Robot type composite material stringer continuous automatic rolling device and method

Abstract

The invention discloses a robot type composite material stringer continuous automatic rolling device and method. The device comprises a rolling workbench, a continuous rolling device, a continuous rolling robot, a continuous rolling device support and a multi-section snakelike rolling device. The continuous rolling device or the multi-section snake-shaped rolling device is installed on the continuous rolling robot, the continuous rolling robot is installed on the movable guide rail, a continuous rolling device support is located on one side of the movable guide rail, and rolling workbenches are arranged on one side or two sides of the movable guide rail. The multi-section snakelike rolling device comprises a second gun changing disc, a multi-section snakelike rolling rack, a second power device and a second flexible compression roller group; according to the multi-section snakelike rolling device, the flexible compression roller set installed below the multi-section snakelike rolling device rolls the variable-curvature composite material forming mold in the horizontal direction through the built-in rotating shaft and the auxiliary air cylinder, a prepreg laying layer set is formed, and manufacturing of the double-curvature composite material stringer is achieved through combination of the rotating shaft and the auxiliary air cylinder.

Description

Technical Field

[0001] The present invention relates to the technical field of automated manufacturing of resin-based fiber-reinforced composite materials, and in particular to a robotic composite material long-beam continuous automatic rolling device and method. Background Art

[0002] Advanced composite materials, such as carbon fiber reinforced resin-based composites, boast advantages such as high specific modulus and high strength. They are widely used in aerospace and other fields, and are becoming increasingly important. With the rapid development and application of high-end aerospace equipment, the use of advanced composite materials is increasing. Their application has gradually expanded from secondary load-bearing components to primary load-bearing components, and traditional metal components have been gradually replaced by advanced composite components.

[0003] Composite materials are widely used in aerospace applications. Stringers, as longitudinal members of the fuselage structure, primarily support the axial forces caused by fuselage bending. They provide support for the skin, increasing the critical stresses for compression and shear instability. They also absorb some of the aerodynamic forces acting on the skin and transmit them to primary load-bearing components such as bulkheads. According to relevant data, the total length of stringers in a commercial aircraft can reach 6,000-8,000 meters.

[0004] Stringers are slender components that can reach lengths of tens of meters. Common stringer cross-sections include T-shaped, I-shaped, C-shaped, and cap-shaped structures. To adapt to the aerodynamic shape of the fuselage, stringers are often designed with variable curvature along their length. Composite stringers, therefore, have large aspect ratios, complex cross-sectional shapes, and require high machining precision, making their manufacturing process extremely challenging. Currently, the domestic manufacturing process for stringer components primarily relies on manual laying, which is labor-intensive, has poor quality stability, and low production efficiency, failing to meet the demands of the rapidly developing aerospace sector. Summary of the Invention

[0005] In order to solve the problems of difficulty, unstable quality and low efficiency in manufacturing composite long stringers, the purpose of the present invention is to provide a robotic continuous automatic rolling device and method for composite long stringers. The device adopts an industrial robot as the manufacturing body and realizes high-efficiency automated manufacturing of composite long stringers through a continuous automatic rolling device.

[0006] To achieve the above object, the present invention provides the following technical solutions:

[0007] A robot-type composite material long stringer continuous automatic rolling device, comprising a rolling workbench, a continuous rolling device, a continuous rolling robot, a continuous rolling device bracket, a multi-section serpentine rolling device and a movable guide rail;

[0008] The continuous rolling device is installed on a continuous rolling robot, the continuous rolling robot is installed on a movable guide rail, the multi-section serpentine rolling device is installed on the continuous rolling robot, the continuous rolling device bracket is located on one side of the movable guide rail, and a rolling workbench is set on one side or both sides of the movable guide rail;

[0009] The multi-section serpentine roller pressing device includes a second gun-changing plate, a multi-section serpentine roller pressing frame, a second power unit and a second flexible roller group. The second flexible roller group is installed on the second power unit, the second power unit is installed on the multi-section serpentine roller pressing frame, the multi-section serpentine roller pressing frame is installed on the second gun-changing plate, and the second gun-changing plate is installed on the continuous roller pressing robot.

[0010] The multi-section serpentine roller pressing frame comprises a rotating shaft and an auxiliary cylinder which enable a second flexible pressing roller group to roll a composite material forming mold with a variable curvature in a horizontal direction.

[0011] Furthermore, the multi-section serpentine roller press frame also includes a multi-section serpentine roller press frame rotating base plate, double-side base plates, a rotating fixed seat, a base fixed seat, an intermediate base plate, a rotating shaft, a cylinder baffle auxiliary cylinder and a robot flange;

[0012] Among them, the foundation fixing seat is installed on the middle foundation plate, the middle foundation plate is installed on the robot flange, the foundation fixing seat is installed on the double-sided foundation plates, the multi-section serpentine roller frame rotating foundation plate is installed on the rotating fixing seat, the double-sided foundation plates are installed on the rotating fixing seat, the rotating fixing seat is installed on the rotating shaft, the rotating shaft is installed on the foundation fixing seat, the fixed end of the cylinder baffle is installed on the multi-section serpentine roller frame rotating foundation plate, the movable end of the cylinder baffle is installed on the double-sided foundation plates, and the auxiliary cylinder is installed on the double-sided foundation plates and the middle foundation plate.

[0013] Furthermore, the continuous rolling robot is a six-joint robot, and the continuous rolling device is installed on the sixth joint of the continuous rolling robot;

[0014] The rolling workbench includes a rolling workbench, a heatable rolling mold and a mold heating device;

[0015] The heatable roller pressing mold is installed on a mold heating device, and the mold heating device is installed on a workbench.

[0016] Furthermore, the continuous rolling device includes a sheet heating and unwinding device, a first flexible pressing roller group, a prepreg layer group, a first power device, a rigid frame of the rolling device and a first gun changing plate;

[0017] The prepreg layup group is installed on the sheet heating and unwinding device, the sheet heating and unwinding device is installed on the rigid frame of the roller pressing device, there are multiple first power devices, the first power devices are installed on the rigid frame of the roller pressing device, the first gun changing plate is installed on the rigid frame of the roller pressing device, and the first flexible pressure roller group is connected to the first power device, wherein the first flexible pressure roller group is a hat-shaped pressure roller group, an L-shaped pressure roller group, an L-shaped flexible airbag or a hat-shaped flexible airbag;

[0018] The rigid frame of the rolling device and the first flexible pressing roller group are arranged on the workbench.

