Tension-free fixed-length cutting machine for slitting automobile roof sponge composite fabric

Abstract

The invention relates to a tension-free fixed-length cutting machine for slitting an automobile roof sponge composite fabric, and belongs to the technical field of composite fabric tailoring, the tension-free fixed-length cutting machine comprises a tension-free conveying system, a dynamic fixed-length control module, a negative pressure adsorption cutting mechanism and a central control host, the tension-free conveying system comprises a differential roller conveyor, an air floatation bearing platform and a CCD deviation rectifying mechanism, a main roller and an auxiliary roller of the differential roller conveyor form a speed gradient to eliminate internal stress, the CCD deviation rectifying mechanism detects fabric deviation amount in real time, and the angle of a guide roller is adjusted through a servo motor. According to the invention, the problems that the compression deformation of a sponge layer is easily caused by mechanical traction during cutting of a traditional cutting machine and the photoelectric distance measurement is invalid due to dimensional deviation and fabric flexibility caused by rebound after cutting are solved, and the modes of differential pressure relief, dynamic measurement and compensation and low-temperature accurate cutting are adopted; zero tension transmission, zero springback error and zero thermal damage in the high-elasticity composite material cutting process are achieved, and key technical support is provided for large-scale mass production of light-weight and environment-friendly ceiling fabric.

Description

Technical Field

[0001] The invention relates to the technical field of composite fabric cutting, in particular to a tension-free fixed-length cutting machine for slitting automobile roof sponge composite fabric. Background Art

[0002] Car roof sponge composite fabric is a multi-layer composite material designed specifically for car interiors. It is made by bonding or hot pressing the sponge layer and the fabric layer. It combines functionality and aesthetics and has become the mainstream choice for modern car roofs.

[0003] Sponge composite fabrics typically feature a three-layer structure, with each layer fulfilling a specific function. The surface fabric layer is made of high-grade fabric, synthetic leather, suede, or genuine leather, providing a delicate touch, beautiful texture, and wear and stain resistance. Some high-end models use a nano-coating to enhance water and stain resistance. The middle buffer layer uses polyurethane sponge or bio-based sponge for sound absorption, noise reduction, thermal insulation, and shock absorption, blocking heat transfer. The bottom substrate layer enhances the structural strength and stability of the material, prevents tearing and deformation, and improves installation fit. The three-layer composite structure is primarily constructed using hot pressing or environmentally friendly adhesive bonding to ensure a secure bond between the layers.

[0004] Since the car roof sponge composite fabric has a porous elastic structure, the existing cutting machine is prone to compression and deformation of the sponge layer due to mechanical traction during cutting, and rebound after cutting causes dimensional deviation. In addition, the elasticity of the fabric makes the photoelectric ranging ineffective, requiring manual re-inspection, which affects processing efficiency. Therefore, a tension-free fixed-length cutting machine for slitting car roof sponge composite fabric is proposed. Through differential floating transmission and laser dynamic length measurement compensation technology, the precise slitting of car roof sponge composite fabric can be achieved. Summary of the Invention

[0005] The present invention provides a tension-free fixed-length cutting machine for slitting sponge composite fabrics for automobile roofs. The machine solves the problems of traditional cutting machines in which mechanical traction during cutting easily leads to compression and deformation of the sponge layer, rebound after cutting causes dimensional deviation, and fabric elasticity causes photoelectric ranging failure. The machine adopts differential pressure release, dynamic measurement and compensation, and low-temperature precision cutting to achieve zero-tension transmission, zero rebound error, and zero thermal damage in the cutting process of highly elastic composite materials, providing key technical support for the large-scale mass production of lightweight and environmentally friendly roof fabrics.

[0006] The present invention solves the above-mentioned technical problems with the following solution: a tension-free fixed-length cutting machine for slitting sponge composite fabrics for automobile roofs, comprising a tension-free transmission system, a dynamic fixed-length control module, a negative pressure adsorption cutting mechanism, and a central control host. The tension-free transmission system comprises a differential roller conveyor, an air-floating support platform, and a CCD correction mechanism. The main roller and auxiliary roller of the differential roller conveyor form a speed gradient to eliminate internal stress. The CCD correction mechanism detects fabric offset in real time and adjusts the guide roller angle via a servo motor.

