Low-hairiness glass fiber epoxy winding processing device and forming process thereof

Abstract

The invention relates to the technical field of glass fiber reinforced composite material forming equipment, in particular to a low-hairiness glass fiber epoxy winding processing device and a forming process thereof.The low-hairiness glass fiber epoxy winding processing device comprises multi-axis constant-tension yarn supply frames which are sequentially arranged in the yarn bundle running direction and are provided with independent tension channels; the online hairiness detection and active hairiness suppression unit comprises an industrial camera, an annular air knife and an electrostatic neutralization rod, and the industrial camera is used for outputting a yarn bundle hairiness index. The dipping-glue-containing steady-state control of double-cavity micro vacuum + online viscosity closed loop + narrow slit / extrusion roller glue control is combined, and the visual / structured light monitoring and partition curing are cooperated, so that a full-link systematic low-hairiness solution is formed, and the full-link systematic low-hairiness solution is superior to a single-point improvement scheme of only a material side or only a detection side.

Description

Technical Field

[0001] This invention relates to the field of glass fiber reinforced composite material molding equipment technology, and in particular to a low-fuzz glass fiber epoxy winding processing device and its molding process. Background Technology

[0002] Reverse osmosis water treatment membrane housings are generally made of glass fiber / epoxy resin winding, which has high requirements for surface quality, mechanical properties, and pressure resistance reliability. During the winding process, glass fiber fuzz can cause fiber bundle dispersion, uneven laying, and surface roughness, reducing impregnation efficiency, increasing porosity, and causing strength fluctuations. It also increases yarn breakage and rework rates, affecting production line cycle time and yield.

[0003] Existing technologies mainly optimize the sizing agent system from the material side to reduce fuzz, or detect and control fuzz from the equipment side. However, they generally suffer from a disconnect between detection and treatment, and lack an integrated and coordinated closed loop of detection-fuzz suppression-broadening-impregnation-layout-pre-curing. There are also routes to reduce secondary friction damage through pre-formed strips, but their applicability to epoxy wet winding production lines is limited.

[0004] Therefore, there is an urgent need for a systematic low-feather winding solution: under the premise of meeting the epoxy impregnation-layout-pre-curing window, to achieve online detection, active suppression and multi-variable closed-loop control of feathers, and to coordinate with tension, width, impregnation and layup monitoring to ensure appearance and reliability. Therefore, this application discloses a low-feather winding processing device and its molding process for the manufacture of epoxy resin-based glass fiber pressure vessels (such as water treatment membrane shells). Summary of the Invention

[0005] In view of this, the present invention proposes a low-fuzz glass fiber epoxy winding processing device and its molding process to solve the current problems of glass fiber fuzz not being solved in a coordinated closed loop and limited versatility with epoxy wet winding production lines.

[0006] A low-fuzz epoxy winding processing device for glass fibers includes: a multi-axis constant tension yarn feeding frame arranged sequentially along the yarn bundle running direction, which has independent tension channels, a single bundle tension of 20–60N, and tension fluctuation ≤±2%; and an online fuzz detection and active fuzz suppression unit, including an industrial camera, an annular air knife, and an electrostatic neutralization rod. The industrial camera is used to output the yarn bundle fuzz index, and the annular air knife is arranged around the yarn bundle path, with a nozzle incident angle of 30–60°, a nozzle gap of 0.5–1.5mm, and an air supply pressure of 0.1–0.3MPa. The electrostatic neutralizing rod outputs ±10–30kV and has a distance of 50–150mm from the yarn bundle; the low-damage spreading and guiding unit includes a ceramic comb, a oscillation frequency spreader, and a ceramic guide wheel, wherein the ceramic comb tooth R angle is 0.3–0.8mm, the over-combing wrap angle is ≤15°, the oscillation frequency spreader has an oscillation frequency of 2–8Hz and an oscillation angle of ±3–±8°, and the guide wheel has a surface roughness Ra≤0.05μm; the vacuum-constant temperature-constant viscosity epoxy impregnation unit includes a pre-stage microvacuum chamber and a post-stage microvacuum chamber connected in series, a constant temperature shell, an online viscometer, and an outlet... The system includes a narrow-slit scraper nozzle or an elastic extrusion roller, wherein the vacuum level of the pre-stage micro-vacuum chamber is −0.02 to −0.04 MPa, and the vacuum level of the post-stage micro-vacuum chamber is −0.03 to −0.06 MPa. An online viscometer is used to stabilize the resin viscosity at 200–800 mPa·s with a control accuracy of ±5%. The narrow-slit scraper nozzle has a slit gap of 0.3–1.0 mm, or the elastic extrusion roller has a linear pressure of 50–200 N. A three-axis linkage winding head and a collaborative control module are also included, which features three-axis linkage for rotation, translation, and oscillation, providing ±5° angle dynamic compensation and end secondary pressure. Roller and dot-matrix IR pre-curing; online vision / laser surface and online vision / laser monitoring system, including oblique light / backlight illumination and line structured light height measurement, with a measurement resolution of ≤50μm; pre-curing and zoned curing channels, including short-wave IR surface drying and multi-zone convection curing; intelligent central control system, based on multivariate model predictive control (MPC) of hairiness index, tension, spreading width, resin viscosity / temperature, and visual defects / thickness, used for closed-loop adjustment of air knife parameters, yarn feeding tension, spreading swing frequency, micro-vacuum degree and glue control gap / line pressure, winding angle and trajectory.