[0019] Furthermore, the first power device includes a power bracket, a power plate, a movable guide rail, a cylinder bracket and a cylinder;

[0020] Among them, the power support is installed on the rigid frame of the roller pressing device, the movable guide rail is installed on the power support, the cylinder support is installed on the power support, the cylinder is installed on the cylinder support, the power plate is installed on the movable guide rail, and the power plate is connected to the cylinder;

[0021] The cylinder ventilation drives the power plate to move, and the power plate moves up and down through the movable guide rail, so that the power plate moves linearly. The power plate is connected to the first flexible pressing roller group and drives the first flexible pressing roller group to roll the prepreg ply group.

[0022] Furthermore, the sheet heating and unwinding device includes a receiving tray, a first heating device, an unwinding frame, a second heating device, a guide roller, a motor-reducer, an unwinding shaft, an unwinding clamping ring, a first passive unwinding ring, a second passive unwinding ring and a first guide shaft;

[0023] Among them, the first heating device is installed on the unwinding frame, the motor-reducer is installed on the unwinding frame, the motor-reducer is connected to the receiving disk, the unwinding shaft is installed on the motor-reducer, the unwinding clamping ring is installed on the unwinding shaft, the first passive unwinding ring is installed on the unwinding clamping ring, the second passive unwinding ring is installed on the first passive unwinding ring, the receiving disk is installed on the second passive unwinding ring, the second heating device is installed on the unwinding frame, the guide roller is installed on the first guide shaft, the first guide shaft is installed on the unwinding frame, and the unwinding frame is installed on the continuous rolling device.

[0024] Furthermore, the prepreg ply group is collected by a receiving tray and installed on the second passive unwinding ring, the first heating device and the second heating device are turned on to heat the material sheets of the prepreg ply group, and then the motor-reducer drives the unwinding shaft to rotate, the unwinding shaft drives the unwinding clamp to rotate, the unwinding clamp drives the first passive unwinding ring to rotate, the first passive unwinding ring drives the second passive unwinding ring to rotate, the second passive unwinding ring drives the receiving tray to rotate, the receiving tray drives the prepreg ply group to unload, and the prepreg ply group is unloaded through the guide roller.

[0025] Furthermore, the first flexible pressing roller group includes a first actuator, a second actuator, a third actuator, a fourth actuator and a fifth actuator provided on the continuous rolling device;

[0026] The first actuator is a flexible airbag, the second actuator is a top surface compacting mechanism, the third actuator is a side surface compacting mechanism, the fourth actuator is a heating and heat preservation mechanism, and the fifth actuator is an R-angle pressing mechanism.

[0027] Furthermore, the second actuator includes a base plate, a second guide shaft, a guide mounting seat, a rotating shaft, a retaining ring, a rotating connecting plate, a replaceable rigid wheel set, a self-aligning ball bearing, a linear guide rail, a spring, a mounting block and a linear bearing;

[0028] Among them, the guide mounting seat is installed on the base plate, the second guide shaft is installed on the guide mounting seat, the linear bearing is installed on the mounting block, the mounting block is installed on the linear guide rail, the linear guide rail is installed on the base plate, the rotating shaft is installed on the mounting block, the retaining ring is installed on the rotating connecting plate, the rotating connecting plate is installed on the self-aligning ball bearing, the self-aligning ball bearing is installed on the rotating shaft, the replaceable rigid wheel set is installed on the rotating connecting plate, and the spring is installed on the second guide shaft.

[0029] A method for continuous automatic rolling of a composite material long stringer using a robot comprises the following steps:

[0030] Step 1: The laid prepreg plies or prepreg ply groups are transported to the forming mold of the transfer station or the continuous rolling station, and the laid prepreg plies are collected by the sheet heating unwinding device. Then, the continuous rolling device or the multi-section serpentine rolling device is driven by the continuous rolling robot to perform the continuous rolling forming action; under the combined action of the temperature field of the combined heating device formed by the heatable rolling mold and the mold heating device and the pressure field of the roller group of the continuous rolling device or the multi-section serpentine rolling device, the prepreg ply group is deformed and applied to the surface of the composite material forming mold; the continuous rolling robot moves along the moving guide rail to perform the first continuous rolling forming along the entire length of the long stringer component;

[0031] Step 2: Scan the prepreg ply group after continuous rolling to check whether there are any defects; if there are defects, repeat step 1 or manually intervene to deal with them; if there are no defects, proceed to the next step;

[0032] Step 3: Place the prepreg ply groups one by one on the previous prepreg ply group that has been rolled, so that the prepreg ply groups are firmly attached to each other, and manufacture a composite material special-shaped long stringer preform blank.

[0033] Compared with the prior art, the present invention has the following beneficial effects:

[0034] The present invention uses a robot to drive a continuous automatic rolling device, which, under the action of a set temperature field and mechanical pressure, causes the prepreg sheet to be fully deformed, quickly compacts the composite material prepreg onto the long stringer forming mold, and realizes the manufacture of composite material special-shaped long stringers. The present invention has a simple structure and can realize high-efficiency, high-quality automated manufacturing of composite material long strings. The multi-section serpentine rolling device uses a built-in rotating shaft and an auxiliary cylinder to enable the flexible pressing roller group installed below to roll the composite material forming mold with variable curvature in the horizontal direction, so that the prepreg ply group is formed, and the combination of the rotating shaft and the auxiliary cylinder realizes the manufacture of double-curvature composite material long strings. Compared with manual laying, the present invention improves the degree of automation and quality stability. Compared with the traditional molding method, the present invention eliminates the upper mold, and at the same time has better flexibility and adaptability, saving costs.

[0035] Furthermore, the mold heating device heats the heatable roller mold, and the sheet heating unwinding device heats the prepreg ply combination. The prepreg ply group is heated by the combined heating, so that the prepreg ply group is heated and softened in a suitable temperature field, so that its flexibility reaches the best, and then the continuous roller pressing robot drives the continuous roller pressing device to lay and form.