[0007] The CCD deviation correction mechanism is provided with an electric telescopic deviation correction guide roller;

[0008] The vacuum adsorption module adopts a vacuum pump, and the vacuum adsorption module is connected to the air floating support platform;

[0009] The dynamic fixed length control module includes a dual-frequency laser interferometer and an online indenter;

[0010] The negative pressure adsorption cutting mechanism includes a vacuum adsorption module, a servo three-axis transmission module, and an ultrasonic cutting knife;

[0011] The central control host is connected to the tension-free transmission system, dynamic fixed-length control module, and negative pressure adsorption cutting mechanism by signal connection. The air-floating support platform, CCD correction mechanism, dual-frequency laser interferometer, online indenter, vacuum adsorption module, servo three-axis transmission module, and ultrasonic cutting knife are all installed on the differential roller conveyor;

[0012] The ultrasonic cutting knife is installed on the driving end of the servo three-axis transmission module.

[0013] On the basis of the above technical solution, the present invention can also be improved as follows.

[0014] Furthermore, the differential roller conveyor includes a conveyor frame, a main conveyor roller, an auxiliary conveyor roller, and a spring pressure roller. The main conveyor roller and the auxiliary conveyor roller are arranged at both ends of the conveyor frame. Two spring pressure rollers are arranged corresponding to the main conveyor roller and the auxiliary conveyor roller. The two spring pressure rollers are installed on the conveyor frame through springs, and the spring pressure rollers can be raised and lowered and slid on the conveyor frame.

[0015] Furthermore, the linear speed ratio of the main conveying roller and the auxiliary conveying roller is set to 1:0.96-0.997, forming a speed gradient to eliminate internal stress.

[0016] Furthermore, the air-floating support platform includes a platform body, a flow-sharing network pipe, a ventilation hood, a three-way valve, an air supply fan, and a dust removal filter. The platform body is evenly provided with ventilation holes, the flow-sharing network pipe is evenly laid in the platform body, the ventilation hood is evenly fixed and connected to the flow-sharing network pipe, and the flow-sharing network pipe, three-way valve, air supply fan, and dust removal filter are connected in sequence.

[0017] Furthermore, the vacuum adsorption module is connected to a three-way valve.

[0018] Furthermore, the dual-frequency laser interferometer emits a composite light beam with a wavelength of 632.8nm / 850nm to monitor the actual length of the fabric in real time, and the online indenter obtains the elastic modulus in real time.

[0019] Further, the porosity of the vacuum adsorption module is 40%, and the adsorption force is ≥200N / m 2 Fix the fabric. The ultrasonic cutting knife has a frequency of 28kHz, an amplitude of 50μm, and the temperature of the knife edge <60°C to prevent melting.

[0020] Further, the central control host processes the sensing data in real time, executes the elastic compensation algorithm, coordinates the actions of each unit, inputs L (set length), and outputs: cutting instruction / speed correction value. The elastic compensation algorithm: dynamically corrects the cutting length according to the elastic modulus E of the material (measured by an online indentation instrument);

[0021] L_{cut}=L_{set}×[1 + k·(E_{standard} / E_{actual}-1)];

[0022] where the compensation coefficient k = 0.35 (for PU sponge), and E 标 is the standard modulus value.

[0023] The beneficial effects of the present invention are as follows: The present invention provides a non-tension fixed-length cutting machine for slitting the composite fabric of automotive ceiling sponge, which has the following advantages:

[0024] 1. It solves the problem that the traditional mechanical traction causes the compression deformation of the sponge layer >15%, and the dimensional deviation after rebound is more than ±3mm. It adopts differential gradient tension control, and the speed difference between the two rollers creates a "negative tension" environment to offset the internal stress of the material. Combined with the air-floating support unit to support with a 0.05MPa air flow suspension, the frictional resistance of the fabric transmission is reduced by 98%, reducing the conveying error;

[0025] 2. The online elastic compensation mechanism dynamically adjusts the cutting point through real-time modulus detection, solves the fixed-length error caused by rebound, uses a dual-frequency laser interferometer to monitor the actual length in real time, dynamically corrects the cutting position through the elastic compensation algorithm, and adjusts immediately according to the elastic modulus measured online. The elastic modulus is obtained in real time through an online indentation instrument, and different density sponges can be dynamically adapted;

[0026] 3. It solves the problem that the traditional hot knife cutting temperature >120°C causes the melting and collapse of the sponge holes. It adopts low-temperature cutting technology, and ultrasonic vibration cutting replaces the traditional hot knife to avoid the collapse of the sponge hole structure. The temperature of the knife edge <60°C, combined with a negative pressure adsorption plate to fix the edge of the fabric, the cut has no melting burrs, and the sponge pore retention rate >99%, thus effectively improving the product yield.