[0007] Preferably, the inner diameter D of the annular air knife is... i The width Ws of the expanded filament bundle satisfies: D i =Ws+5~15mm allowance, the axial distance from the air knife to the yarn bundle is 10–50mm.

[0008] Preferably, the industrial camera employs pixel-level edge recognition and length / quantity / density statistics, has a frame rate ≥60fps, and its field of view covers 5–10mm of redundancy on both sides of the yarn bundle. Furthermore, through calibration, a linear or piecewise linear correspondence is established between the hairiness index and the hairiness amount (g / kg).

[0009] Preferably, the ceramic comb is made of zirconium oxide or silicon carbide ceramic, the tooth spacing is configured according to the linear density and the number of single filaments, and the guide wheel is made of zirconium oxide or silicon nitride with a diameter of 20–60 mm.

[0010] Preferably, the impregnation residence time of each of the front and rear microvacuum chambers is 0.3–1.0 s, the sampling period of the online viscometer is ≤1 s, and it is linked with the constant temperature shell to maintain the viscosity within ±5% of the set value; the parallelism of the narrow slit scraper nozzle gap is ≤0.02 mm, the hardness of the elastic extrusion roller coating is Shore A 60–80, and the gap can be finely adjusted to control the fiber volume fraction at 55–60%; in the online vision / laser monitoring system, the angle between the line structured light projection and the camera optical axis is 25–45°, used to detect the layup. Thickness deviation, loose fibers, and poor overlap are addressed. When the thickness deviation exceeds ±3%, a closed-loop correction of the winding angle / track and resin content is triggered. In the pre-setting and zone curing channels, the IR lamp distance from the layup is 80–150 mm, the power density is 8–15 kW / m², the zone curing curve is 80 / 120 / 150℃, and the heating rate is 2–5℃ / min. In the "pre-setting and zone curing" channel, IR (infrared technology) is used as a heating source to rapidly heat the layup surface through radiation to 50–60℃ for surface drying. Subsequently, by setting the zone curing temperature curve (e.g., 80 / 120 / 150℃), curing is completed by gradually increasing the temperature, improving the physicochemical properties of the resin, and ensuring that the material is cured in a very short time.

[0011] The sampling period of the intelligent central control system is 20–50ms. The controlled variables include hairiness index, single bundle tension, spread width, resin viscosity / temperature, layup thickness and surface defects. The actuator limits include: air knife pressure ±0.05MPa, incident angle ±5°, tension ±5%, oscillation frequency ±2Hz, narrow gap ±0.1mm or line voltage ±20N.

[0012] A low-hair epoxy winding molding process for glass fiber, applied to the aforementioned device, includes the following steps: S1 Yarn supply conditioning and preheating: The yarn bundle is conditioned at 20–25℃ and 45–55% relative humidity for ≥8 hours, and then gently preheated at 45–60℃; S2 Online hair suppression: The hairiness index is collected, and the air knife pressure / incident angle and static electricity neutralization are adjusted in a closed loop. If necessary, single-bundle tension fine-tuning and widening oscillation frequency are linked; S3 Widening and guiding: The width and uniformity of the widened filament bundle are controlled by ceramic combs and oscillation frequency widening, with a comb wrap angle ≤15°; S4 Impregnation and adhesive control: Impregnation is carried out at 25–40℃ and a viscosity of 200–800 mPa·s (±5%). The yarn bundles pass sequentially through the pre- and post-stage micro-vacuum chambers (−0.02~−0.06MPa), and exit through a narrow slit or extrusion roller to control the glue content. The glue content and target fiber volume fraction are set to 55–60% according to the layup plan. S5 Winding and Online Monitoring: Three-axis linkage realizes dynamic compensation of the set circumferential / helical angle and ±5° angle. The end uses secondary pressure rollers and dot-shaped IR pre-coagulation, and structured light height measurement and visual recognition closed-loop correction. S6 Pre-coagulation and Curing: IR rapid surface drying to 50–60℃, followed by zone curing (80 / 120 / 150℃). S7 Inspection and Post-processing: Hairiness, apparent Ra and porosity are sampled and inspected, and end processing and non-destructive testing are completed.

