Composite material filling forming system

Abstract

The embodiment of the invention discloses a composite material filling forming system. In the filling process, the data acquisition module acquires operation data of the glue injection pump and the vacuum pump and detection signals of the first sensor and the second sensor in real time. The monitoring module judges according to the collected signals of the first sensor and the second sensor, and when the first sensor detects that resin coverage exists in a glue injection area and the second sensor communicated with the area also detects that resin coverage exists, the monitoring module generates a glue injection completion signal corresponding to the glue injection area. According to the composite material filling forming system, the first sensor and the second sensor are arranged in the glue injection area and the vacuum channel, the monitoring module and the control module are combined, real-time monitoring and intelligent control over the resin flowing state in the composite material filling forming process are achieved, the forming consistency and equipment safety are improved, and the production efficiency is improved. The device has the advantages of high automation degree, simplicity and convenience in operation and reliable forming quality.

Description

Technical Field

[0001] The present invention relates to the technical field of composite material filling and molding, and in particular to a composite material filling and molding system. Background Art

[0002] Composite filling molding is a common composite material manufacturing process. During manufacturing, dry fiber preforms (such as glass fiber and carbon fiber preforms) are first placed in a mold. A cavity is formed inside the mold. Next, the mold is closed and sealed to ensure that there is no leakage when the resin is injected. Liquid resin is poured into the mold using a pump or vacuum, and the resin will penetrate all the fibers. The resin in the mold is then heated (or at room temperature) to cure, causing the resin to harden and form the final product. After curing is complete, the mold is opened and the molded composite product is removed.

[0003] Existing composite material filling and molding systems only use pumps or vacuums for processing, resulting in poor fluidity of the liquid resin. When the resin is pumped in or vacuum-guided to flow, the resin only flows in the direction of the pumping or guidance, and cannot cover all positions in the cavity. Once the coverage is incomplete, it will affect the quality of the finished product.

[0004] Generally, a sensor is installed in the cavity to collect the resin flow conditions in each injection area inside the mold. Therefore, the location of the sensor is particularly important. If it is simply installed in the mold, it can only detect the local resin flow conditions in the injection area.

[0005] In the case where a glue injection pump and a vacuum pump are used together to assist the resin flow in the mold, however, simply using sensors to collect data from the glue injection area in the mold cannot control the shut-off time of the vacuum pump, and it can only be shut down by manual judgment. If the vacuum pump is shut down too early, it will affect the resin flow rate. If the vacuum pump is shut down too late, resin will be sucked into the vacuum pump, making the subsequent vacuum pump unusable. Therefore, the glue injection speed and shut-off time can only be controlled manually, and cannot be adjusted based on the glue injection status and glue injection flow rate during the glue injection process, resulting in poor consistency of the resin after injection and curing. Summary of the Invention

[0006] Based on this, it is necessary to address the above problems and propose a composite material filling and molding system to solve the above technical problems.

[0007] On the one hand, a composite material filling and molding system is proposed, comprising:

[0008] The mold has a plurality of glue injection areas, glue injection channels and vacuum channels, and each of the glue injection areas is connected to at least one of the glue injection channels and one of the vacuum channels;

[0009] A glue injection pump connected to the glue injection channel;

[0010] a vacuum pump connected to the vacuum channel;

[0011] A first sensor is provided in the glue injection area;

[0012] a second sensor disposed in the vacuum channel;

[0013] A data acquisition module, configured to acquire operating data of the glue injection pump and the vacuum pump in each of the glue injection areas;

[0014] a monitoring module configured to collect data from the first sensor in each of the injection areas and the second sensor in the vacuum channel connected to the injection area, and generate a signal indicating that injection is complete for the area if both the first sensor and the second sensor receive signals indicating that the area is covered by the injection;

[0015] The control module receives the signal indicating that the glue injection in the area is completed, and turns off the vacuum pump that has completed the glue injection according to the signal indicating that the glue injection in the area is completed.

[0016] In at least one embodiment of the present application, at least one first sensor is provided at each corner within the glue injection area, and at least four second sensors are provided at equal intervals along the length direction of the vacuum channel.