[0027] The above description is only an overview of the technical solution of the present invention. In order to be able to understand the technical means of the present invention more clearly and implement it according to the content of the specification, the following takes the preferred embodiments of the present invention and combines the drawings to describe in detail as follows. The specific implementation manners of the present invention are given in detail by the following embodiments and their drawings. Brief Description of the Drawings

[0028] The drawings described herein are used to provide a further understanding of the present invention and constitute a part of this application. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0029] Figure 1 A schematic structural diagram of a tension-free fixed-length cutting machine for slitting composite sponge fabrics for automobile roofs provided by one embodiment of the present invention;

[0030] Figure 2 A front view of a tension-free fixed-length cutting machine for slitting composite sponge fabrics for automobile roofs provided by one embodiment of the present invention;

[0031] Figure 3 A schematic diagram of the structure of a tension-free fixed-length cutting machine for slitting composite sponge fabrics for automobile roofs, as viewed from above, provided in one embodiment of the present invention;

[0032] Figure 4 A schematic structural diagram of an air-floating support platform in a tension-free fixed-length cutting machine for slitting composite sponge fabrics for automobile roofs provided by one embodiment of the present invention;

[0033] Figure 5 This is a system architecture diagram of a tension-free fixed-length cutting machine for slitting sponge composite fabrics for automobile roofs provided by one embodiment of the present invention.

[0034] In the accompanying drawings, the components represented by the reference numerals are as follows:

[0035] 1. Central control unit; 2. Differential roller conveyor; 201. Conveyor frame; 202. Main conveyor roller; 203. Auxiliary conveyor roller; 204. Spring pressure roller; 3. Air floatation support platform; 301. Platform body; 302. Flow-sharing network pipe; 303. Ventilation hood; 304. Three-way valve; 305. Air supply fan; 306. Dust filter; 4. CCD correction mechanism; 5. Dual-frequency laser interferometer; 6. Online indenter; 7. Vacuum adsorption module; 8. Servo three-axis transmission module; 9. Ultrasonic cutting knife. DETAILED DESCRIPTION

[0036] The following is combined with Figure 1-5 The principles and features of the present invention are described, and the examples given are only for the purpose of explaining the present invention and are not intended to limit the scope of the present invention. The following paragraphs describe the present invention in more detail by way of example with reference to the accompanying drawings. The advantages and features of the present invention will become more apparent from the following description and claims. It should be noted that the drawings are in a very simplified form and are not in exact proportions, and are only used for the purpose of conveniently and clearly assisting in illustrating the embodiments of the present invention.

[0037] It should be noted that when a component is referred to as being "fixed to" another component, it may be directly on the other component or there may also be a central component. When a component is considered to be "connected to" another component, it may be directly connected to the other component or there may also be a central component. When a component is considered to be "set on" another component, it may be directly set on the other component or there may also be a central component. The terms "vertical", "horizontal", "left", "right" and similar expressions used herein are for illustrative purposes only.

[0038] 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 in this 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.

[0039] like Figure 1-5 As shown, the present invention provides a tension-free fixed-length cutting machine for slitting sponge composite fabrics for automobile roofs, comprising a tension-free transmission system, a dynamic fixed-length control module, a negative pressure adsorption cutting mechanism, and a central control host 1. The tension-free transmission system comprises a differential roller conveyor 2, an air-floating support platform 3, and a CCD correction mechanism 4. The main roller and auxiliary roller of the differential roller conveyor 2 form a speed gradient to eliminate internal stress. The CCD correction mechanism 4 detects fabric offset in real time and adjusts the guide roller angle via a servo motor.

[0040] The CCD correction mechanism 4 is provided with an electric telescopic correction guide roller;

[0041] The vacuum adsorption module 7 uses a vacuum pump, and the vacuum adsorption module 7 is connected to the air floating support platform 3;

[0042] The dynamic fixed length control module includes a dual-frequency laser interferometer 5 and an online indenter 6;

[0043] The negative pressure adsorption cutting mechanism includes a vacuum adsorption module 7, a servo three-axis transmission module 8, and an ultrasonic cutting knife 9;

[0044] The central control host 1 is connected to the tension-free transmission system, dynamic fixed-length control module, and negative pressure adsorption cutting mechanism by signal connection. The air-floating support platform 3, CCD correction mechanism 4, dual-frequency laser interferometer 5, online indenter 6, vacuum adsorption module 7, servo three-axis transmission module 8, and ultrasonic cutting knife 9 are all installed on the differential roller conveyor 2;

[0045] The ultrasonic cutting blade 9 is installed on the driving end of the servo three-axis transmission module 8.