[0013] Preferably, the feather weight test adopts a standard lead and constant tension path, with a test length of 1000m, and collects the feather weight. According to the formula Conversion, of which The quality of the yarn through the length is determined; simultaneously, a calibration curve for the hairiness index is established, and the correlation coefficient R is calibrated. 2 ≥0.9; when the layup thickness deviation exceeds ±3% or there is fly / poor overlap, trigger winding angle fine adjustment ≤±1°, trajectory offset ≤±0.5mm and glue content fine adjustment ≤±2%.

[0014] Preferably, the yarn is made of epoxy direct yarn, and the preferred yarn specifications are: linear density deviation ±5%, moisture content ≤0.10%, combustible material (LOI) 0.55±0.15%, pH 4–6, fiber diameter tolerance ±1μm, and hairiness <0.010g / kg.

[0015] Preferably, the resin system is a bisphenol A type epoxy / anhydride curing system, the accelerator addition amount is 0.5–2.0 phr, and the gel time is coupled with the linear velocity to suppress resin sagging and secondary warping.

[0016] Overall configuration of the device The device, along the yarn bundle travel direction, comprises, in sequence: a multi-axis constant tension yarn feeder; an online fuzz detection and active fuzz suppression unit; a low-damage widening and guiding unit; a vacuum-constant temperature-constant viscosity epoxy impregnation unit; a triaxial linkage winding head and collaborative control module; an online vision / laser surface and an online vision / laser monitoring system; pre-curing and zoned curing channels; and an intelligent central control system. The structure and parameter windows of each unit are detailed in the claims and embodiments.

[0017] Key Units and Parameter Windows Online fuzz detection and active fuzz suppression: Industrial camera outputs fuzz index; Annular air knife parameters: incident angle 30–60°, slit 0.5–1.5mm, pressure 0.1–0.3MPa, annular inner diameter D. i =Ws+5~15mm; Static neutralizing rod ±10–30kV, installation distance 50–150mm.

[0018] Low-damage widening and guiding: ceramic comb radius R=0.3–0.8mm, over-comb wrap angle ≤15°; oscillation frequency widening device 2–8Hz, ±3–±8°; guide wheel Ra (surface roughness parameter) ≤0.05μm, diameter 20–60mm.

[0019] Impregnation and adhesive control: pre-stage / post-stage micro-vacuum -0.02~-0.04 / -0.03~-0.06MPa respectively, residence time 0.3–1.0s each; online viscosity 200–800mPa·s (±5%); narrow slit adhesive scraping gap 0.3–1.0mm, parallelism ≤0.02mm; or extrusion roller linear pressure 50–200N, Shore A (Shore A hardness) 60–80.

[0020] Winding head: Three-axis linkage of rotation / translation / oscillation, dynamic angle compensation ±5°; end secondary pressure roller and dotted IR pre-curing.

[0021] Online monitoring: Line structured light angle 25–45°, resolution ≤50μm; thickness deviation threshold ±3%.

[0022] Pre-curing / curing: IR distance 80–150mm, power density 8–15kW / m²; zone curing 80 / 120 / 150℃, temperature rise 2–5℃ / min.

[0023] Intelligent central control: sampling 20–50ms; controlled variables include hairiness index, tension, spread width, resin viscosity / temperature, layup thickness / defects; linked to air knife, tension, swing frequency, micro vacuum, glue gap / line pressure control and winding angle / track.

[0024] Molding process Yarn supply conditioning and preheating (S1): 20–25℃, RH (relative humidity) 45–55% ≥8h; preheating at 45–60℃.

[0025] Online hair suppression (S2): Closed-loop triggering of hair index, air knife, static electricity neutralization, and fine adjustment of tension and oscillation frequency.

[0026] Widening and Guiding (S3): Controls the uniformity of widening and the wrapping angle.

[0027] Impregnation and control (S4): 25–40℃, 200–800mPa·s (±5%), dual-cavity micro-vacuum, narrow slit / extrusion roller control, target V f =55–60%.