[0036] Furthermore, by automatically changing the gun tray to replace different types of continuous rolling devices, continuous and automated manufacturing of long stringer preforms with different cross-sectional shapes such as C-shaped, L-shaped, and T-shaped can be achieved;

[0037] Furthermore, the flexible airbag in the continuous automatic rolling device can perform initial flexible rolling on the prepreg sheet; the flexible pressing roller group can fit the variable curvature rolling mold in the height direction through the linear motion of the linear guide rail and the rotational motion of the self-aligning ball bearing.

[0038] The present invention provides a robot-type continuous automatic rolling method for composite material long stringers, which comprises the following steps: transporting the laid prepreg plies or prepreg ply groups to a forming mold of a transfer station or a continuous rolling station, collecting the laid prepreg plies by a sheet heating and unwinding device, and then driving a continuous rolling device or a multi-section serpentine rolling device by a continuous rolling robot to perform continuous rolling forming; under the combined action of the temperature field of the combined heating device formed by the heatable rolling mold and the mold heating device and the pressure field of the roller group of the continuous rolling device or the multi-section serpentine rolling device, the prepreg ply group is deformed and applied to the surface of the composite material forming mold; the continuous rolling robot moves along a movable guide rail and performs the first continuous rolling forming on the entire length of the long stringer component; scanning the prepreg ply groups after continuous rolling, and if there are no defects, placing the prepreg ply groups one by one on the previous group of prepreg plies that have been rolled, so that the prepreg ply groups are firmly attached to each other, thereby manufacturing a composite material special-shaped long stringer preform blank. The rolling method of the present invention is easy to control and can realize automatic rolling of a double-curvature long stringer. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Figure 1 This is a schematic diagram of a continuous automatic roller pressing device;

[0040] Figure 2 It is a schematic diagram of the rolling station;

[0041] Figure 3 It is a schematic diagram of a continuous roller pressing device;

[0042] Figure 4 Schematic diagram of a web heating and unwinding device; wherein (a) is a three-dimensional schematic diagram and (b) is a cross-sectional view;

[0043] Figure 5 Schematic diagram of the flexible pressure roller group;

[0044] Figure 6 Schematic diagram of the actuator;

[0045] Figure 7 This is a schematic diagram of the power unit;

[0046] Figure 8 This is a schematic diagram of the continuous roller pressing device bracket;

[0047] Figure 9 It is a schematic diagram of a multi-section serpentine roller pressing device;

[0048] Figure 10 Schematic diagram of the rigid frame of the multi-section serpentine roller pressing device; (a) is a side view, and (b) is a top view;

[0049] Figure 11 Schematic diagram of a hat-type roller pressing group; wherein (a) is a stereoscopic view and (b) is a side view;

[0050] Figure 12 Schematic diagram of an L-shaped roller pressing group; wherein (a) is a stereoscopic view and (b) is a side view;

[0051] Figure 13 Schematic diagram of a flexible airbag; (a) is an L-shaped flexible airbag, and (b) is a cap-shaped flexible airbag;

[0052] Explanation of the numbers in the figure:

[0053] 1 is the rolling station, 2 is the continuous rolling device, 3 is the continuous rolling robot, 4 is the continuous rolling device bracket, 5 is the multi-section serpentine rolling device, and 6 is the moving guide rail;

[0054] 1-1 is a roller pressing workbench, 1-2 is a heatable roller pressing mold, and 1-3 is a mold heating device;

[0055] 2-1 is the sheet heating and unwinding device, 2-2 is the flexible pressing roller group, 2-3 is the prepreg layer group, 2-4 is the first power device, 2-5 is the rigid frame of the roller pressing device, and 2-6 is the first gun changing plate;

[0056] 2-1-1 is the receiving tray, 2-1-2 is the first heating device, 2-1-3 is the unwinding frame, 2-1-4 is the second heating device, 2-1-5 is the guide roller, 2-1-6 is the first guide shaft, 2-1-7 is the motor-reducer, 2-1-8 is the unwinding shaft, 2-1-9 is the unwinding clamping ring, 2-1-10 is the first passive unwinding ring, and 2-1-11 is the second passive unwinding ring;

[0057] 2-2-1 is the first actuator, 2-2-2 is the second actuator, 2-2-3 is the third actuator, 2-2-4 is the fourth actuator, and 2-2-5 is the fifth actuator;

[0058] 2-2-2-1 is the base plate, 2-2-2-2 is the second guide shaft, 2-2-2-3 is the guide mounting seat, 2-2-2-4 is the rotating shaft, 2-2-2-5 is the retaining ring, 2-2-2-6 is the rotating connecting plate, 2-2-2-7 is the replaceable flexible wheel set, 2-2-2-8 is the self-aligning ball bearing, 2-2-2-9 is the linear guide rail, 2-2-2-10 is the spring, 2-2-2-11 is the mounting block, and 2-2-2-12 is the linear bearing;

[0059] 2-4-1 is the power bracket, 2-4-2 is the power plate, 2-4-3 is the moving guide rail, 2-4-4 is the cylinder bracket, and 2-4-5 is the cylinder;

[0060] 4-1 is the roller pressing device positioning device, 4-2 is the roller pressing device bracket;

[0061] 5-1 is the second gun-changing plate, 5-2 is the multi-section serpentine roller press frame, 5-3 is the second power unit, and 5-4 is the flexible press roller group;

[0062] 5-2-1 is the rotating base plate of the multi-section serpentine roller press frame, 5-2-2 is the double-sided base plate, 5-2-3 is the rotating fixed seat, 5-2-4 is the basic fixed seat, 5-2-5 is the middle base plate, 5-2-6 is the rotating shaft, 5-2-7 is the cylinder baffle, 5-2-8 is the auxiliary cylinder, and 5-2-9 is the robot flange;

[0063] 6-1 is a hat-shaped rolling group, 6-2 is an L-shaped rolling group, 6-3 is an L-shaped flexible airbag, and 6-4 is a hat-shaped flexible airbag. DETAILED DESCRIPTION

[0064] To facilitate understanding of the present invention, the present invention will be described more fully below with reference to the accompanying drawings. The accompanying drawings illustrate preferred embodiments of the present invention. However, the present invention may be implemented in a variety of different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and comprehensive understanding of the disclosure of the present invention.

