A multi-angle automatic winding control system and method for a complex profile preform

Abstract

The application discloses a kind of complex profile preform multi-angle automatic winding control system and method, belong to textile technical field.The different winding mode of complex profile preform, the rotation axis R of control preform rotary motion is established, the longitudinal axis Y of control winding fiber along preform axial movement, control winding fiber along the radial axis X of fabric radial advance and retreat movement, through the linear synchronization or nonlinear cam coupling relationship of R, Y axis, control winding path movement, through the gradient control method of X, Y axis, realize the profiled winding of winding fiber.The application is suitable for large size, multi-variety, complex stereo fabric fast development;Realize complex stereo fabric constant tension multi-angle winding, guarantee that fabric winding fiber line is not loose, satisfy product quality requirement;Realize stereo fabric low cost, efficient, high-precision winding preparation, satisfy the demand of complex profile fabric winding grid uniformity, provide technical guarantee for stereo fabric diversity development.

Description

Technical Field

[0001] This invention belongs to the field of textile technology, and in particular relates to a multi-angle automatic winding control system and method for complex-shaped prefabricated bodies. Background Technology

[0002] With the development of aerospace technology, the demand for diverse prefabricated structures is constantly increasing to meet the requirements of working in complex environments. Prefabricated structures used as composite material reinforcement skeletons are therefore developing towards larger sizes, complex shapes, high-precision conformal design, and rapid, low-cost fabrication. In the prefabrication process, winding is a key step, playing a crucial role in shaping and increasing bulk density. Therefore, in the fabrication of complex, irregularly shaped prefabricated structures, the fiber bundle winding effect directly determines the fabric quality. Traditional manual winding methods suffer from problems such as low control precision, large fluctuations in uniformity, and low efficiency.

[0003] Invention patent No. 202410082764.3 discloses an integrated forming method for needle-punched rotary preforms, which achieves helical and circumferential winding by uniformly setting several nails at both ends of a rotary mandrel; Invention patent No. 202311790626.2 discloses a fiber winding device and fiber winding method, which uses a laser sensor to obtain the external dimensions of the model and controls the fiber winding in combination with a predetermined target pressure value to ensure control of the internal pressure of the model; Utility model patent No. 202221411179.6 discloses an integrated compaction and winding device for casing preforms, which ensures that the tension of the preform is maintained as required for winding, thereby controlling the fiber curvature of the preform winding and improving the stiffness and strength of the composite material casing.

[0004] Most existing winding technologies are only suitable for prefabricated bodies with regular shapes. When dealing with irregularly shaped prefabricated bodies, manual addition of anchors is required, which is difficult to meet the needs of large-size, complex irregular shapes, high-precision contouring, and rapid, low-cost manufacturing. Therefore, it is necessary to propose an automatic winding control system and method for complex surfaces at multiple angles, which can realize automatic winding in the preparation process of complex irregular fabrics, ensuring the internal quality of the product and improving the preparation efficiency. Summary of the Invention

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

[0006] To achieve the objective of this invention, a multi-angle automatic winding control method for complex-shaped prefabricated bodies is disclosed, comprising the following steps:

[0007] Step 1: Set the motion control device for the complex-shaped precast body as the rotation axis R, the radial motion control device for the winding fiber along the precast body as the radial axis X, and the axial motion control device for the winding fiber along the precast body as the longitudinal axis Y. Control the rotation of the precast body to the initial position using the rotation axis R. The initial position is the starting point of the first oblique winding curve, and this point is set as the zero point of the rotation axis R. Based on the initial position of the precast body, set the position of the bottom of the precast body as the zero point of the longitudinal axis Y, and set the position within 1 cm of the precast body surface as the zero point of the radial axis X. Establish the origin of the three-axis coordinate system for the winding motion of the complex-shaped precast body.

[0008] Step 2: Based on the complex surface preform winding molding process, select the winding mode and input the setting values ​​of the winding fiber tension F and tension deviation ±ΔF;

[0009] Step 3: The radial axis X frame is equipped with a laser position sensor. The laser position sensor moves with the longitudinal axis Y and remains at the same position relative to the origin of the radial axis X. 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 to be wound close to the preform 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 synchronous 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, the control curve of the constant speed rotation of the preform and the variable speed reciprocating motion of the winding fiber is determined, the motion of the rotation axis R and the longitudinal axis Y is controlled, and the equal grid control requirements of the variable angle oblique winding of the complex surface preform are realized.