[0017] In at least one embodiment of the present application, the composite material filling and molding system further includes:

[0018] Data acquisition module, used to collect resin flow images during the filling process;

[0019] The data processing module includes a recursive analysis module, a wavelet analysis module, a wavelet packet decomposition module, a Fourier transform module, and a Hilbert-Huang transform module. The data processing module analyzes the flow data of the resin to generate an analysis result.

[0020] In at least one embodiment of the present application, the composite material filling and molding system further includes:

[0021] The regulating module regulates the working states of the glue injection pump and the vacuum pump according to the analysis result.

[0022] In at least one embodiment of the present application, the composite material filling and molding system further includes:

[0023] The feature extraction module is used to extract data information from the resin flow image to generate resin flow data.

[0024] In at least one embodiment of the present application, the composite material filling and molding system further includes:

[0025] The leakage monitoring module is used to obtain the vacuum data in each of the injection areas and the injection data in each of the injection areas, and determine whether there is a leak based on the vacuum data and the injection data. If there is a leak, a leakage signal is generated and sent to the control module to control the vacuum pump and the injection pump in the leakage area to stop working and isolate the leakage area.

[0026] In at least one embodiment of the present application, the composite material filling and molding system further includes:

[0027] The judgment module is used to judge the number of the glue injection areas and generate a glue adjustment signal according to the number of the glue injection areas. When the number of the glue injection areas is greater than the preset value of the glue injection areas, the glue injection area in the middle is selected according to the distribution of the glue injection areas, and the glue injection area in the middle is marked as the first glue injection position. Based on the first glue injection position and the remaining glue injection areas, glue injection process data is generated, and the glue injection process data is sent to the control module to adjust the glue injection speed of the glue injection pump.

[0028] In at least one embodiment of the present application, the composite material filling and molding system further includes:

[0029] The vacuum pre-processing module generates vacuum pre-processing data before glue injection, and sends the vacuum pre-processing data to the control module, so that the control module performs pre-vacuum processing on the mold according to the vacuum pre-processing data.

[0030] In at least one embodiment of the present application, the composite material filling and molding system further includes:

[0031] An electric push rod is provided on the glue injection channel and the vacuum channel, and is used to control the opening or closing of the glue injection channel and the vacuum channel.

[0032] In at least one embodiment of the present application, the composite material filling and molding system further includes:

[0033] The data storage module is used to store all data in the composite material infusion molding process.

[0034] Implementing the composite material filling and molding system of this embodiment will have at least the following beneficial effects:

[0035] The composite material filling and molding system provided above. During the filling process, the data acquisition module collects real-time operating data from the injection pump and vacuum pump, as well as detection signals from the first and second sensors. The monitoring module determines based on the collected signals from the first and second sensors. When the first sensor detects resin coverage within the injection area, and the second sensor connected to the area also detects resin coverage, the monitoring module generates a "glue injection completion signal" for the corresponding injection area.

[0036] After receiving the injection completion signal, the control module determines that the injection task in the injection area has been completed and, based on this, shuts off the vacuum pump connected to the injection area. This prevents the vacuum pump from continuing to pump, preventing excessive resin from being sucked into the vacuum pump and causing damage to the equipment.

[0037] This composite material filling and molding system achieves real-time monitoring and intelligent control of the resin flow state during the composite material filling and molding process by setting a first sensor and a second sensor in the injection area and the vacuum channel, and combining a monitoring module with a control module, thereby improving molding consistency and equipment safety. It has the advantages of a high degree of automation, simple operation, and reliable molding quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0039] in:

[0040] Figure 1 A partial structural block diagram of a composite material filling and molding system in one embodiment;

[0041] Figure 2 is a structural block diagram of a data processing module in one embodiment;

[0042] Figure 3 This is another structural block diagram of a composite material filling and molding system in one embodiment.