[0065] In addition, when an element in the present invention is referred to as being "fixed to" or "disposed on" another element, it may be directly on the other element or there may be an intermediate element. When an element is referred to as being "connected to" another element, it may be directly connected to the other element or there may be an intermediate element. The terms "vertical," "horizontal," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only implementation method.

[0066] See also Figure 1 The present invention relates to a robotic composite long stringer continuous automatic rolling device, comprising a rolling workbench 1, a continuous rolling device 2, a continuous rolling robot 3, a continuous rolling device bracket 4, a multi-section serpentine rolling device 5, and a movable guide rail 6. The continuous rolling device 2 is mounted on the continuous rolling robot 3, the multi-section serpentine rolling device 5 is mounted on the continuous rolling robot 3, and the continuous rolling device 2 and the multi-section serpentine rolling device 5 are replaceable via a gun plate changer. The continuous rolling robot 3 is mounted on the movable guide rail 6 and is capable of moving along the movable guide rail 6. The continuous rolling device bracket 4 is located on one side of the movable guide rail 6, and the rolling workbench 1 is located on the other side of the movable guide rail 6. The rolling workbench 1 can also be provided on both sides of the movable guide rail 6.

[0067] Specifically, the continuous rolling robot 3 is a six-joint robot, and the continuous rolling device 2 is installed on the sixth joint of the continuous rolling robot 3. The continuous rolling device 2 is driven by the continuous rolling robot 3 to lay the prepreg ply group 2-3 on the composite material forming mold on the rolling workbench 1 to realize the manufacture of composite material special-shaped long stringers.

[0068] See also Figure 2-Figure 3 The rolling workbench 1 includes a rolling workbench 1-1, a heatable rolling mold 1-2 and a mold heating device 1-3; wherein the mold heating device 1-3 is installed on the workbench 1-1, and the heatable rolling mold 1-2 is installed on the mold heating device 1-3; the mold heating device 1-3 heats the heatable rolling mold 1-2.

[0069] The continuous rolling device 2 includes a sheet heating and unwinding device 2-1, a first flexible pressing roller group 2-2, a prepreg layer group 2-3, a first power device 2-4, a rolling device rigid frame 2-5 and a first gun changing plate 2-6.

[0070] Among them, the prepreg ply group 2-3 is installed on the sheet heating and unwinding device 2-1, the sheet heating and unwinding device 2-1 is installed on the rigid frame 2-5 of the rolling device, there are multiple first power units 2-4, the first power unit 2-4 is installed on the rigid frame 2-5 of the rolling device, the first gun changing plate 2-6 is installed on the rigid frame 2-5 of the rolling device, the first flexible pressure roller group 2-2 is connected to the first power unit 2-4, and the first flexible pressure roller group 2-2 is divided into three categories, namely, a hat-type pressure roller group 6-1, an L-type pressure roller group 6-2, an L-type flexible airbag 6-3 or a hat-type flexible airbag 6-4.

[0071] The rigid frame 2-5 of the rolling device and the first flexible pressing roller group 2-2 are arranged on the workbench 1-1.

[0072] The continuous rolling device 2 is installed on the sixth joint of the continuous rolling robot 3 through the first gun changing plate 2 - 6 .

[0073] The mold heating device 1-3 heats the heatable roller mold 1-2, and the sheet heating unwinding device 2-1 heats the prepreg ply group 2-3. The prepreg ply group 2-3 is heated by combined heating, and then the continuous roller pressing robot 3 drives the continuous roller pressing device 2 to lay and form.

[0074] See also Figure 4 In (a) and (b), the material heating and unwinding device 2-1 includes a receiving tray 2-1-1, a first heating device 2-1-2, an unwinding frame 2-1-3, a second heating device 2-1-4, a guide roller 2-1-5, a motor-reducer 2-1-7, an unwinding shaft 2-1-8, an unwinding clamping ring 2-1-9, a first passive unwinding ring 2-1-10, a second passive unwinding ring 2-1-11 and a first guide shaft 2-1-6.

[0075] Among them, the first heating device 2-1-2 is installed on the unwinding frame 2-1-3, the motor-reducer 2-1-7 is installed on the unwinding frame 2-1-3, the motor-reducer 2-1-7 is connected to the receiving tray 2-1-1, the unwinding shaft 2-1-8 is installed on the motor-reducer 2-1-7, the unwinding clamping ring 2-1-9 is installed on the unwinding shaft 2-1-8, the first passive unwinding ring 2-1-10 is installed on the unwinding clamping ring 2-1-9, the second passive unwinding ring 2-1-11 is installed on the first passive unwinding ring 2-1-10, the receiving tray 2-1-1 is installed on the second passive unwinding ring 2-1-11, the second heating device 2-1-4 is installed on the unwinding frame 2-1-3, the guide roller 2-1-5 is installed on the first guide shaft 2-1-6, and the first guide shaft 2-1-6 is installed on the unwinding frame 2-1-3.

[0076] The unwinding frame 2-1-3 is installed on the rigid frame 2-5 of the roller pressing device.

[0077] The second prepreg ply group 2-3 is collected by the receiving tray 2-1-1 and installed on the second passive unwinding ring 2-1-11, the first heating device 2-1-2 and the second heating device 2-1-4 are turned on to heat the sheet of the second prepreg ply group 2-3, and then the motor-reducer 2-1-7 drives the unwinding shaft 2-1-8 to rotate, the unwinding shaft 2-1-8 drives the unwinding clamping ring 2-1-9 to rotate, the unwinding clamping ring 2-1-9 drives the first passive unwinding ring 2-1-10 to rotate, the first passive unwinding ring 2-1-10 drives the second passive unwinding ring 2-1-11 to rotate, the second passive unwinding ring 2-1-11 drives the receiving tray 2-1-1 to rotate, the receiving tray 2-1-1 drives the prepreg ply group 2-3 to unload, and the prepreg ply group 2-3 is unloaded through the guide roller 2-1-5.

[0078] See also Figure 5 The first flexible pressure roller group 2-2 consists of five groups of actuators, namely the first actuator 2-2-1, the second actuator 2-2-2, the third actuator 2-2-3, the fourth actuator 2-2-4 and the fifth actuator 2-2-5.