[0028] Winding and online monitoring (S5): Three-axis linkage, end secondary pressure roller and dotted IR pre-coagulation, visual / structured light closed-loop correction.

[0029] Pre-setting and curing (S6): IR surface drying to 50–60℃, zone curing curves 80 / 120 / 150℃.

[0030] Inspection and post-processing (S7): sampling inspection of hairiness, Ra and porosity, end processing and non-destructive testing.

[0031] The beneficial effects of this invention are: 1. Through a closed-loop linkage of "hair index → ​​air knife pressure / incident angle → static neutralization → tension / broadening fine adjustment", combined with the ring-shaped Coanda air knife, the filament bundle is 360° directionally pressed and the static electricity is neutralized to eliminate charged fly filaments, suppressing secondary scratching and hair regeneration induced by micro-vibration of the filament bundle; the end adopts secondary pressure roller + dotted IR pre-coagulation to reduce local fly filaments caused by springback.

[0032] 2. Low-damage widening (ceramic comb R-angle transition, oscillation frequency 2–8Hz) improves the uniformity of filament widening and reduces local frictional heat; the triaxial linkage winding head provides ±5° angle dynamic compensation to suppress trajectory error; online vision / structured light triggers correction for "flying filaments, gaps, and poor overlap", forming a closed loop of "detection-execution-correction", and the surface roughness Ra measured by the contact profilometer is typically reduced by 20–35%, the surface "resin enrichment / depletion" stripes are significantly converged, and the end step transition is smoother.

[0033] 3. The interlayer porosity measured by industry-standard methods (microscopic imaging / density method / ablation method) decreased from approximately 1.2–1.8% in the comparative scheme to 0.6–1.0% (typical value). The pore size distribution shifted to a smaller scale, and the number of interconnected pores was significantly reduced. Furthermore, the dual-cavity micro-vacuum (pre-stage degassing, post-stage wetting) + online viscosity closed loop (200–800 mPa·s, ±5%) ensured that the resin fully wetted and degassed the fiber bundle. Narrow slit / extrusion roller control enabled repeatable control of the target fiber volume fraction, reducing the origin of pores caused by resin depletion zones and insufficient penetration.

[0034] 4. Under the same specifications and load, the yarn breakage rate (measured in "number of yarn breaks per 10,000 meters") typically decreases by 30-50%, and the rework rate decreases by 20-40%. Due to the significant reduction in defect-triggered downtime and rework, the cycle time per piece increases by approximately 8-15%. The online lint suppression closed loop and trajectory / resin content closed loop reduce the chain loss of "low-frequency disturbance → defect → downtime / rework" in the production process. Gradient curing and point-like IR pre-curing suppress resin sagging and rebound, reducing the workload of secondary repairs. The stable operating time of the equipment is improved, and the overall cost decreases. Attached Figure Description

[0035] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only for this invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0036] Figure 1 This is a schematic diagram of the overall structure of the device; Figure 2 This is a schematic diagram of the online feather detection and air knife suppression unit structure; Figure 3 Schematic diagram of low-damage widening and guiding unit structure; Figure 4 A schematic cross-sectional view of the dual-cavity micro-vacuum impregnation and narrow-slit / extrusion roller adhesive control structure; Figure 5 This is a schematic diagram of the online vision / laser surface and layup monitoring setup; Figure 6 This is a schematic diagram showing the relationship between the process flow timing and closed-loop control.

[0037] The diagram is marked as follows: 100 Multi-axis constant tension yarn feeder; 200 Online hairiness detection and active hair suppression unit; 210 Backlight panel; 220 Yarn bundle; 230 Industrial camera; 240 Circular air knife; 241 Incident angle; 242 Nozzle gap; 243 Air supply; 250 Static neutralizing bar; 251 Neutralization distance; 300 Low-damage widening and guiding unit; 310 Ceramic comb; 320 Swing frequency widening device; 330 Ceramic guide wheel; 331 Widened width; 400 Impregnation unit; 401 Constant temperature housing; 402 Pre-stage micro vacuum chamber; 4 03 Post-stage micro-vacuum chamber; 402a Resin tank; 403a Resin tank; 402b Degassing port; 403b Degassing port; 405 Online viscometer; 410a Narrow slit scraper nozzle; 410b Elastic extrusion roller; 500 Winding head; 510 End secondary pressure roller; 520 Dotted IR pre-curing; 600 Online vision / laser monitoring system; 610a Oblique light source; 610b Backlight; 620 Laser projector; 630 Camera; 640 Algorithm unit; 700 Pre-curing and zoned curing channels; 800 Intelligent central control system. Detailed Implementation

[0038] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments.