[0043] in:

[0044] 100. Composite material filling and molding system;

[0045] 110, mold; 110a, glue injection area; 110b, glue injection channel; 110c, vacuum channel;

[0046] 120, glue injection pump; 130, vacuum pump; 140, first sensor; 141, second sensor; 142, electric push rod;

[0047] 150. Data acquisition module; 151. Monitoring module; 153. Control module; 154. Data acquisition module; 155. Data processing module; 1551. Recursive analysis module; 1552. Wavelet analysis module; 1553. Wavelet packet decomposition module; 1554. Fourier transform module; 1555. Hilbert-Huang transform module; 156. Adjustment module; 157. Feature extraction module; 158. Leakage monitoring module; 159. Judgment module; 160. Vacuum pretreatment module; 161. Data storage module. DETAILED DESCRIPTION

[0048] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0049] A composite material filling and molding system 100 is proposed, comprising:

[0050] The mold 110 has multiple glue injection areas 110a, glue injection channels 110b and vacuum channels 110c, and each of the glue injection areas 110a is connected to at least one of the glue injection channels 110b and one of the vacuum channels 110c;

[0051] A glue injection pump 120, connected to the glue injection channel 110b;

[0052] A vacuum pump 130 connected to the vacuum channel 110c;

[0053] A first sensor 140 is provided in the glue injection area 110a;

[0054] A second sensor 141 is provided in the vacuum channel 110c;

[0055] A data acquisition module 150 is configured to acquire operating data of the glue injection pump 120 and the vacuum pump 130 in each of the glue injection areas 110a;

[0056] The monitoring module 151 is configured to collect data from the first sensor 140 in each of the injection areas 110 a and the second sensor 141 in the vacuum channel 110 c connected to the injection area 110 a. If both the first sensor 140 and the second sensor 141 receive signals indicating that the injection is covered, the monitoring module 151 generates a signal indicating that the injection is complete for that area.

[0057] The control module 153 receives the glue injection completion signal for the area, and turns off the vacuum pump 130 after the glue injection is completed according to the glue injection completion signal for the area.

[0058] Please refer to Figure 1-Figure 3 In this embodiment, during the filling process, the data acquisition module 150 collects real-time operating data from the injection pump 120 and vacuum pump 130, as well as detection signals from the first sensor 140 and the second sensor 141. The monitoring module 151 makes a determination based on the signals collected from the first and second sensors 140, 141. When the first sensor 140 detects that the injection area 110a is covered with resin, and the second sensor 141 connected to the injection area also detects that the area is covered with resin, the monitoring module 151 generates a "glue injection completion signal" corresponding to the injection area 110a.

[0059] After receiving the injection completion signal, the control module 153 determines that the injection task of the injection area 110a has been completed and, based on this, controls the vacuum pump 130 connected to the injection area 110a to shut down. This prevents the vacuum pump 130 from continuing to pump, preventing excessive resin from being sucked into the vacuum pump 130 and causing damage to the equipment.

[0060] By implementing dual monitoring through the first sensor 140 and the second sensor 141 in the injection area 110a and the vacuum channel 110c, it is possible to accurately judge the resin infusion status of each area in real time, automatically generate a signal for completing the injection, avoid relying on manual experience and judgment, and improve the accuracy of injection control and the automation level of the injection process.

[0061] The control module 153 can automatically shut down the corresponding vacuum pump 130 according to the injection completion signal output by the monitoring module 151, effectively preventing the vacuum pump 130 from continuing to work after the injection is completed, causing the resin to be sucked in, preventing damage to the equipment and extending the service life of the equipment.

[0062] Since the resin flow state of each injection area 110a can be monitored in real time, it is ensured that each area is fully infiltrated and the detection is complete, thereby greatly improving the consistency and molding quality of the product and reducing process defects such as voids and dry spots.

[0063] Through intelligent monitoring and timely response, the risk of manual operation errors can be effectively reduced, especially in complex process environments where multi-zone injection is carried out simultaneously, thereby improving the safety and stability of the entire production process.

[0064] The composite material filling and molding system 100 realizes real-time monitoring and intelligent control of the resin flow state during the composite material filling and molding process by setting a first sensor 140 and a second sensor 141 in the injection area 110a and the vacuum channel 110c, and combining the monitoring module 151 and the control module 153, thereby improving the molding consistency and equipment safety, and has the advantages of a high degree of automation, simple operation, and reliable molding quality.

[0065] In at least one embodiment of the present application, at least one first sensor 140 is provided at each corner of the glue injection area 110a, and at least four second sensors 141 are equidistantly provided along the length of the vacuum channel 110c.