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

[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 axis Y and the rotation axis R return to the starting coordinate point, waiting for the next winding task.

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

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

[0016]

[0017] In the formula, D is the radial axis X-axis positioning target position; L is the laser position sensor detection position, L min For the minimum value, L max The maximum value is h; the position of the longitudinal axis Y is h; the total height of the precast body is H; and the gradient coefficient is K, which ranges from 0.1 to K. max .

[0018] Furthermore, in step 5, in the circumferential winding mode, the linear synchronization relationship between the rotation axis R and the longitudinal axis Y is established through a synchronization coupling coefficient k, which is:

[0019] k = a * 36 * ρ

[0020] Where a is the direction coefficient. When a = -1, the rotation axis R is synchronized in the opposite direction to the longitudinal axis Y. When a = 1, the rotation axis R is synchronized in the positive direction to the longitudinal Y axis. By controlling the direction of movement of the rotation axis R through a, the yarn output positions of adjacent two layers are opposite, which meets the stress requirements of the top of the preform in different unit layers. ρ is the circumferential winding grid spacing, with the unit being roots / cm.

[0021] Furthermore, in step 5, in the oblique winding mode, the preform rotation axis R is the master axis, moving at a constant speed, and the winding fiber longitudinal motion axis Y is the slave axis, following the master 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 motion axis Y. This is achieved by establishing the angle θ of the rotation axis R. ij Position h relative to the longitudinal axis Y ij The coordinates of the diagonal winding between them (θ) ij h ij N obliquely wound cam coupling curves are formed to achieve oblique reciprocating winding of N wound fibers along the axial direction of the preform from bottom to top and from top to bottom, as detailed below:

[0022] (1) Based on the requirement of the grid spacing d for the oblique winding of the preform, determine the total number N of oblique windings in the preform and the starting angle α of each oblique winding fiber at the bottom of the preform. i , where i is the number of diagonally 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 unwound area at the top of the preform is H0. To avoid fiber accumulation at the top of the preform, the first winding curve is used as the baseline at the top, and the remaining N-1 curves are wound at the top with varying heights in step heights s. The preform is divided into heights Δh along the longitudinal axis Y. iDivide into, Δh i [∈1,2.5]mm, to ensure that the winding angle does not change abruptly; combined with the cross-sectional perimeter of the precast body, determine the angle θ of the rotation axis R. ij Position h relative to the longitudinal axis Y ij The calculation method is as follows:

[0024]

[0025] In the formula, M i Let l be the number of winding points of the i-th oblique winding cam curve; p For the preform at p*Δh i The perimeter of the cross section at the height; j is the j-th winding point on the i-th oblique winding cam curve, 1≤j≤M i .

[0026] Furthermore, in step 6, under the oblique winding mode, based on the requirements of large wrap angle and small fiber waste, an automatic connection method for non-slipping winding curves of multiple fibers is established to improve the efficiency of oblique winding and the consistency of winding quality.

[0027] (1) Based on the end point of the i-th oblique winding cam curve after passing through the wrap angle δ, count the number r of cam coupling curves that have completed oblique winding, r∈[0,N], and determine the allowable angle β for no slippage and automatic connection to the next oblique winding. i :

[0028] r = r + 1

[0029]

[0030] In the formula, θ i The angle of the end point 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 automatically connected, δ∈[90,270].

[0031] (2) β i The starting angle α of the remaining Nr root obliquely wound cam curves m Perform comparisons one by one until the deviation Δ im When Δ im When the value is at its minimum, it indicates the starting angle α of the oblique winding of the m-th oblique winding cam curve. m With β i The closest one is the next one to wind the m-th oblique winding cam curve, and the number m is assigned to i;

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

[0033] Furthermore, during the winding process, a tension sensor is used to detect the yarn tension F1 in real time and compare it with the control input tension F. A 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 ±ΔF.

[0034] To achieve the objective of this invention, this invention also discloses a multi-angle automatic winding control system for complex-shaped preforms, including a winding fiber yarn cylinder, a motion control device for complex-shaped preforms, a motion control device for winding fibers along the axial direction of the preform, a motion control device for winding fibers along the radial direction of the preform, a winding fiber tension control and status monitoring module, and a centralized winding motion control module.