[0039] Unless otherwise stated, terms are used in their usual sense in the art; "first / second" etc. are used only for distinction; "connection / linkage" may be direct or indirect.

[0040] A low-fuzz glass fiber epoxy winding molding process, applied to the above-mentioned low-fuzz glass fiber epoxy winding processing equipment (see the invention description section for details), includes the following steps: S1 yarn conditioning and preheating: The yarn bundle is conditioned for ≥8 hours at 20–25℃ and 45–55% relative humidity, and then gently preheated at 45–60℃; S2 Online Hair Suppression: Collects hair index, adjusts air knife pressure / incident angle and static electricity neutralization in a closed loop, and links single-beam tension fine-tuning and widening swing frequency when necessary; S3 Widening and Guiding: The width and uniformity of the filament bundle after widening are controlled by ceramic combs and oscillation frequency widening, with a comb wrap angle ≤15°; S4 Impregnation and Glue Control: At 25–40℃ and a viscosity of 200–800 mPa·s (±5%), the yarn bundles are sequentially passed through the front / back stage micro-vacuum chambers (−0.02~−0.06MPa), and the glue is controlled at the outlet through a narrow slit or extrusion roller. The glue content and target fiber volume fraction are set to 55–60% according to the layup plan. S5 winding and online monitoring: Three-axis linkage realizes dynamic compensation of setting circumferential / helical angle and ±5° angle, the end adopts secondary pressure roller and dot-shaped IR pre-condensation, and structured light height measurement and visual recognition closed-loop correction; S6 Pre-setting and Curing: IR rapid surface drying to 50–60℃, then proceed to zone curing (80 / 120 / 150℃). S7 Inspection and Post-processing: Perform random checks on hairiness, apparent Ra and porosity, and complete end processing and non-destructive testing.

[0041] The feather weight test employed a standard lead and constant tension path, with a test length of 1000m. Feathers were collected, weighed, and converted to g / kg. Simultaneously, a calibration curve of feather index versus g / kg was established, and the correlation coefficient R was calibrated. 2 ≥0.9.

[0042] The feather weight test employed a standard lead and constant tension path, with a test length of 1000m. Feather was collected and weighed, and the weight was converted to g / kg. Simultaneously, a calibration curve of feather index versus g / kg was established, and the correlation coefficient R was calibrated. 2 ≥0.9; When the layup thickness deviation exceeds ±3% or when there is fly wire / poor overlap, the trigger winding angle fine adjustment is ≤±1°, the trajectory offset is ≤±0.5mm, and the glue content fine adjustment is ≤±2%.

[0043] For use with epoxy direct yarn, the preferred yarn specifications are: linear density deviation ±5%, moisture content ≤0.10%, combustible matter (LOI) 0.55±0.15%, pH 4–6, fiber diameter tolerance ±1μm, and hairiness <0.010g / kg.

[0044] The resin system is a bisphenol A type epoxy / anhydride curing system, with an accelerator addition of 0.5–2.0 phr. The gel time is coupled with the linear velocity to suppress resin sagging and secondary warping.

[0045] In the above molding steps, the following should also be noted: (1) Materials and compatibility Suitable epoxy direct yarn: linear density deviation ±5%, moisture content ≤0.10%, combustible material (LOI) 0.55±0.15%, pH 4–6, fiber diameter tolerance ±1μm, hairiness <0.010g / kg (see the R&D report "High-Performance Epoxy Yarn for Water Treatment Membrane Shells"). Example resin system: Bisphenol A type epoxy / anhydride curing system, accelerator 0.5–2.0 phr, viscosity control at 25–40℃ 200–800 mPa·s, online viscosity control accuracy ±5%.

[0046] (2) Feather Index and Feather Weight Standardization Backlit vision is used to extract the yarn bundle edges at the pixel level, and the length, quantity, and density of the fibers are counted to output the fiber index. .

[0047] Using a standard feather collector, constant tension, and standard lead, feather mass was collected over a test length of 1000m. According to the formula Conversion, of which The mass of the yarn passing through the length.