[0066] Please refer to Figure 1-Figure 3 In this embodiment, during the filling process, the corners of the injection area 110a are often the most difficult areas for resin flow to fully cover, making them prone to defects such as incomplete filling and trapped bubbles. Therefore, first sensors 140 are deployed at the corners of the injection area 110a to monitor the resin flow in these critical areas. This corner monitoring effectively captures abnormalities such as edge retention and insufficient coverage, ensuring that the resin fully covers the entire injection area 110a.

[0067] At least four second sensors 141 are evenly spaced along the length of vacuum channel 110c, which connects to injection area 110a. These sensors provide real-time sensing of the resin flow along the vacuum guide path. These multi-point distribution of second sensors 141 allows for more accurate detection of the resin's flow rate, coverage, and endpoint within vacuum channel 110c, helping to determine whether injection is complete.

[0068] During the molding process, the data acquisition module 150 continuously collects detection data from the first sensor 140 and the second sensor 141. Based on this data, the monitoring module 151 determines in real time whether there are uncovered areas or flow anomalies in each injection zone 110a. It then generates an injection completion signal based on the coverage signals from the first and second sensors 140, 141. The control module 153 further intelligently controls the vacuum pump 130 in the corresponding zone to shut down based on the injection completion signal to prevent over-pumping or resin aspiration.

[0069] Since corners are the areas most prone to forming voids and dry spots in traditional injection molding, the method of setting a first sensor 140 at the corners can realize real-time monitoring of the flow state of the corners and promptly detect the problem of insufficient resin coverage, thereby ensuring that the molding quality of the entire injection area 110a is more uniform and complete.

[0070] Multiple second sensors 141 arranged equidistantly along the length of the vacuum channel 110c can describe in detail the advancement process of the resin in the vacuum channel 110c, and timely capture resin flow abnormalities (such as blockage, abnormally slowed speed, etc.), which helps to accurately determine the timing of completion of injection and improve the timeliness and accuracy of the vacuum pump 130 shutdown control.

[0071] Multi-point, multi-directional real-time monitoring covers the problems missed by traditional single-point monitoring, effectively reducing molding defects caused by local lack of glue injection and local bubble retention, and improving the consistency and quality pass rate of composite products from the source.

[0072] In at least one embodiment of the present application, the composite material filling and molding system 100 further includes:

[0073] A data acquisition module 154 is used to collect images of resin flow during the filling process;

[0074] The data processing module 155 includes a recursive analysis module 1551, a wavelet analysis module 1552, a wavelet packet decomposition module 1553, a Fourier transform module 1554 and a Hilbert-Huang transform module 1555. The data processing module 155 analyzes the flow data of the resin to generate an analysis result.

[0075] In at least one embodiment of the present application, the composite material filling and molding system 100 further includes:

[0076] The adjustment module 156 adjusts the working states of the glue injection pump 120 and the vacuum pump 130 according to the analysis result.

[0077] In at least one embodiment of the present application, the composite material filling and molding system 100 further includes:

[0078] The feature extraction module 157 is used to extract data information from the resin flow image to generate resin flow data.

[0079] Please refer to Figure 1-Figure 3In this embodiment, during the filling process, the system uses data acquisition module 154 (a camera or sensor array located outside mold 110) to collect real-time image data of the resin flow within each injection area 110a. This flow image data can reflect information such as the position of the resin front, flow velocity changes, and localized retention or voids.

[0080] The collected flow image data is processed by the feature extraction module 157 and converted into time series data or multi-dimensional feature data representing the flow state of the resin, which serves as input for subsequent signal analysis.

[0081] The data processing module 155 includes a recursive analysis module 1551, a wavelet analysis module 1552, a wavelet packet decomposition module 1553, a Fourier transform module 1554, and a Hilbert-Huang transform module 1555, which process the flow data respectively:

[0082] Recursive analysis module 1551: analyzing the dynamic change law and nonlinear mutation phenomenon in the resin flow process;

[0083] Wavelet analysis module 1552: identifies flow velocity changes and anomalies (e.g., holes, gaps, underfilling, etc.) within a local time scale;

[0084] Wavelet packet decomposition module 1553: subdivides the signal with higher frequency resolution and distinguishes the characteristics of different frequency bands;

[0085] Fourier transform module 1554: Analyzes the overall frequency characteristics of the flow process and captures periodic or stability characteristics;

[0086] Hilbert-Huang Transform Module 1555: Extracts instantaneous frequency and local energy changes from flow data to accurately describe complex flow behavior.