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

[0036] Motion control device for complex-shaped precast bodies: used to control the rotational motion of complex-shaped precast bodies;

[0037] Fiber winding axial movement control device: used to control the axial movement of the winding fiber along the complex surface preform, matching the rotational movement of the complex surface preform;

[0038] Radial motion control device for wound fibers along the preform: Installed on the axial motion control device for wound fibers along the preform, used to control the radial motion of the wound fibers along the complex-shaped preform, so that the wound fibers are close to the fabric surface;

[0039] Winding fiber tension control and status monitoring module: connected to the winding fiber yarn bobbin, installed on the winding fiber axial movement control device along the preform, including tension control module, tension detection sensor, yarn breakage detection sensor, and position sensor, to detect in real time the yarn tension, yarn breakage status, and distance of the winding fiber radial movement control device from the complex-shaped preform during the winding process under different winding modes; and to control the fiber winding tension in an online closed loop according to the expected tension value.

[0040] The winding motion centralized control module is connected to the complex surface preform motion control device, the winding fiber axial motion control device, the winding fiber radial motion control device, and the winding fiber tension control and status monitoring module to establish the motion relationship between the complex surface preform and the winding fiber.

[0041] Furthermore, the centralized control module for winding motion uses a PLC that supports motion control functions as its CPU, supporting multi-axis servo synchronous and cam curve coupled motion under CANopen or Ethercat bus communication conditions; 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 breakage detection sensor signal through the digital input module, and if a yarn breakage occurs, it records the distance between the winding fiber radial motion control device and the complex-shaped preform at the breakage point, the yarn tension, the output value of the torque motor, and pauses the winding mechanism movement, outputting a yarn breakage warning.

[0042] Compared with existing technologies, the significant advancements of this invention are: 1) Compared with existing winding technologies, 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, and complex irregular-shaped three-dimensional fabrics; 2) By utilizing tension detection and adjustment, the fiber winding tension is controlled online in a closed loop, realizing constant tension multi-angle winding of complex irregular-shaped fabrics, ensuring that the wound fiber lines do not loosen, and meeting product quality requirements; 3) This invention can achieve low-cost, efficient, and high-precision winding preparation of three-dimensional fabrics, and can meet the requirement of uniform winding mesh for complex contour fabrics, providing technical support for the diversified development of three-dimensional fabrics.

[0043] To more clearly illustrate the functional characteristics and structural parameters of the present invention, further explanation is provided below in conjunction with the accompanying drawings and specific embodiments. Attached Figure Description

[0044] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this application, illustrate exemplary embodiments of the invention and, together with their description, serve to explain the invention and do not constitute an undue limitation thereof. In the drawings:

[0045] Figure 1 This is a structural diagram of a multi-angle automatic winding control system for complex-shaped prefabricated bodies according to the present invention;

[0046] Figure 2 This is a schematic diagram of the oblique winding control parameters for a complex-shaped preform according to the present invention;

[0047] Figure 3 This is a schematic diagram of the structure of a multi-angle automatic winding control device for complex-shaped prefabricated bodies according to the present invention;

[0048] Figure 4 This is a schematic diagram of the automatic oblique winding cam coupling curve for a complex-shaped prefabricated body according to the present invention;

[0049] Figure 5 This is a schematic diagram of an automatically circumferentially wound preform according to the present invention;

[0050] Figure 6 This is a schematic diagram of the overall process of a multi-angle automatic winding control method for complex-shaped prefabricated bodies according to the present invention. Detailed Implementation

[0051] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort 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-shaped prefabricated fabrics includes a winding fiber yarn bobbin, a motion control device for the complex-shaped prefabricated body, a motion control device for the winding fiber along the axial direction of the prefabricated body, a motion control device for the winding fiber along the radial direction of the prefabricated body, a winding fiber tension control and status monitoring module, and a centralized winding motion control module, as detailed below:

[0053] The wound fiber yarn bobbin is installed on the radial movement control device of the wound fiber along the preform;

[0054] A motion control device for complex-shaped precast bodies is used to control the rotational motion of complex-shaped precast bodies.

[0055] The winding fiber axial movement control device is used to control the movement of the winding fiber along the axial direction of the complex-shaped preform, matching the rotational movement of the complex-shaped preform.