[0079] The first actuator 2-2-1 is a flexible airbag, the second actuator 2-2-2 is a top surface compacting mechanism, the third actuator 2-2-3 is a side surface compacting mechanism, the fourth actuator 2-2-4 is a heating and heat preservation mechanism, and the fifth actuator 2-2-5 is an R-angle pressing mechanism.

[0080] The first actuator 2-2-1 is installed on the first power unit 2-4, the second actuator 2-2-2 is installed on the first power unit 2-4, the third actuator 2-2-3 is installed on the first power unit 2-4, the fourth actuator 2-2-4 is installed on the first power unit 2-4, and the fifth actuator 2-2-5 is installed on the first power unit 2-4.

[0081] The first actuator 2-2-1 preforms the prepreg ply group 2-3, the second actuator 2-2-2 compacts the top surface of the prepreg ply group 2-3, and the third actuator 2-2-3 compacts the side surface of the prepreg ply group 2-3. Because the third actuator 2-2-3 and the fifth actuator 2-2-5 are far apart, a heating and insulation mechanism (i.e., the fourth actuator 2-2-4) is set up, and the fifth actuator 2-2-5 performs R corner trimming on the prepreg ply group 2-3.

[0082] See also Figure 6The second actuator 2-2-2 includes a base plate 2-2-2-1, a second guide shaft 2-2-2-2, a guide mounting seat 2-2-2-3, a rotating shaft 2-2-2-4, a retaining ring 2-2-2-5, a rotating connecting plate 2-2-2-6, a replaceable rigid wheel set 2-2-2-7, a self-aligning ball bearing 2-2-2-8, a linear guide rail 2-2-2-9, a spring 2-2-2-10, a mounting block 2-2-2-11 and a linear bearing 2-2-2-12.

[0083] Among them, the guide mounting seat 2-2-2-3 is mounted on the base plate 2-2-2-1, the second guide shaft 2-2-2-2 is mounted on the guide mounting seat 2-2-2-3, the linear bearing 2-2-2-12 is mounted on the mounting block 2-2-2-11, the mounting block 2-2-2-11 is mounted on the linear guide rail 2-2-2-9, the linear guide rail 2-2-2-9 is mounted on the base plate 2-2-2-1, and the rotating shaft 2-2-2-4 is mounted. On the mounting block 2-2-2-11, the retaining ring 2-2-2-5 is mounted on the rotating connecting plate 2-2-2-6, the rotating connecting plate 2-2-2-6 is mounted on the self-aligning ball bearing 2-2-2-8, the self-aligning ball bearing 2-2-2-8 is mounted on the rotating shaft 2-2-2-4, the replaceable rigid wheel set 2-2-2-7 is mounted on the rotating connecting plate 2-2-2-6, and the spring 2-2-2-10 is mounted on the second guide shaft 2-2-2-2.

[0084] The replaceable rigid wheel set 2-2-2-7 includes a flexible wheel support frame, a support shaft and a flexible layer (the flexible layer is made of silicone rubber, polyurethane, airbag or nylon, etc.), the support shaft is arranged on the flexible wheel support frame, and the flexible layer is arranged on the support shaft.

[0085] The first flexible pressure roller group 2-2 is in contact with the heatable roller mold 1-2. Through the change of curvature on the heatable roller mold 1-2, the first flexible pressure roller group 2-2, the rotating connecting plate 2-2-2-6 and the retaining ring 2-2-2-5 rotate on the self-aligning ball bearing 2-2-2-8. The rotating shaft 2-2-2-4 is set on the mounting block 2-2-2-11. The mounting block 2-2-2-11 drives the linear bearing 2-2-2-12 to slide left and right on the second guide shaft 2-2-2-2. The mounting block 2-2-2-11 slides left and right on the linear guide rail 2-2-2-9.

[0086] See also Figure 7 The first power unit 2-4 includes a power bracket 2-4-1, a power plate 2-4-2, a movable guide rail 2-4-3, a cylinder bracket 2-4-4 and a cylinder 2-4-5;

[0087] Among them, the power bracket 2-4-1 is installed on the rigid frame 2-5 of the rolling device, the movable guide rail 2-4-3 is installed on the power bracket 2-4-1, the cylinder bracket 2-4-4 is installed on the power bracket 2-4-1, the cylinder 2-4-5 is installed on the cylinder bracket 2-4-4, the power plate 2-4-2 is installed on the movable guide rail 2-4-3, and the power plate 2-4-2 is connected to the cylinder 2-4-5.

[0088] The cylinder 2-4-5 is ventilated to drive the power plate 2-4-2 to move, and the power plate 2-4-2 moves up and down through the movable guide rail 2-4-3, so that the power plate 2-4-2 moves linearly. The power plate 2-4-2 is connected to the first flexible pressure roller group 2-2, and drives the first flexible pressure roller group 2-2 to roll the prepreg ply group 2-3.

[0089] See also Figure 8 The continuous rolling device bracket 4 includes a rolling device bracket 4-2, and rolling device positioning devices 4-1 are arranged on both sides of the top of the rolling device bracket 4-2. A continuous rolling device 2 or a multi-section serpentine rolling device 5 is arranged on the positioning device 4-1. The continuous rolling device 2 is replaced by the first gun changing disk 2-6, and the multi-section serpentine rolling device 5 is replaced by the second gun changing disk 5-1. According to the parts to be processed, the continuous rolling device 2 or the multi-section serpentine rolling device 5 is used for rolling, thereby realizing continuous and automatic rolling of the composite material long stringer.

[0090] See also Figure 9 The multi-section serpentine roller device 5 includes a second gun-changing disc 5-1, a multi-section serpentine roller frame 5-2, a second power unit 5-3 and a second flexible pressure roller group 5-4. The multi-section serpentine roller frame 5-2 is installed on the second gun-changing disc 5-1, the second power unit 5-3 is installed on the multi-section serpentine roller frame 5-2, the second flexible pressure roller group 5-4 is installed on the second power unit 5-3, the tool side of the second gun-changing disc 5-1 is connected to the tool, and the robot side of the second gun-changing disc 5-1 is installed on the continuous rolling robot 3.