[0087] The data processing module 155 generates comprehensive flow state analysis results based on the above analysis, including flow rate, flow uniformity, flow anomaly warning and other information.

[0088] The adjustment module 156 receives the flow analysis results and automatically adjusts the injection speed, pressure or opening and closing state of the injection pump 120 according to the flow state, and adjusts the exhaust rate or closing timing of the vacuum pump 130 to ensure that the resin fills the injection area 110a in the best state and prevents flow stagnation or excessive suction.

[0089] By acquiring flow images in real time and combining them with data from local sensor points, we can dynamically grasp information such as the resin flow front, distribution density, and speed changes, significantly improving the perception range and depth of the filling process.

[0090] With the help of various signal processing technologies such as recursion, wavelet, wavelet packet, Fourier, Hilbert-Huang transform, etc., it is possible to accurately identify small, short-term, local abnormal events in the flow process (such as local flow stagnation, sudden change in resin velocity, poor infiltration of fiber accumulation area), and provide early warning of potential defects.

[0091] By feeding the analysis results back to the adjustment module 156, the system can autonomously adjust the operating parameters of the injection pump 120 and the vacuum pump 130 according to the real-time flow state, realize intelligent closed-loop control based on the flow state, avoid human intervention, and improve control accuracy and reliability.

[0092] The infusion rhythm is intelligently adjusted to ensure that the resin flow speed in each injection area 110a is coordinated and consistent, effectively avoiding molding defects such as voids, inclusions, and insufficient infiltration, thereby improving the consistency and overall yield of composite products.

[0093] In at least one embodiment of the present application, the composite material filling and molding system 100 further includes:

[0094] The leakage monitoring module 158 is used to obtain the vacuum data in each of the injection areas 110a and the injection data in each of the injection areas 110a, and determine whether there is a leak based on the vacuum data and the injection data. If there is a leak, a leakage signal is generated and sent to the control module 153 to control the vacuum pump 130 and the injection pump 120 in the leakage area to stop working and isolate the leakage area.

[0095] Please refer to Figure 1-Figure 3 In this embodiment, during the filling and molding process, the leakage monitoring module 158 collects vacuum data (such as vacuum degree, pressure change) and injection data (such as injection pressure, resin flow rate, injection amount) inside each injection area 110a in real time.

[0096] The leakage monitoring module 158 comprehensively determines whether there is leakage in the glue injection area 110a based on the collected vacuum data and glue injection data. The judgment basis may include:

[0097] Abnormal fluctuations occur in the vacuum data (such as the pressure cannot be maintained, continues to drop, etc.), the injection data is abnormal (such as the injection flow rate increases significantly but does not correspond to the resin coverage of the injection area 110a), and there are unreasonable deviations between the vacuum and injection data (such as the resin quickly enters the vacuum channel 110c when vacuuming).

[0098] When the leakage monitoring module 158 determines that a certain injection area 110 a has a leak based on data analysis, it immediately generates a corresponding leakage signal.

[0099] The leak signal is sent to control module 153, which instructs the vacuum pump 130 and injection pump 120 corresponding to the leaking area to stop operation, preventing further resin loss or damage to the equipment. Simultaneously, the system isolates the leaking area, physically and fluidically disconnecting it from the remaining normal injection areas 110a. This ensures that the overall infusion process can continue normally in other areas, preventing the entire product from being scrapped due to a localized leak.

[0100] Through the joint intelligent analysis of vacuum data and injection data, anomalies can be detected quickly and accurately at the early stage of leakage, and timely responses can be made to prevent the leakage from expanding or affecting the overall injection process.

[0101] Through leak detection and regional isolation, only the local area where the leak occurs needs to be treated, without discarding the entire composite product, which greatly improves the product molding success rate and material utilization rate, and significantly reduces manufacturing costs.