[0056] The winding fiber radial movement control device is installed on the winding fiber axial movement control device of the preform and is used to control the winding fiber radial movement along the complex surface preform, so that the winding fiber is close to the fabric surface.

[0057] The winding fiber tension control and status monitoring module is connected to the winding fiber yarn bobbin and installed on the winding fiber axial movement control device along the preform. It includes a tension control module, a tension detection sensor, a yarn breakage detection sensor, and a position sensor. It can detect the yarn tension, yarn breakage status, and distance of the winding fiber radial movement control device from the complex-shaped preform in real time during the winding process under different winding modes. Based on the expected tension value, it can control the fiber winding tension in an online closed loop.

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

[0059] The motion control device for the complex surface prefabricated body uses Delta A3 series servo driver ASD-A3-1521-M that supports CANOpen communication and servo motor ECMC-EW1315SS with absolute encoder to control the rotation axis R, driving the complex surface prefabricated body to rotate at a certain speed. The fabric can be an irregularly shaped rotary body or a standard rotary body.

[0060] The control device for the movement of the winding fiber along the axial direction of the preform uses Delta's servo driver ASD-A3-0721-M that supports CANOpen communication and a servo motor ECM-A3L-CA0807SS1 with an absolute encoder to control the longitudinal axis X movement, so as to meet the requirements of the actuator to wind the fabric along the longitudinal direction.

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

[0062] The winding motion centralized control module uses Delta DVP15MC-11T, which supports motion control functions, as its CPU. It supports multi-axis servo synchronization and cam curve coupling motion under CANopen or Ethercat bus communication. It also expands with one analog input / output module, DVP06XA-S.

[0063] The tension sensor uses the Jinno JZHL-M1 series tension sensor with a detection range of 0-20N; the position detection unit uses the Shendawei SW-LDS20DB high-precision ranging laser displacement sensor with a measurement 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 realize radial axis Y gradient follow-up and control the Dongfang Motor TM series torque motor to adjust the yarn winding tension in a closed loop.

[0064] The DVP15MC-11T centralized control module for winding motion 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 master axis and the longitudinal axis Y as the slave axis. Taking the winding of large-sized complex-shaped precast bodies as an example, this example also provides a method for multi-angle automatic winding control of complex-shaped precast bodies, such as... Figure 6 As shown, the specific steps are as follows:

[0065] Step 1: Set the motion control device for the complex-shaped precast body as the rotation axis R, the radial motion control device for the winding fiber along the precast body as the radial axis X, and the axial motion control device for the winding fiber along the precast body as the longitudinal axis Y. Control the rotation of the precast body to the initial position using the rotation axis R. The initial position is the starting point of the first oblique winding curve, and this point is set as the zero point of the rotation axis R. Based on the initial position of the precast body, set the position of the bottom of the precast body as the zero point of the longitudinal axis Y, and set the position within 1 cm of the precast body surface as the zero point of the radial axis X. Establish the origin of the three-axis coordinate system for the winding motion of the complex-shaped precast body.

[0066] Step 2: Based on the winding molding process of complex surface preforms, select the winding mode and input the setting values ​​of the winding fiber tension F and the tension deviation ±ΔF;

[0067] Step 3: The radial axis X frame is equipped with a laser position sensor. The laser position sensor moves with the longitudinal axis Y and remains at the same position relative to the origin of the radial axis X. 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 to be wound close to the preform 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 synchronous 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, the control curve of the constant speed rotation of the preform and the variable speed reciprocating motion of the winding fiber is determined, the motion of the rotation axis R and the longitudinal axis Y is controlled, and the equal grid control requirements of the variable angle oblique winding of the complex surface preform are realized.

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

[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 axis Y and the rotation axis R return to the starting coordinate point, waiting for the next winding task.

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

[0073] k = a * 36 * ρ

[0074] Where a is the direction coefficient. When a = -1, the rotation axis R is synchronized in the opposite direction to the longitudinal axis Y. When a = 1, the rotation axis R is synchronized in the positive direction to the longitudinal Y axis. By controlling the direction of movement of the rotation axis R through a, the yarn output positions of adjacent two layers are opposite, which meets the stress requirements of the top of the preform in different unit layers. ρ is the circumferential winding grid spacing, with the unit being roots / cm.