[0046] like Figure 1As shown, the differential roller conveyor 2 includes a conveyor frame 201, a main conveying roller 202, an auxiliary conveying roller 203, and a spring pressure roller 204. The main conveying roller 202 and the auxiliary conveying roller 203 are arranged at both ends of the conveyor frame 201. Two spring pressure rollers 204 are provided corresponding to the main conveying roller 202 and the auxiliary conveying roller 203. The two spring pressure rollers 204 are installed on the conveyor frame 201 through springs. The spring pressure rollers 204 can be raised and lowered and slid on the conveyor frame 201. The linear speed ratio of the main conveying roller 202 and the auxiliary conveying roller 203 is set to 1:0.96-0.997, forming a speed gradient to eliminate internal stress.

[0047] like Figure 4 As shown, the air-floating support platform 3 includes a platform body 301, a flow-sharing network pipe 302, a ventilation cover 303, a three-way valve 304, an air supply fan 305, and a dust removal filter 306. The platform body 301 is evenly provided with ventilation holes, the flow-sharing network pipe 302 is evenly laid in the platform body 301, and the ventilation cover 303 is evenly fixed and connected to the flow-sharing network pipe 302. The flow-sharing network pipe 302, the three-way valve 304, the air supply fan 305, and the dust removal filter 306 are connected in sequence.

[0048] Preferably, the vacuum adsorption module 7 is connected to the three-way valve 304 .

[0049] Preferably, the dual-frequency laser interferometer 5 emits a composite light beam with a wavelength of 632.8nm / 850nm to monitor the actual length of the fabric in real time, and the online indenter 6 obtains the elastic modulus in real time.

[0050] Preferably, the vacuum adsorption module 7 has an opening rate of 40% and an adsorption force of ≥ 200 N / m 2 Fix the fabric, ultrasonic cutting knife 9 frequency 28kHz, amplitude 50μm, blade temperature <60℃ to prevent melting.

[0051] Preferably, the central control host 1 processes the sensor data in real time, executes the elastic compensation algorithm, coordinates the actions of each unit, inputs L (set length), and outputs: cutting instruction / speed correction value.

[0052] The specific working principle and method of use of the present invention are as follows:

[0053] S1: The fabric enters the differential roller conveyor 2 at a speed of 5m / min. The speed difference between the main conveyor roller 202 and the auxiliary conveyor roller 203 is 1%-4%, which releases the tension. The spring pressure roller 204 can squeeze the fabric at the top of the main conveyor roller 202 and the auxiliary conveyor roller 203 to prevent slipping during the conveying process. The main conveyor roller 202 is provided with a diamond knurled surface to increase the friction coefficient to μ = 0.8 to ensure effective traction. The mirror-polished silicon coating of the auxiliary conveyor roller 203 reduces the friction coefficient to μ = 0.3 to promote sliding release.

[0054] S2: Start the air supply fan 305 to transmit the filtered air to the three-way valve 304 through the dust filter 306. The air is evenly discharged from 303 through the flow equalizing network pipe 302, so that the air flow can be evenly discharged from the through holes at the top of the platform main body 301, and inject an air flow of 0.05 MPa to make the fabric in a suspended state with a gap of 0.5 mm, thereby effectively reducing the frictional resistance to lift the fabric, making the fabric pass more stably and precisely. The dual-frequency laser interferometer 5 collects length data every 0.1 s and transmits it to the central control host 1;

[0055] S3: The central control host 1 calculates the actual cutting position according to the elastic compensation formula. When the accumulated length reaches the set cutting length, stop the differential drum conveyor 2;

[0056] Elastic compensation algorithm: Measured by the online indentation instrument based on the elastic modulus E of the material, dynamically correct the cutting length;

[0057] L_{cut} = L_{set}×[1 + k·(E_{standard} / E_{actual} - 1)];

[0058] where the compensation coefficient k = 0.35 for PU sponge, E 标 is the standard modulus value;

[0059] S4: Stop the air supply fan 305, start the vacuum adsorption module 7, and the platform main body 301 generates an adsorption force ≥ 200 N / m 2 to fix the fabric, and drive the ultrasonic cutting knife 9 to cut and process the fabric through the servo three-axis transmission module 8.

[0060] It should be noted that in this article, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. The content not described in detail in this specification belongs to the prior art well-known to those skilled in the art. <关于本发明的说明>

[0061] The above is only the preferred embodiment of the present invention, and does not impose any form of limitation on the present invention; any ordinary technician in the industry can smoothly implement the present invention according to the illustrations in the specification and the above description; however, any equivalent changes made by those skilled in the art within the scope of the technical solution of the present invention by using the technical content disclosed above, such as slight modifications, evolutions, etc., are all equivalent embodiments of the present invention; at the same time, any equivalent changes, modifications, evolutions, etc. made to the above embodiments based on the essential technology of the present invention still fall within the protection scope of the technical solution of the present invention.