[0102] During the large-scale filling and molding process carried out simultaneously in multiple injection areas 110a, even if leakage occurs in some areas, the system can quickly isolate the problem area to ensure the continuity and stability of the injection process in other areas and avoid overall shutdown.

[0103] In at least one embodiment of the present application, the composite material filling and molding system 100 further includes:

[0104] The judgment module 159 is used to judge the number of the glue injection areas 110a and generate a glue adjustment signal according to the number of the glue injection areas 110a. When the number of the glue injection areas 110a is greater than the preset value of the glue injection areas 110a, the glue injection area 110a located in the middle is selected according to the distribution of the glue injection areas 110a, and the glue injection area 110a in the middle is marked as the first glue injection position. Glue injection process data is generated based on the first glue injection position and the remaining glue injection areas 110a, and the glue injection process data is sent to the control module 153 to adjust the glue injection speed of the glue injection pump 120.

[0105] Please refer to Figure 1-Figure 3 In this embodiment, the judgment module 159 first obtains the quantity information of the glue injection area 110a set inside the current mold 110, which is determined by system initialization data, sensor feedback information or preset process parameters.

[0106] The judgment module 159 compares the obtained number of injection areas 110a with a preset threshold value. If the number of injection areas 110a is greater than a preset value of injection areas 110a (e.g., a set reasonable parallel injection number threshold), a signal for adjusting injection is generated to start the optimization process of injection.

[0107] When there are a large number of injection areas 110a, the judgment module 159 prioritizes the injection area 110a located in the middle of the entire area as the starting area for the first injection based on the spatial distribution information of the injection areas 110a. Prioritizing the injection of the middle area can promote uniform diffusion of the resin to the surrounding area, which helps to optimize the overall infiltration effect.

[0108] The judgment module 159 plans a reasonable glue injection sequence and strategy based on the determined first glue injection position and the remaining glue injection areas 110a to form glue injection process data. The glue injection process data includes specific parameters such as the glue injection start time, glue injection speed, and priority order of each glue injection area 110a.

[0109] The injection process data is transmitted to the control module 153 , and the control module 153 dynamically adjusts the injection speed, injection sequence and start time of the injection pump 120 based on the data, thereby achieving efficient and reasonable filling control in the scenario of multiple injection areas 110a.

[0110] By judging the number of injection areas 110a in real time and dynamically determining the first injection position according to the spatial layout, the injection sequence is automatically planned to avoid the inefficiency and errors of manually setting the injection path, thereby improving the overall intelligence level of the system.

[0111] Prioritizing the injection of glue in the middle area can effectively shorten the resin flow path, promote the diffusion of resin to the surrounding area, reduce the difference in flow resistance, reduce the probability of molding defects such as voids and dry spots, and improve the consistency and infiltration quality of the product.

[0112] In at least one embodiment of the present application, the composite material filling and molding system 100 further includes:

[0113] The vacuum pre-processing module 160 generates vacuum pre-processing data before glue injection, and sends the vacuum pre-processing data to the control module 153, so that the control module 153 performs pre-vacuum processing on the mold 110 according to the vacuum pre-processing data.

[0114] Please refer to Figure 1-Figure 3 In this embodiment, before the filling and molding process begins, the vacuum pre-processing module 160 generates corresponding vacuum pre-processing data based on preset process requirements, mold structural characteristics, and environmental conditions. The vacuum pre-processing data may include information such as the pre-vacuuming time, the target vacuum pressure, the required vacuuming rate, and the vacuuming stability determination criteria.

[0115] The vacuum pre-processing module 160 sends the generated vacuum pre-processing data to the control module 153. The control module 153 starts the vacuum pump 130 and performs a pre-vacuum operation based on the received data, processing the internal environment of the mold 110 according to the specified parameters.

[0116] The control module 153 controls the operation of the vacuum pump 130, gradually reducing the air pressure inside the mold 110 to the set target vacuum level and maintaining a stable period of time to ensure that the residual gas, moisture or impurities inside the mold 110 are fully discharged, creating a stable, uniform and undisturbed molding environment for subsequent resin injection.