[0075] like Figure 2 , 3 As shown in Figure 4, in the oblique winding mode, the preform rotation axis R is the master axis, moving at a constant speed, and the winding fiber longitudinal motion axis Y is the slave axis, following the master 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 motion axis Y. This is achieved by establishing the angle θ of the rotation axis R. ij Position h relative to the longitudinal axis Y ij The coordinates of the diagonal winding between them (θ) ij h ij N obliquely wound cam coupling curves are formed to achieve oblique reciprocating winding of N wound fibers along the axial direction of the preform from bottom to top and from top to bottom, as detailed below:

[0076] (1) Based on the requirement of the grid spacing d for the oblique winding of the preform, determine the total number N of oblique windings in the preform and the starting angle α of each oblique winding fiber at the bottom of the preform. i , where i is the number of diagonally 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 unwound area at the top of the preform is H0. To avoid fiber accumulation at the top of the preform, the first winding curve is used as the baseline at the top, and the remaining N-1 curves are wound at the top with varying heights in step heights s. The preform is divided into heights Δh along the longitudinal axis Y. i Divide into, Δh i [∈1,2.5]mm, to ensure that the winding angle does not change abruptly; combined with the cross-sectional perimeter of the precast body, determine the angle θ of the rotation axis R. ij Position h relative to the longitudinal axis Y ij The calculation method is as follows:

[0078]

[0079]

[0080] In the formula, M i Let l be the number of winding points of the i-th oblique winding cam curve; p For the preform at p*Δh iThe perimeter of the cross section at the height; j is the j-th winding point on the i-th oblique winding cam curve, 1≤j≤M i .

[0081] like Figure 4 , 5 As shown, based on the degree of change in the thickness of the preform surface, a gradient control method of "gradient horizontal feed" is adopted to establish a control method in which the radial axis X position follows the longitudinal axis Y position, so as to realize the gradient radial feed adjustment of the winding fiber, so as to control the fiber to wind closely around the preform in real time.

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

[0083]

[0084] In the formula, D is the radial axis X-axis positioning target position; L is the laser position sensor detection position, L min For the minimum value, L max The maximum value is h; the position of the longitudinal axis Y is h; the total height of the precast body is H; and the gradient coefficient is K, which ranges 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, an automatic connection method for non-slipping winding curves of multiple fibers is established to improve the efficiency of oblique winding and the consistency of winding quality.

[0086] (1) Based on the end point of the i-th oblique winding cam curve after passing through the wrap angle δ, count the number r of cam coupling curves that have completed oblique winding, r∈[0,N], and determine the allowable angle β for no slippage and automatic connection to the next oblique winding. i :

[0087] r = r + 1

[0088]

[0089] In the formula, θ i The angle of the end point 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].

[0090] (2) β i The starting angle α of the remaining Nr root obliquely wound cam curves m Perform comparisons one by one until the deviation Δ im When Δ im When the value is at its minimum, it indicates the starting angle α of the oblique winding of the m-th oblique winding cam curve. m With β iThe closest one is the next one to wind the m-th oblique winding cam curve, and the number m is assigned to i;

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

[0092] This invention provides a multi-angle automatic winding control system and method for complex-shaped preforms. Compared with existing winding technologies, it offers a low-cost, fast-response automatic winding control method, which is more suitable for the rapid development of multi-variety, complex, and irregularly shaped three-dimensional fabrics. By utilizing tension detection and adjustment, it achieves online closed-loop control of fiber winding tension, realizing constant tension winding of complex-shaped preforms, ensuring that the wound fiber threads do not loosen, and meeting product quality requirements. This invention enables low-cost, efficient, and high-precision winding preparation of three-dimensional fabrics, and can meet the requirement of uniform winding mesh for complex contour fabrics, providing technical support for the diversified development of three-dimensional fabrics.

