contour fabrics, and provide technical guarantee for the diversified development of three-dimensional fabrics.

[0093] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0094] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A multi-angle automatic winding control method for a complex profile preform, characterized in that: The following steps are involved: Step 1, set the complex profile preform motion control device as the rotation axis R, the winding fiber radial motion control device along the preform as the radial axis X, and the winding fiber axial motion control device along the preform as the longitudinal axis Y, and control the preform rotational motion to the initial position with the rotation axis R, the initial position is the starting point of the first oblique winding curve, and this is set as the zero point of the rotation axis R; based on the initial position of the preform, the position of the bottom of the preform is set as the zero point of the longitudinal axis Y, and the position within 1 cm close to the preform profile is set as the zero point of the radial axis X, and the origin of the three-axis coordinate system for the winding motion of the complex profile preform is established; Step 2: According to the winding molding process of the complex surface preform, the winding mode is selected, and the setting values ​​of the winding fiber line tension F and the tension deviation ±ΔF are input; Step 3, the radial axis X frame is equipped with a laser position sensor, which moves with the longitudinal axis Y and remains unchanged relative to the radial axis X origin. The laser position sensor does not move with the radial axis X and is arranged in front of the winding yarn outlet to detect changes in the thickness of the preform surface in advance; Step 4: Establish a gradient control method for the radial axis X displacement to follow the longitudinal axis Y displacement, so as to control the winding fiber and the preform to be wound closely in real time, while avoiding interference between the winding device and the preform surface; Step 5, when the circumferential winding mode is selected, a linear synchronization relationship between the rotation axis R and the longitudinal axis Y is established according to the circumferential spacing winding requirements; when the oblique winding mode is selected, a nonlinear cam coupling relationship between the rotation axis R and the longitudinal axis Y is established according to the grid spacing winding requirements, and the control curves of the constant speed rotation of the preform and the variable speed reciprocating motion of the winding fiber are determined, and the movement of the rotation axis R and the longitudinal axis Y is controlled to achieve the equal grid control requirements of the variable angle oblique winding of the complex surface preform; Step 6: When the oblique winding mode is selected, a method for automatically connecting multiple fiber winding curves without slippage is established according to the number of winding curves, the starting point and the end point of each curve, so as to realize continuous movement of all oblique winding curves and improve winding efficiency and grid consistency; Step 7. When all winding tasks are completed, the radial axis X automatically returns to the origin position. After the return is completed, the longitudinal Y axis and the rotation axis R return to the starting coordinate point and wait for the next winding task.

2. The method for controlling multi-angle automatic winding of a complex profile preform according to claim 1, characterized in that: In step 4, based on the thickness variation of the preform surface, a gradient control method of "gradient radial feed" is adopted to establish a control method in which the radial axis X position follows the longitudinal axis Y position variation, so as to realize the gradient radial feed adjustment of the winding fiber, so as to control the fiber and the preform to be wound close to each other in real time; D=K*L*h / H Where D is the radial axis X positioning target position; L is the detection position of the laser position sensor, L min is the minimum value, L max is the maximum value; h is the longitudinal axis Y position; H is the total height of the preform; K is the gradient coefficient, ranging from 0.1 to K max .

3. The method for controlling multi-angle automatic winding of a complex-shaped preform according to claim 1, characterized in that: In step 5, in the hoop winding mode, the linear synchronization relationship between the rotation axis R and the longitudinal axis Y is established by the synchronization coupling coefficient k, and the synchronization coupling coefficient k is: k=a*36*ρ Wherein, a is the directional coefficient. When a=-1, the rotation axis R is synchronized in the opposite direction with the longitudinal axis Y; when a=1, the rotation axis R is synchronized in the positive direction with the longitudinal axis T. By controlling the movement direction of the rotation axis R by a, the yarn output positions of the two adjacent layers are opposite, which meets the force requirements of the preform at the top of different unit layers; ρ is the circumferential winding grid spacing, and the unit is root / cm.

4. The method for controlling multi-angle automatic winding of a complex-shaped preform according to claim 1, characterized in that: In step 5, in the oblique winding mode, the preform rotation axis R is taken as the main axis, which moves at a constant speed, and the winding fiber longitudinal movement axis Y is taken as the slave axis, which follows the movement of the main axis. A nonlinear cam coupling relationship is established between the angle of the preform rotation axis R and the absolute position of the winding fiber longitudinal movement axis Y. By establishing the angle θ of the rotation axis R ij The position h with respect to the longitudinal axis Y ij The coordinate points (θ ij ,h ij ) forms N oblique winding cam coupling curves, and realizes the oblique reciprocating winding of N winding fibers from bottom to top and from top to bottom along the axial direction of the preform, as follows: Based on the requirements of the preform oblique winding grid spacing d, determine the total number of preform oblique winding fibers N, the starting angle α of each oblique winding fiber at the bottom of the preform i , i is the number of obliquely wound fibers, i∈[1,N]; Each oblique winding cam coupling curve starts from the zero point of the longitudinal axis Y, the total height of the preform is H, and the height of the non-winding area at the top of the preform is H0. In order to avoid the accumulation of winding fibers at the top of the preform, the first winding curve is used as the reference line at the top, and the remaining N-1 curves are wound at the top with a step height s. The preform is divided into longitudinal heights Δh along the longitudinal axis Y. i Divide, Δh i ∈[1,2.5]mm to ensure that the winding angle does not change suddenly; combined with the cross-sectional perimeter of the preform, determine the angle θ of the rotation axis R ij The position h with respect to the longitudinal axis Y ij The calculation method is: Where M i is the number of winding points of the i-th oblique winding cam curve; l p is the preform at p*Δh i The cross-sectional perimeter at the height; j is the jth winding point on the i-th oblique winding cam curve, 1≤j≤M i .