[0117] Only after the vacuum pretreatment reaches the set standard, the system is allowed to enter the resin injection stage to ensure the smooth progress of the subsequent infusion process.

[0118] By pre-vacuuming, residual impurities such as air and water vapor inside the mold 110 can be removed in advance, reducing the risk of bubbles and inclusions during injection, and significantly improving the resin infiltration quality.

[0119] The vacuum environment after sufficient pretreatment can provide uniform and consistent negative pressure guiding force, ensuring stable and smooth flow of resin during the injection process, which helps to form dense and defect-free composite products.

[0120] It effectively avoids problems such as voids, dry spots, and bubbles caused by insufficient local vacuum, and significantly improves the consistency, mechanical properties, and appearance quality of composite products.

[0121] In at least one embodiment of the present application, the composite material filling and molding system 100 further includes:

[0122] The electric push rod 142 is provided on the glue injection channel 110b and the vacuum channel 110c. The electric push rod 142 is used to control the opening or closing of the glue injection channel 110b and the vacuum channel 110c.

[0123] Please refer to Figure 1-Figure 3 In this embodiment, electric push rods 142 are respectively provided in the injection channel 110b and the vacuum channel 110c, and can physically open or close the corresponding channels through axial expansion and contraction. The electric push rods 142 can drive valve mechanisms, sliders, or other sealing devices to achieve channel opening and closing control.

[0124] The electric push rod 142 is in communication with the control module 153 of the system. The control module 153 sends an opening or closing instruction to the electric push rod 142 according to the filling and molding process flow, real-time monitoring results or data analysis results.

[0125] Before glue injection begins, the control module 153 controls the electric push rod 142 to open the glue injection channel 110b, allowing liquid resin to flow smoothly from the glue injection pump 120 into the glue injection area 110a in the mold 110. At the same time, according to the process requirements at different stages, the electric push rod 142 can be controlled to close certain channels to restrict the resin flow path and achieve more precise injection control.

[0126] Similarly, during the vacuuming phase, the control module 153 instructs the electric push rod 142 to open the vacuum channel 110c, creating a negative pressure environment. When a particular injection area 110a is fully filled and vacuuming needs to be interrupted, the control module 153 instructs the electric push rod 142 to close the corresponding vacuum channel 110c to prevent excessive resin extraction or the vacuum pump 130 from drawing in resin.

[0127] Based on real-time monitoring data (such as flow status, pressure data, injection completion signal, etc.), the control module 153 can dynamically control the electric push rod 142 to accurately switch the opening or closing status of the injection channel 110b and the vacuum channel 110c at different time points, ensuring that the entire injection-vacuuming process is executed efficiently and accurately.

[0128] In at least one embodiment of the present application, the composite material filling and molding system 100 further includes:

[0129] The data storage module 161 is used to store all data during the composite material infusion molding process.

[0130] Please refer to Figure 1-Figure 3 In this embodiment, the data storage module 161 receives and stores real-time data from various modules of the system, including but not limited to: operating data of the injection pump 120 and the vacuum pump 130 (such as pressure, flow, start and stop time), resin flow state data collected by the first sensor 140 and the second sensor 141, image data collected by the flow image acquisition module, flow analysis results processed by the data processing module 155 through algorithms such as recursive analysis, wavelet analysis, wavelet packet decomposition, Fourier transform, and Hilbert-Huang transform, injection control instructions and start and stop records of the vacuum pump 130 of the control module 153, and relevant process status information generated by the leakage monitoring module 158, the judgment module 159, and the vacuum pretreatment module 160.

[0131] The data storage module 161 can classify and store the above data according to time series, injection area 110a number, sensor number, etc. to ensure data integrity and traceability. It can use local storage devices (such as industrial storage servers, hard disk arrays) or synchronize to a cloud database.

[0132] By completely and systematically collecting and storing data from various stages such as glue injection, vacuuming, resin flow, and molding monitoring, we ensure that every link in the filling and molding process is recorded in detail, facilitating subsequent query and traceability.

[0133] When molding defects or product problems occur, they can be quickly traced back to specific process and parameter changes, clarifying the cause, helping to define responsibilities, implement quality improvements, and correct problems.