[0093] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

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

Claims

1. A method for automatic multi-angle winding control of complex-shaped precast bodies, characterized in that, Includes the following steps: Step 1: Set the motion control device for the complex-shaped precast body as the rotation axis R, the radial motion control device for the winding fibers along the precast body as the radial axis X, and the axial motion control device for the winding fibers along the precast body as the longitudinal axis Y. Control the rotation of the precast body to the initial position using the rotation axis R. The initial position is the starting point of the first oblique winding curve, and this point is set as the zero point of the rotation axis R. Based on the initial position of the precast body, set the position of the bottom of the precast body as the zero point of the longitudinal axis Y, and set the position within 1 cm of the precast body surface as the zero point of the radial axis X. Establish the origin of the three-axis coordinate system for the winding motion of the complex-shaped precast body. Step 2: Based on the winding molding process of complex surface preforms, select the winding mode and input the setting values ​​of the winding fiber tension F and the tension deviation ±ΔF; Step 3: The radial axis X frame is equipped with a laser position sensor. The laser position sensor moves with the longitudinal axis Y and remains at the same position relative to the origin of the radial axis X. 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 to be wound close to the preform 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 synchronous 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, the control curve of the constant speed rotation of the preform and the variable speed reciprocating motion of the winding fiber is determined, the motion of the rotation axis R and the longitudinal axis Y is controlled, and the equal grid control requirements of the variable angle oblique winding of the complex surface preform are realized. Step 6: When the oblique winding mode is selected, an automatic connection method for multiple fiber winding curves without slippage is established based on the number of winding curves, the starting point and the ending point of each curve, so as to realize the continuous movement of all oblique winding curves and improve winding efficiency and mesh 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, waiting for the next winding task. In step 4, based on the degree of change in the thickness of the preform surface, a gradient control method of "gradient radial feed" is adopted to establish a control method in which the position of the radial axis X follows the change of the position of the longitudinal axis Y, so as to realize the gradient radial feed adjustment of the winding fiber and control the fiber to be wound close to the preform in real time. D = K * L * h / H In the formula, D is the radial axis X-axis positioning target position; L is the laser position sensor detection position, L min For the minimum value, L max The maximum value is h; the position of the longitudinal axis Y is h; the total height of the precast body is H; and the gradient coefficient is K, which ranges from 0.1 to K. max ; In step 5, during the circumferential winding mode, the linear synchronization relationship between the rotation axis R and the longitudinal axis Y is established through a synchronization coupling coefficient k, which is: k = a * 36 * ρ Where a is the direction coefficient. When a = -1, the rotation axis R is synchronized in the opposite direction to the longitudinal axis Y. When a = 1, the rotation axis R is synchronized in the positive direction to the longitudinal Y axis. By controlling the direction of movement of the rotation axis R through a, the yarn output positions of adjacent two layers are opposite, which meets the stress requirements of the top of the preform in different unit layers. ρ is the circumferential winding grid spacing, with the unit being roots / cm.

2. The method for automatic multi-angle winding control of complex-shaped prefabricated bodies according to claim 1, characterized in that, In step 5, during the oblique winding mode, the preform rotation axis R is the master axis, moving at a constant speed, while the winding fiber longitudinal motion axis Y is the slave axis, following the master 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 motion axis Y. This is achieved by establishing the angle θ of the rotation axis R. ij Position h relative to the longitudinal axis Y ij The coordinates of the diagonal winding between them (θ) ij h ij N obliquely wound cam coupling curves are formed to achieve oblique reciprocating winding of N wound fibers along the axial direction of the preform from bottom to top and from top to bottom, as detailed below: Based on the requirement of the grid spacing d for the oblique winding of the preform, the total number N of obliquely wound fibers in the preform and the starting angle α of each obliquely wound fiber at the bottom of the preform are determined. i , where i is the number of diagonally 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 unwound area at the top of the preform is H0. To avoid fiber accumulation at the top of the preform, the first winding curve is used as the baseline, and the remaining N-1 curves are wound at the top with varying heights in step heights s. The preform is divided into heights Δh along the longitudinal axis Y. i Divide into, Δh i The winding angle is set to [1, 2.5] mm to ensure that the winding angle does not change abruptly; the angle θ of the rotation axis R is determined by combining the perimeter of the precast section. ij Position h relative to the longitudinal axis Y ij The calculation method is as follows: In the formula, M i Let l be the number of winding points of the i-th oblique winding cam curve; p For the preform at p*Δh i The perimeter of the cross section at the height; j is the j-th winding point on the i-th oblique winding cam curve, 1≤j≤M i .