[0091] The multi-section serpentine roller pressing device 5 can be replaced by the second gun changing plate 5-1, and the second power device 5-3 and the second flexible pressing roller group 5-4 roll the prepreg ply group 2-3, so that the prepreg ply group 2-3 is formed in the heatable rolling mold 1-2.

[0092] See also Figure 10 In (a) and (b), the multi-section serpentine roller frame 5-2 includes a multi-section serpentine roller frame rotating base plate 5-2-1, a double-sided base plate 5-2-2, a rotating fixed seat 5-2-3, a basic fixed seat 5-2-4, an intermediate base plate 5-2-5, a rotating shaft 5-2-6, a cylinder baffle 5-2-7, an auxiliary cylinder 5-2-8 and a robot flange 5-2-9.

[0093] Among them, the basic fixing seat 5-2-4 is installed on the middle basic plate 5-2-5, the middle basic plate 5-2-5 is installed on the robot flange 5-2-9, the basic fixing seat 5-2-4 is installed on the double-sided basic plate 5-2-2, the multi-section serpentine roller frame rotating basic plate 5-2-1 is installed on the rotating fixing seat 5-2-3, the double-sided basic plate 5-2-2 is installed on the rotating fixing seat 5-2-3, the rotating fixing seat 5-2-3 is installed on the rotating shaft 5-2-6, and the rotating shaft 5-2-6 is installed on the basic fixing seat 5-2-4, the cylinder baffle 5-2-7 is installed on the multi-section serpentine roller frame rotating basic plate 5-2-1 and the double-sided basic plate 5-2-2, and the auxiliary cylinder 5-2-8 is installed on the double-sided basic plate 5-2-2 and the middle basic plate 5-2-5.

[0094] The multi-section serpentine roller pressing device 5 rolls on the heated roller pressing mold 1-2, and the multi-section serpentine roller pressing frame rotating base plate 5-2-1 and the double-sided base plate 5-2-2 can both perform planar rotational motion around the rotation axis 5-2-6, wherein the curvature change on the heated roller pressing mold 1-2 drives the multi-section serpentine roller pressing frame rotating base plate 5-2-1 to perform planar rotational motion around the rotation axis 5-2-6, and the auxiliary cylinder 5-2-8 provides auxiliary power and cooperates with the cylinder baffle 5-2-7 to return the multi-section serpentine roller pressing frame rotating base plate 5-2-1, and the curvature change on the heated roller pressing mold 1-2 causes the double-sided base plate 5-2-2 to perform planar rotational motion around the rotation axis 5-2-6, and the auxiliary cylinder 5-2-8 provides auxiliary power and cooperates with the cylinder baffle 5-2-7 to return the double-sided base plate 5-2-2.

[0095] The multi-section serpentine roller pressing frame 5-2 can perform rolling of complex heatable roller pressing molds 1-2 through its own rotating shaft 5-2-6.

[0096] See also Figure 10 In (b), the second flexible pressing roller group 5-4 of the multi-section serpentine rolling device 5 cooperates with the rotating fixed seat 5-2-3, the basic fixed seat 5-2-4 and the rotating shaft 5-2-6, and can rotate at a certain angle on the plane to adapt to the change of the curvature of the long stringer. The auxiliary cylinder 5-2-8 and the cylinder baffle 5-2-7 make the rotation angle of the multi-section serpentine rolling frame 5-2 have certain constraints, thereby improving the rolling efficiency.

[0097] See also Figure 11 In (a) and (b), when the first flexible pressing roller group 2-2 is a hat-shaped pressing roller group 6-1, the hat-shaped pressing roller group 6-1 is used to realize the hat-shaped pressing mold to perform rolling.

[0098] See also Figure 12In (a) and (b), when the first flexible pressing roller group 2-2 is an L-shaped pressing roller group 6-2, the L-shaped pressing roller group 6-2 is used to realize the L-shaped pressing mold for rolling.

[0099] See also Figure 13 In (a) and (b), when the first flexible pressing roller group 2-2 is an L-shaped flexible airbag 6-3 or a hat-shaped flexible airbag 6-4, the L-shaped and hat-shaped rolling molds are pre-formed by the L-shaped flexible airbag 6-3 and the hat-shaped flexible airbag 6-4, so that the hat-shaped rolling roller group 6-1 or the L-shaped rolling roller group 6-2 used later can have a better forming effect.

[0100] The present invention provides a method for continuous automatic rolling of a composite material long stringer using a robot based on the device, comprising the following steps:

[0101] Step 1: Automatically lay out the prepreg ply group 2-3 according to the designed ply angle, and transport the laid out prepreg ply group 2-3 to the transfer station. The laid out prepreg ply group is collected by the sheet heating and unwinding device 2-1 and then collected and wound onto the receiving tray 2-1-1.

[0102] Alternatively, the prepreg ply group that has been laid out in advance is directly placed horizontally on the heatable rolling mold 1-2 installed on the rolling workbench 1-1;

[0103] The prepreg ply group 2-3 wound on the receiving tray 2-1-1 is gradually unwound to the roll forming area formed by the roll forming device and the mold as the roll forming device moves; the horizontally placed prepreg ply group is directly placed in the roll forming area formed by the roll forming device and the mold without unwinding;

[0104] Step 2: The continuous rolling robot 3 then drives the continuous rolling device 2 or the multi-section serpentine rolling device 5 to implement the continuous rolling forming process. The prepreg ply group 2-3 wound on the sheet heating unwinding device 2-1 or placed horizontally on the heatable mold 1-2 is deformed under the combined action of the temperature field formed by the mold heating device 1-3 heating the heatable rolling mold 1-2 and the pressure field of the pressing roller group of the continuous rolling device 2 (or the multi-section serpentine rolling device 5), and is applied to the surface of the composite material forming mold; the continuous rolling robot 3 moves along the movable guide rail 6 to implement the first continuous rolling forming along the entire length of the long stringer component;

[0105] Step 3: Use a defect detection device to scan the prepreg ply group 2-3 after continuous rolling to detect whether there are defects; if there are defects, repeat step 2 or manually intervene to deal with them; if there are no defects, proceed to the next step;

[0106] Step 4: Repeat steps 1, 2, and 3, and roll prepreg ply groups 2-3 one by one onto the previous group of prepreg plies that have been roll-formed, so that the prepreg ply groups formed layer by layer are tightly attached to each other, until the roll-forming of all prepreg ply groups is completed, and finally a composite material special-shaped long stringer preform blank is manufactured.