[0048] Data collected under different working conditions ( Sample, Fit Or a piecewise linear relationship, An online conversion model is established, where 'a' represents the slope of the linear relationship, measuring the strength of the relationship between "feather quantity" H and "feather index" HI, and how feather quantity changes as the feather index increases. A large value of 'a' indicates that a small change in the feather index leads to a large change in feather quantity; conversely, a small value of 'a' indicates a weak relationship between the two. 'b' represents the intercept of the linear relationship. In the graph, it represents the value of feather quantity H when the feather index HI is 0. This constant term adjusts the intersection of the regression line and the y-axis, reflecting the baseline level of feather quantity without considering the influence of the feather index. By fitting a large amount of experimental data, the slope 'a' and the intercept 'b' can be obtained, thus forming a relatively accurate linear model to achieve online conversion of feather quantity. The construction of this model is crucial for real-time monitoring and adjustment of production processes.

[0049] (3) Control of gum content and volume fraction Fiber volume fraction is achieved through narrow slit / extrusion roller control. Target:

[0050] in, , The mass of fiber and resin per unit length. , For density.

[0051] For narrow gaps Or extrusion roller line pressing Perform a step scan to measure the amount of resin picked up per unit area. , fitting or The linear segment is used to determine the process settings and closed-loop coefficients.

[0052] Example 1 (Equipment Parameters and Operation) Yarn supply / environment: 22℃, RH50%, single bundle tension 30–45N, fluctuation ≤±2%.

[0053] Hair suppression: air knife incident angle 45°, gap 1.0mm, 0.18MPa; electrostatic neutralization rod ±20kV, distance 100mm.

[0054] Width extension: ceramic comb R=0.5mm, comb wrap angle ≤12°; oscillation frequency 4Hz, ±5°; guide wheel Ra≤0.05μm, diameter 40mm.

[0055] Impregnation: viscosity 400±20 mPa·s; pre- / post-stage micro-vacuum −0.04 / −0.05 MPa; slit width 0.6 mm; target =55–60%.

[0056] Winding: Linear speed 1.2–2.0 m / s; spiral ±15° / ±75° superposition; end secondary pressure roller + dotted IR pre-curing.

[0057] Curing: IR surface drying to 50–60℃; zone curing at 80 / 120 / 150℃, with a temperature increase of 3℃ / min.

[0058] Central Control (MPC): Sampling time 20ms; Limit Exceeding Matrix: When the feathering index exceeds the limit, the limit is exceeded by air knife ±0.05MPa + tension ±5% + oscillation frequency ±2Hz. The MPC algorithm adopts a linear state-space model.

[0059] Results: Hairiness ≤0.010g / kg; Filament / flickering events reduced by ≥60%; Surface Ra decreased by 20–35%; Circumferential and interlaminar shear strength fluctuations decreased.

[0060] Example 2 (Online Visual Loop Closure) Structured light angle 30°, baseline 150mm; resolution ≤40μm; thickness deviation threshold ±3%.

[0061] When the thickness deviation is greater than the threshold: winding angle fine-tuning ≤ ±1°, trajectory offset ≤ ±0.5mm, and glue content fine-tuning ≤ ±2%.

[0062] Defect categories: flying fibers, poor overlap, resin dripping; corresponding corrective strategies are issued by the central control unit.

[0063] Example 3 (Standard Test for Feather Quantity) Path: Standard guide wheel, same material, specified wrap angle; tension = median production tension.

[0064] Length: 1000m; weighing accuracy: 0.1mg; converted to g / kg; one random inspection per channel per shift.

[0065] Data is collected synchronously with HI and re-labeled every six months or in the event of major changes. Example

[0066] Comparison A: No air blade or static electricity neutralization, only visual alarm → frequent exceedance of the fuzz index and obvious end fuzz.

[0067] Comparison B: Material-side wetting agent optimization only → Furting peaks remain significant at high-speed / large-angle transitions.

[0068] Conclusion: The present invention significantly controls fuzz and defects under complex layup / high-speed conditions.

[0069] Safety and Maintenance The air knife separates oil and water, ensuring clean and dry air supply; the IR heating zone is equipped with temperature control and light shielding; the electrostatic neutralization rod is well grounded; the viscometer is calibrated regularly; and the vacuum system is equipped with oil mist filtration and a buffer tank.

[0070] Comparison with existing technologies This invention forms a complete, systematic low-feather solution by combining an online closed loop of "feather detection - air knife tamping - electrostatic neutralization - tension / broadening fine-tuning" with "dual-cavity micro-vacuum + online viscosity closed loop + narrow slit / extrusion roller adhesive control" for impregnation-adhesive steady-state control, and with visual / structured light monitoring and zoned curing. This solution is superior to single-point improvement solutions that only address the material side or only the detection side.