3. The method for automatic multi-angle winding control of complex-shaped prefabricated bodies according to claim 1, characterized in that, In step 6, under the oblique winding mode, based on the requirements of large wrap angle and small fiber waste, an automatic connection method for non-slipping winding curves of multiple fibers is established to improve the efficiency of oblique winding and the consistency of winding quality. Based on the ending point of the i-th obliquely wound cam curve after passing through the wrap angle δ, count the number r of cam coupling curves that have completed oblique winding, r∈[0,N], and determine the allowable angle β for no slippage and automatic connection to the next oblique winding. i : r＝r+1 In the formula, θ i The angle at the end point 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 automatically connected, δ∈[90,270]; β i The starting angle α of the remaining Nr root obliquely wound cam curves m Perform comparisons one by one until the deviation Δ im When Δ im When the value is at its minimum, it indicates the starting angle α of the oblique winding of the m-th oblique winding cam curve. m With β i The closest one is the next one to wind the m-th oblique winding cam curve, and the number m is assigned to i; Δ im = |β i - α m | where 1 ≤ i, m ≤ N and i ≠ m.

4. The method for automatic multi-angle winding control of complex-shaped prefabricated bodies according to claim 1, characterized in that, During the winding process, a tension sensor is used to detect the yarn tension F1 in real time and compare it with the control input tension F. A 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 ±ΔF.

5. A multi-angle automatic winding control system for complex-shaped precast bodies, said system being based on the multi-angle automatic winding control method for complex-shaped precast bodies according to any one of claims 1-4, characterized in that, It includes a wound fiber yarn bobbin, a motion control device for complex-shaped prefabricated bodies, a motion control device for wound fibers along the axial direction of the prefabricated body, a motion control device for wound fibers along the radial direction of the prefabricated body, a wound fiber tension control and status monitoring module, and a centralized control module for wound motion, as detailed below: Winding fiber yarn bobbin: Installed on the radial movement control device of the winding fiber along the preform; Motion control device for complex-shaped prefabricated bodies: used to control the rotational motion of the complex-shaped prefabricated bodies; A fiber winding movement control device along the axial direction of the preform: used to control the movement of the fiber winding along the axial direction of the complex-shaped preform, matching the rotational movement of the complex-shaped preform; A control device for the radial movement of the wound fiber along the preform: installed on the control device for the axial movement of the wound fiber along the preform, used to control the radial movement of the wound fiber along the complex-shaped preform, so that the wound fiber is close to the fabric surface; The winding fiber tension control and status monitoring module is connected to the winding fiber yarn bobbin and installed on the winding fiber axial movement control device of the preform. It includes a tension control module, a tension detection sensor, a yarn breakage detection sensor, and a position sensor. It can detect the yarn tension, yarn breakage status, and distance of the winding fiber radial movement control device from the complex-shaped preform in real time during the winding process under different winding modes. Based on the expected tension value, it can control the fiber winding tension in an online closed loop. The winding motion centralized control module is connected to the complex surface preform motion control device, the winding fiber axial motion control device, the winding fiber radial motion control device, and the winding fiber tension control and status monitoring module, respectively, to establish the motion relationship between the complex surface preform and the winding fiber.

6. The multi-angle automatic winding control system for complex-shaped prefabricated bodies according to claim 5, characterized in that, The complex-shaped precast body motion control device, the winding fiber axial motion control device, and the winding fiber radial motion control device are all driven by servo motors with brakes. The encoders of the servo motors are absolute encoders to ensure that the motion position is not lost in the power-off state, and each servo motor is connected to a corresponding servo driver.

7. The multi-angle automatic winding control system for complex-shaped prefabricated bodies according to claim 5, characterized in that, The tension control module in the winding fiber tension control and status 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 tension / compression sensor, and the position sensor adopts a high-precision laser position sensor, which is installed directly above the yarn outlet to realize the detection of the winding fiber tension, the distance between the winding fiber radial movement control device and the complex surface preform.

8. The multi-angle automatic winding control system for complex-shaped prefabricated bodies according to claim 5, characterized in that, The centralized control module for winding motion uses a PLC that supports motion control functions as its CPU, supporting multi-axis servo synchronous and cam curve coupled motion under CANopen or Ethercat bus communication. The CPU acquires 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 breakage detection sensor signal through the digital input module. If a yarn breakage occurs, it records the distance between the winding fiber radial motion control device and the complex-shaped preform at the breakage point, the yarn tension, and the output value of the torque motor, and pauses the winding mechanism movement, outputting a yarn breakage warning.

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