[0134] By analyzing historical molding data, we can identify the optimal process window conditions, optimize the injection sequence, injection speed, and vacuum extraction parameters, and improve product consistency and molding success rate.

[0135] The technical features of the above embodiments can be combined arbitrarily. To make the description concise, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0136] The above-described embodiments merely represent several implementation methods of the present application. While the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that a person skilled in the art could make various modifications and improvements without departing from the spirit of the present invention, all of which fall within the scope of protection of the present invention. Therefore, the scope of protection of the present invention shall be determined by the appended claims.

Claims

1. A composite material filling and molding system, characterized in that: The composite material filling and molding system includes: The mold has a plurality of glue injection areas, glue injection channels and vacuum channels, and each of the glue injection areas is connected to at least one of the glue injection channels and one of the vacuum channels; A glue injection pump connected to the glue injection channel; a vacuum pump connected to the vacuum channel; A first sensor is provided in the glue injection area; a second sensor disposed in the vacuum channel; A data acquisition module, configured to acquire operating data of the glue injection pump and the vacuum pump in each of the glue injection areas; a monitoring module configured to collect data from the first sensor in each of the injection areas and the second sensor in the vacuum channel connected to the injection area, and generate a signal indicating that injection is complete for the area if both the first sensor and the second sensor receive signals indicating that the area is covered by the injection; The control module receives the signal indicating that the glue injection in the area is completed, and turns off the vacuum pump that has completed the glue injection according to the signal indicating that the glue injection in the area is completed.

2. The composite material filling and molding system according to claim 1, characterized in that: At least one first sensor is provided at each corner within the glue injection area, and at least four second sensors are provided at equal intervals along the length direction of the vacuum channel.

3. The composite material filling and molding system according to claim 1, characterized in that: The composite material filling and molding system also includes: Data acquisition module, used to collect resin flow images during the filling process; The data processing module includes a recursive analysis module, a wavelet analysis module, a wavelet packet decomposition module, a Fourier transform module, and a Hilbert-Huang transform module. The data processing module analyzes the flow data of the resin to generate an analysis result.

4. The composite material filling and molding system according to claim 3, characterized in that: The composite material filling and molding system also includes: The regulating module regulates the working states of the glue injection pump and the vacuum pump according to the analysis result.

5. The composite material filling and molding system according to claim 3, characterized in that: The composite material filling and molding system also includes: The feature extraction module is used to extract data information from the resin flow image to generate resin flow data.

6. The composite material filling and molding system according to claim 3, characterized in that: The composite material filling and molding system also includes: The leakage monitoring module is used to obtain the vacuum data in each of the injection areas and the injection data in each of the injection areas, and determine whether there is a leak based on the vacuum data and the injection data. If there is a leak, a leakage signal is generated and sent to the control module to control the vacuum pump and the injection pump in the leakage area to stop working and isolate the leakage area.

7. The composite material filling and molding system according to claim 3, characterized in that: The composite material filling and molding system also includes: The judgment module is used to judge the number of the glue injection areas and generate a glue adjustment signal according to the number of the glue injection areas. When the number of the glue injection areas is greater than the preset value of the glue injection areas, the glue injection area in the middle is selected according to the distribution of the glue injection areas, and the glue injection area in the middle is marked as the first glue injection position. Based on the first glue injection position and the remaining glue injection areas, glue injection process data is generated, and the glue injection process data is sent to the control module to adjust the glue injection speed of the glue injection pump.

8. The composite material filling and molding system according to claim 3, characterized in that: The composite material filling and molding system also includes: The vacuum pre-processing module generates vacuum pre-processing data before glue injection, and sends the vacuum pre-processing data to the control module, so that the control module performs pre-vacuum processing on the mold according to the vacuum pre-processing data.

9. The composite material filling and molding system according to claim 3, characterized in that: The composite material filling and molding system also includes: An electric push rod is provided on the glue injection channel and the vacuum channel, and is used to control the opening or closing of the glue injection channel and the vacuum channel.

10. The composite material filling and molding system according to claim 1, characterized in that: The composite material filling and molding system also includes: The data storage module is used to store all data in the composite material infusion molding process.

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