Claims

1. A tension-free fixed-length cutting machine for slitting composite sponge fabrics for automobile roofs, comprising a tension-free transmission system, a dynamic fixed-length control module, a negative pressure adsorption cutting mechanism, and a central control host (1), characterized in that: The tension-free transmission system comprises a differential roller conveyor (2), an air-floating support platform (3), and a CCD deviation correction mechanism (4). The main roller and auxiliary roller of the differential roller conveyor (2) form a speed gradient to eliminate internal stress. The CCD deviation correction mechanism (4) detects the fabric offset in real time and adjusts the guide roller angle through a servo motor. The CCD deviation correction mechanism (4) is provided with an electrically operated telescopic deviation correction guide roller; The vacuum adsorption module (7) uses a vacuum pump, and the vacuum adsorption module (7) is connected to the air-floating support platform (3); The dynamic fixed-length control module includes a dual-frequency laser interferometer (5) and an online indenter (6); The negative pressure adsorption cutting mechanism comprises a vacuum adsorption module (7), a servo three-axis transmission module (8), and an ultrasonic cutting knife (9); The central control host (1) is connected to the tension-free transmission system, the dynamic fixed-length control module, and the negative pressure adsorption cutting mechanism by signal; the air-floating support platform (3), the CCD correction mechanism (4), the dual-frequency laser interferometer (5), the online indenter (6), the vacuum adsorption module (7), the servo three-axis transmission module (8), and the ultrasonic cutting knife (9) are all installed on the differential roller conveyor (2); The ultrasonic cutting blade (9) is installed on the driving end of the servo three-axis transmission module (8).

2. The tension-free fixed-length cutting machine for slitting automobile roof sponge composite fabrics according to claim 1, characterized in that: The differential roller conveyor (2) comprises a conveyor frame (201), a main conveying roller (202), an auxiliary conveying roller (203), and a spring pressure roller (204); the main conveying roller (202) and the auxiliary conveying roller (203) are arranged at both ends of the conveyor frame (201); two spring pressure rollers (204) are arranged corresponding to the main conveying roller (202) and the auxiliary conveying roller (203); the two spring pressure rollers (204) are mounted on the conveyor frame (201) via springs; and the spring pressure rollers (204) can be raised and lowered and slid on the conveyor frame (201).

3. The tension-free fixed-length cutting machine for slitting automobile roof sponge composite fabrics according to claim 1, characterized in that: The linear speed ratio of the main conveying roller (202) and the auxiliary conveying roller (203) is set to 1:0.96-0.99, forming a speed gradient to eliminate internal stress.

4. The tension-free fixed-length cutting machine for slitting automobile roof sponge composite fabrics according to claim 1, characterized in that: The air-floating support platform (3) comprises a platform body (301), a flow-sharing network pipe (302), a ventilation cover (303), a three-way valve (304), an air supply fan (305), and a dust removal filter (306); the platform body (301) is evenly provided with ventilation holes; the flow-sharing network pipe (302) is evenly laid in the platform body (301); the ventilation cover (303) is evenly fixed and connected to the flow-sharing network pipe (302); the flow-sharing network pipe (302), the three-way valve (304), the air supply fan (305), and the dust removal filter (306) are connected in sequence.

5. The tension-free fixed-length cutting machine for slitting automobile roof sponge composite fabrics according to claim 1, characterized in that: The vacuum adsorption module (7) is in communication with the three-way valve (304).

6. The tension-free fixed-length cutting machine for slitting automobile roof sponge composite fabrics according to claim 1, characterized in that: The dual-frequency laser interferometer (5) emits a composite light beam with a wavelength of 632.8nm / 850nm to monitor the actual length of the fabric in real time, and the online indenter (6) obtains the elastic modulus in real time.

7. The tension-free fixed-length cutting machine for slitting automobile roof sponge composite fabrics according to claim 1, characterized in that: The vacuum adsorption module (7) has an opening rate of 40% and an adsorption force of ≥200 N / m 2 The fabric is fixed, and the ultrasonic cutting knife (9) has a frequency of 28 kHz, an amplitude of 50 μm, and a blade temperature of less than 60° C. to prevent melting.

8. The tension-free fixed-length cutting machine for slitting automobile roof sponge composite fabrics according to claim 1, characterized in that: The central control host (1) processes the sensor data in real time, executes the elastic compensation algorithm, coordinates the actions of each unit, inputs L (set length), and outputs: cutting instruction / speed correction value.

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