[0107] The above description is merely a description of the preferred embodiment of the present invention and is not to be construed as limiting the claims. The present invention is not limited to the above embodiment, and variations in the specific structure are permitted. Any variations made within the scope of the independent claims of the present invention are also within the scope of protection of the present invention.

[0108] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this invention pertains. The terms used herein in the specification of the present invention are for the purpose of describing specific embodiments only and are not intended to limit the present invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

Claims

1. A robotic composite long stringer continuous automatic rolling device, characterized in that: It comprises a rolling workbench (1), a continuous rolling device (2), a continuous rolling robot (3), a continuous rolling device bracket (4), a multi-section serpentine rolling device (5) and a movable guide rail (6); wherein the continuous rolling device (2) or the multi-section serpentine rolling device (5) is mounted on a continuous rolling robot (3), the continuous rolling robot (3) is mounted on a movable guide rail (6), the continuous rolling device bracket (4) is located on one side of the movable guide rail (6), and a rolling workbench (1) is provided on one side or both sides of the movable guide rail (6); The multi-section serpentine roller pressing device (5) comprises a second gun-changing disc (5-1), a multi-section serpentine roller pressing frame (5-2), a second power device (5-3) and a second flexible pressing roller group (5-4); the second flexible pressing roller group (5-4) is mounted on the second power device (5-3); the second power device (5-3) is mounted on the multi-section serpentine roller pressing frame (5-2); the multi-section serpentine roller pressing frame (5-2) is mounted on the second gun-changing disc (5-1); and the second gun-changing disc (5-1) is mounted on the continuous rolling robot (3); The multi-section serpentine roller pressing frame (5-2) comprises a rotating shaft (5-2-6) and an auxiliary cylinder (5-2-8) capable of enabling a second flexible pressing roller group (5-4) to roll a composite material forming mold with a variable curvature in a horizontal direction.

2. The robot-type composite material long stringer continuous automatic rolling device according to claim 1 is characterized in that: The multi-section serpentine roller press frame (5-2) further comprises a multi-section serpentine roller press frame rotating base plate (5-2-1), a double-side base plate (5-2-2), a rotating fixed seat (5-2-3), a base fixed seat (5-2-4), an intermediate base plate (5-2-5), a rotating shaft (5-2-6), a cylinder baffle (5-2-7), an auxiliary cylinder (5-2-8) and a robot flange (5-2-9); Among them, the basic fixed seat (5-2-4) is installed on the middle basic plate (5-2-5), the middle basic plate (5-2-5) is installed on the robot flange (5-2-9), the basic fixed seat (5-2-4) is installed on the double-sided basic plates (5-2-2), the multi-section serpentine roller frame rotating basic plate (5-2-1) is installed on the rotating fixed seat (5-2-3), the double-sided basic plates (5-2-2) are installed on the rotating fixed seat (5-2-3), and the rotating fixed seat (5-2-3) is installed on the rotating shaft (5-2-6), the rotating shaft (5-2-6) is installed on the basic fixed seat (5-2-4), the fixed end of the cylinder baffle (5-2-7) is installed on the multi-section serpentine roller frame rotating base plate (5-2-1), the movable end of the cylinder baffle (5-2-7) is installed on the double-side base plates (5-2-2), and the auxiliary cylinder (5-2-8) is installed on the double-side base plates (5-2-2) and the middle base plate (5-2-5).

3. The robot-type composite material long stringer continuous automatic rolling device according to claim 1 is characterized in that: The continuous rolling robot (3) is a six-joint robot, and the continuous rolling device (2) is installed on the sixth joint of the continuous rolling robot (3); The rolling workbench (1) comprises a rolling workbench (1-1), a heatable rolling mold (1-2) and a mold heating device (1-3); The heatable roller pressing mold (1-2) is installed on a mold heating device (1-3), and the mold heating device (1-3) is installed on a workbench (1-1).

4. The robot-type composite material long stringer continuous automatic rolling device according to claim 3 is characterized in that: The continuous rolling device (2) comprises a sheet heating unwinding device (2-1), a first flexible pressing roller group (2-2), a prepreg layer group (2-3), a first power device (2-4), a rolling device rigid frame (2-5) and a first gun changing plate (2-6); The prepreg layer group (2-3) is installed on the sheet heating and unwinding device (2-1), the sheet heating and unwinding device (2-1) is installed on the rigid frame (2-5) of the rolling device, there are multiple first power devices (2-4), the first power devices (2-4) are installed on the rigid frame (2-5) of the rolling device, the first gun changing plate (2-6) is installed on the rigid frame (2-5) of the rolling device, and the first flexible pressing roller group (2-2) is connected to the first power device (2-4), wherein the first flexible pressing roller group (2-2) is a hat-shaped pressing roller group (6-1), an L-shaped pressing roller group (6-2), an L-shaped flexible airbag (6-3) or a hat-shaped flexible airbag (6-4); The rigid frame (2-5) of the rolling device and the first flexible pressing roller group (2-2) are arranged on the workbench (1-1).

5. The robot-type composite material long stringer continuous automatic rolling device according to claim 4 is characterized in that: The first power device (2-4) includes a power support (2-4-1), a power plate (2-4-2), a movable guide rail (2-4-3), a cylinder support (2-4-4) and a cylinder (2-4-5); The power support (2-4-1) is installed on the rigid frame (2-5) of the roller pressing device, the movable guide rail (2-4-3) is installed on the power support (2-4-1), the cylinder support (2-4-4) is installed on the power support (2-4-1), the cylinder (2-4-5) is installed on the cylinder support (2-4-4), the power plate (2-4-2) is installed on the movable guide rail (2-4-3), and the power plate (2-4-2) is connected to the cylinder (2-4-5); The cylinder (2-4-5) is ventilated to drive the power plate (2-4-2) to move, and the power plate (2-4-2) moves up and down through the movable guide rail (2-4-3), thereby causing the power plate (2-4-2) to move linearly. The power plate (2-4-2) is connected to the first flexible pressing roller group (2-2) and drives the first flexible pressing roller group (2-2) to roll the prepreg ply group (2-3).