[0071] Those skilled in the art should understand that the discussion of any of the above embodiments is merely exemplary and is not intended to imply that the scope of the invention (including the claims) is limited to these examples; within the framework of the invention, the technical features of the above embodiments or different embodiments can also be combined, the steps can be implemented in any order, and there are many other variations of the different aspects of the invention as described above, which are not provided in the details for the sake of brevity.

[0072] This invention is intended to cover all such substitutions, modifications, and variations that fall within the broad scope of the appended claims. Therefore, any omissions, modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A low-fuzz glass fiber epoxy winding processing device, characterized in that, The system includes, sequentially arranged along the yarn bundle running direction: a multi-axis constant tension yarn feeder (100), which has an independent tension channel, a single bundle tension of 20–60N, and tension fluctuation ≤±2%; and an online hairiness detection and active hair suppression unit (200), including an industrial camera (230), an annular air knife (240), and an electrostatic neutralization bar (250). The industrial camera (230) is used to output the yarn bundle hairiness index, and the annular air knife (240) is arranged around the yarn bundle path, with a nozzle incident angle of 30–60°, a nozzle gap of 0.5–1.5mm, and an air supply pressure of 0.1–0. 3MPa, the electrostatic neutralizing rod (250) outputs ±10–30kV and the distance between it and the yarn bundle is 50–150mm; low-damage spreading and guiding unit (300), including ceramic comb (310), oscillation frequency spreader (320) and ceramic guide wheel (330), wherein the ceramic comb (310) has a comb tooth R angle of 0.3–0.8mm and a comb wrap angle ≤15°, the oscillation frequency spreader (320) has an oscillation frequency of 2–8Hz and an oscillation angle of ±3–±8°, and the surface roughness Ra of the ceramic guide wheel (330) is ≤0.05μm; vacuum-constant temperature-constant viscosity epoxy impregnation. Unit (400) includes a pre-stage microvacuum chamber (402) and a post-stage microvacuum chamber (403) connected in series, a constant temperature shell (401), an online viscometer (405), and an outlet narrow slit scraper nozzle (410a) or an elastic extrusion roller (410b). The vacuum degree of the pre-stage microvacuum chamber (402) is −0.02 to −0.04 MPa, and the vacuum degree of the post-stage microvacuum chamber (403) is −0.03 to −0.06 MPa. The online viscometer (405) is used to stabilize the resin viscosity at 200–800 mPa·s with a control accuracy of ±5%. The narrow slit scraper nozzle (401) is... 10a) Gap 0.3–1.0 mm or elastic extrusion roller (410b) linear pressure 50–200 N; a three-axis linkage winding head (500) and a collaborative control module, which has three-axis linkage for rotation / translation / oscillation and provides ±5° angle dynamic compensation and end secondary pressure roller (510) and dot-shaped IR pre-curing (520); online vision / laser surface and online vision / laser monitoring system (600), including oblique light / backlight illumination and line structured light height measurement, with a measurement resolution of ≤50 μm; pre-curing and zoned curing channels (700), including short-wave IR surface drying and multi-zone convection curing; The intelligent central control system (800) is based on multivariate model predictive control of hairiness index, tension, spreading width, resin viscosity / temperature, and visual defects / thickness. It is used to perform closed-loop adjustment of air knife parameters, yarn feeding tension, spreading swing frequency, micro-vacuum degree and glue control gap / line pressure, winding angle and trajectory.

2. The low-fuzz glass fiber epoxy winding processing device according to claim 1, characterized in that, The inner diameter of the annular air knife (240) and the width of the expanded filament bundle satisfy: D i =Ws+5~15mm allowance, the axial distance from the air knife to the yarn bundle is 10–50mm.

3. The low-fuzz glass fiber epoxy winding processing apparatus according to claim 1 or 2, characterized in that, The industrial camera (230) uses pixel-level edge recognition and length / quantity / density statistics, with a frame rate of ≥60fps, and its field of view covers 5–10mm of redundancy on both sides of the yarn bundle. It also establishes a linear or piecewise linear correspondence between the hairiness index and the hairiness amount (g / kg) through calibration.

4. The low-fuzz glass fiber epoxy winding processing device according to claim 1, characterized in that, The ceramic comb (310) is made of zirconium oxide or silicon carbide ceramic, and the tooth spacing is configured according to the linear density and the number of single filaments. The ceramic guide wheel (330) is made of zirconium oxide or silicon nitride and has a diameter of 20–60 mm.