5. The method for controlling multi-angle automatic winding of a complex profile preform according to claim 1, characterized in that: In step 6, in the oblique winding mode, based on the requirements of large wrap angle and small fiber waste, an automatic connection method for multiple fiber winding curves without slippage is established to improve the oblique winding efficiency and the consistency of winding quality; According to the end point of the i-th oblique winding cam curve after the δ wrap angle, the number of cam coupling curves that have completed oblique winding is counted r, r∈[0,N], and the allowable angle β for automatic connection to the next oblique winding without slippage is determined i : r＝r+1 In the formula, θ i is the end point angle of the rotation axis R when the i-th oblique winding cam curve is completed; δ is the wrap angle between different oblique winding cam curves without slippage and automatic connection, δ∈[90,270]; β i The starting angle α of the remaining Nr oblique winding cam curves m Compare them one by one until the deviation Δ im , when Δ im When the value is the smallest, it indicates that the oblique winding starting angle α of the mth oblique winding cam curve m With β i The closest, that is, the next time the mth oblique winding cam curve is wound, the m number is assigned to i; Δ im = |β i - α m | where 1 ≤ i, m ≤ N and i ≠ m.

6. The method for controlling multi-angle automatic winding of a complex-shaped preform according to claim 1, characterized in that: During the winding process, the tension sensor is used to detect the yarn tension F1 in real time and compare it with the control input tension F. The torque motor is used to control the fiber winding tension in an online closed loop and compare it with the expected value F in real time to ensure that the error between the detected tension and the expected tension is within the range of ±ΔF.

7. A multi-angle automatic winding control system for a complex-shaped preform, the system is based on a multi-angle automatic winding control method for a complex-shaped preform according to any one of claims 1 to 6, characterized in that: It includes winding fiber yarn tube, complex surface preform motion control device, winding fiber axial motion control device along preform, winding fiber radial motion control device along preform, winding fiber tension control and state monitoring module, winding motion centralized control module, as follows: Winding fiber yarn drum: installed on the winding fiber radial movement control device along the preform; Complex profile preform motion control device: used to control the rotational motion of the complex profile preform; A device for controlling the axial movement of the winding fiber along the preform: used to control the axial movement of the winding fiber along the complex profile preform to match the rotational movement of the complex profile preform; A device for controlling radial movement of the winding fibers along the preform: installed on the device for controlling axial movement of the winding fibers along the preform, and used to control the radial movement of the winding fibers along the complex-shaped preform, so that the winding fibers are close to the fabric surface; Winding fiber tension control and status monitoring module: connected to the winding fiber yarn drum, installed on the winding fiber axial motion control device along the preform, including a tension control module, a tension detection sensor, a yarn break detection sensor, and a position sensor, which detects the yarn tension, yarn breakage status, and the distance between the winding fiber radial motion control device and the complex surface preform in real time during the winding process under different winding modes, and controls the fiber winding tension in an online closed loop according to the expected tension value; Winding motion centralized control module: connected with the complex surface preform motion control device, the winding fiber axial motion control device along the preform, the winding fiber radial motion control device along the preform, and the winding fiber tension control and state monitoring module respectively, to establish the motion relationship between the complex surface preform and the winding fiber.

8. The multi-angle automatic winding control system for complex profile preforms according to claim 7 is characterized in that: The complex surface preform motion control device, the winding fiber axial motion control device and the winding fiber radial motion control device are respectively driven by servo motors with brakes. The encoder of the servo motor is an absolute encoder to ensure that the motion position is not lost in the power-off state, and each servo motor is connected to the corresponding servo driver.

9. The multi-angle automatic winding control system for complex profile preforms according to claim 7 is characterized in that: The tension control module in the winding fiber tension control and state monitoring module adopts a torque motor, and the torque motor shaft is connected to the winding fiber through a yarn guide wheel; the tension detection sensor adopts a pull / pressure sensor, and the position sensor adopts a high-precision laser position sensor, which is installed just above the yarn outlet to realize the winding fiber line tension and the distance detection between the winding fiber radial motion control device and the complex surface preform.

10. The multi-angle automatic winding control system for complex profile preforms according to claim 7, characterized in that: The winding motion centralized control module adopts a PLC supporting motion control function as the CPU, and supports multi-axis servo synchronization and cam curve coupling motion under CANopen or Ethercat bus communication status; the CPU obtains the yarn tension and position in real time during the yarn winding process through the analog input module; the CPU controls the torque motor to adjust the yarn tension through the analog output module; the CPU receives the yarn break detection sensor signal through the digital input module, and if the yarn breaks, the distance between the winding fiber along the radial motion control device of the preform and the complex surface preform at the yarn break, the yarn tension, and the output value of the torque motor are recorded, and the winding mechanism movement is paused, and a yarn break warning is output.

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