6. The robot-type composite material long stringer continuous automatic rolling device according to claim 4, characterized in that: The sheet heating and unwinding device (2-1) comprises a receiving tray (2-1-1), a first heating device (2-1-2), an unwinding frame (2-1-3), a second heating device (2-1-4), a guide roller (2-1-5), a motor-reducer (2-1-7), an unwinding shaft (2-1-8), an unwinding clamping ring (2-1-9), a first passive unwinding ring (2-1-10), a second passive unwinding ring (2-1-11) and a first guide shaft (2-1-6); Among them, the first heating device (2-1-2) is installed on the unwinding frame (2-1-3), the motor-reducer (2-1-7) is installed on the unwinding frame (2-1-3), the motor-reducer (2-1-7) is connected to the receiving tray (2-1-1), the unwinding shaft (2-1-8) is installed on the motor-reducer (2-1-7), the unwinding clamping ring (2-1-9) is installed on the unwinding shaft (2-1-8), the first passive unwinding ring (2-1-10) is installed on the unwinding clamping ring (2-1-9), the first The second passive unwinding ring (2-1-11) is installed on the first passive unwinding ring (2-1-10), the receiving tray (2-1-1) is installed on the second passive unwinding ring (2-1-11), the second heating device (2-1-4) is installed on the unwinding frame (2-1-3), the guide roller (2-1-5) is installed on the first guide shaft (2-1-6), the first guide shaft (2-1-6) is installed on the unwinding frame (2-1-3), and the unwinding frame (2-1-3) is installed on the continuous rolling device (2).

7. The robot-type composite material long stringer continuous automatic rolling device according to claim 6, characterized in that: The prepreg ply group (2-3) is collected by a receiving tray (2-1-1) and mounted on a second passive unwinding ring (2-1-11). The first heating device (2-1-2) and the second heating device (2-1-4) are turned on to heat the sheets of the prepreg ply group (2-3). The motor-reducer (2-1-7) drives the unwinding shaft (2-1-8) to rotate, and the unwinding shaft (2-1-8) drives the unwinding clamping ring (2-1-9) to rotate. The unwinding clamping ring (2-1-9) drives the first passive unwinding ring (2-1-10) to rotate, the first passive unwinding ring (2-1-10) drives the second passive unwinding ring (2-1-11) to rotate, the second passive unwinding ring (2-1-11) drives the receiving tray (2-1-1) to rotate, the receiving tray (2-1-1) drives the prepreg ply group (2-3) to unwind, and the prepreg ply group (2-3) unwinds through the guide roller (2-1-5).

8. The robot-type composite material long stringer continuous automatic rolling device according to claim 4, characterized in that: The first flexible pressing roller group (2-2) comprises a first actuator (2-2-1), a second actuator (2-2-2), a third actuator (2-2-3), a fourth actuator (2-2-4) and a fifth actuator (2-2-5) which are arranged on the continuous rolling device (2); The first actuator (2-2-1) is a flexible airbag, the second actuator (2-2-2) is a top surface compacting mechanism, the third actuator (2-2-3) is a side surface compacting mechanism, the fourth actuator (2-2-4) is a heating and heat preservation mechanism, and the fifth actuator (2-2-5) is an R-angle pressing mechanism.

9. The robot-type composite material long stringer continuous automatic rolling device according to claim 8, characterized in that: The second actuator (2-2-2) includes a base plate (2-2-2-1), a second guide shaft (2-2-2-2), a guide mounting seat (2-2-2-3), a rotating shaft (2-2-2-4), a retaining ring (2-2-2-5), a rotating connecting plate (2-2-2-6), a replaceable rigid wheel set (2-2-2-7), a self-aligning ball bearing (2-2-2-8), a linear guide rail (2-2-2-9), a spring (2-2-2-10), a mounting block (2-2-2-11) and a linear bearing (2-2-2-12); Among them, the guide mounting seat (2-2-2-3) is mounted on the base plate (2-2-2-1), the second guide shaft (2-2-2-2) is mounted on the guide mounting seat (2-2-2-3), the linear bearing (2-2-2-12) is mounted on the mounting block (2-2-2-11), the mounting block (2-2-2-11) is mounted on the linear guide rail (2-2-2-9), the linear guide rail (2-2-2-9) is mounted on the base plate (2-2-2-1), and the rotating shaft (2-2-2-4) is mounted On the mounting block (2-2-2-11), the snap ring (2-2-2-5) is mounted on the rotating connecting plate (2-2-2-6), the rotating connecting plate (2-2-2-6) is mounted on the self-aligning ball bearing (2-2-2-8), the self-aligning ball bearing (2-2-2-8) is mounted on the rotating shaft (2-2-2-4), the replaceable rigid wheel set (2-2-2-7) is mounted on the rotating connecting plate (2-2-2-6), and the spring (2-2-2-10) is mounted on the second guide shaft (2-2-2-2).

10. A method for continuous automatic rolling of composite material long stringers using a robot based on the device of claim 4, characterized in that: The following steps are involved: Step 1: transporting the laid prepreg plies or prepreg ply groups (2-3) to the forming mold of the transfer station or the continuous rolling station, collecting the laid prepreg plies through the sheet heating unwinding device (2-1), and then the continuous rolling robot (3) drives the continuous rolling device (2) or the multi-section serpentine rolling device (5) to perform the continuous rolling forming action; under the combined action of the temperature field of the combined heating device formed by the heatable rolling mold (1-2) and the mold heating device (1-3) and the pressure field of the roller group of the continuous rolling device (2) or the multi-section serpentine rolling device (5), the prepreg ply group is deformed and applied to the surface of the composite material forming mold; the continuous rolling robot (3) moves along the moving guide rail (6) to perform the first continuous rolling forming along the entire length of the long stringer component; Step 2: Scan the prepreg ply group (2-3) after continuous rolling to check whether there are any defects; if there are defects, repeat step 1 or manually intervene to deal with them; if there are no defects, proceed to the next step; Step 3: placing the prepreg ply groups (2-3) one by one on the previous prepreg ply group that has been rolled, so that the prepreg ply groups are firmly attached to each other, and manufacturing a composite material special-shaped long stringer preform blank.

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