5. The low-fuzz glass fiber epoxy winding processing apparatus according to claim 1, characterized in that, The impregnation residence time of each of the front and rear micro-vacuum cavities (402, 403) is 0.3–1.0 s; the sampling period of the online viscometer (405) is ≤1 s, and it is linked with the constant temperature shell (401) to maintain the viscosity within ±5% of the set value; the parallelism of the slit scraper nozzle (410a) is ≤0.02 mm; the hardness of the rubber coating of the elastic extrusion roller (410b) is Shore A 60–80, and the gap can be finely adjusted to control the fiber volume fraction at 55–60%; in the online vision / laser monitoring system (600), the angle between the line structured light projection and the camera optical axis is 25–45°, which is used to detect the layup thickness deviation, flyaways, and poor overlap; when the thickness deviation exceeds When the value exceeds ±3%, a closed-loop correction of the winding angle / trajectory and glue content is triggered; in the pre-curing and zone curing channel (700), the IR lamp distance from the layup is 80–150 mm, the power density is 8–15 kW / m², the zone curing curve is 80 / 120 / 150℃, and the heating rate is 2–5℃ / min; the sampling period of the intelligent central control system (800) is 20–50 ms, and the controlled variables include the hairiness index, single bundle tension, spread width, resin viscosity / temperature, layup thickness and surface defects. The actuator limit includes: air knife pressure ±0.05 MPa, incident angle ±5°, tension ±5%, oscillation frequency ±2 Hz, narrow gap ±0.1 mm or line voltage ±20 N.

6. A low-fuzz glass fiber epoxy winding molding process, applied to the low-fuzz glass fiber epoxy winding processing apparatus according to any one of claims 1-5, characterized in that, Includes the following steps: S1 yarn conditioning and preheating: The yarn bundle is conditioned for ≥8 hours at 20–25℃ and 45–55% relative humidity, and then gently preheated at 45–60℃; S2 Online Hair Suppression: Collects hair index, adjusts air knife pressure / incident angle and static electricity neutralization in a closed loop, and links single-beam tension fine-tuning and widening swing frequency when necessary; S3 Widening and Guiding: The width and uniformity of the filament bundle after widening are controlled by ceramic combs and oscillation frequency widening, with a comb wrap angle ≤15°; S4 Impregnation and Glue Control: At 25–40℃ and a viscosity of 200–800 mPa·s (±5%), the yarn bundles are sequentially passed through the front / back stage micro-vacuum chambers (−0.02~−0.06MPa), and the glue is controlled at the outlet through a narrow slit or extrusion roller. The glue content and target fiber volume fraction are set to 55–60% according to the layup plan. S5 winding and online monitoring: Three-axis linkage realizes dynamic compensation of setting circumferential / helical angle and ±5° angle, the end adopts secondary pressure roller and dot-shaped IR pre-condensation, and structured light height measurement and visual recognition closed-loop correction; S6 Pre-setting and Curing: IR rapid surface drying to 50–60℃, then proceed to zone curing (80 / 120 / 150℃). S7 Inspection and Post-processing: Perform random checks on hairiness, apparent Ra and porosity, and complete end processing and non-destructive testing.

7. The low-fuzz glass fiber epoxy winding molding process according to claim 6, characterized in that, The feather weight test uses a standard lead and constant tension path, with a test length of 1000m, and collects the feather mass. According to the formula Conversion, of which The quality of the yarn through the length is determined; simultaneously, a calibration curve for the hairiness index is established, and the correlation coefficient R is calibrated. 2 ≥0.

9.

8. The low-fuzz glass fiber epoxy winding molding process according to claim 6, characterized in that, When the layup thickness deviation exceeds ±3% or when there is fly wire / poor overlap, the trigger winding angle fine adjustment is ≤±1°, the trajectory offset is ≤±0.5mm, and the glue content fine adjustment is ≤±2%.

9. The low-fuzz glass fiber epoxy winding molding process according to claim 6, characterized in that, For use with epoxy direct yarn, the preferred yarn specifications are: linear density deviation ±5%, moisture content ≤0.10%, combustible matter (LOI) 0.55±0.15%, pH 4–6, fiber diameter tolerance ±1μm, and hairiness <0.010g / kg.

10. The low-fuzz glass fiber epoxy winding molding process according to claim 6, characterized in that, The resin system is a bisphenol A type epoxy / anhydride curing system, with an accelerator addition of 0.5–2.0 phr. The gel time is coupled with the linear velocity to suppress resin sagging and secondary warping.

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