High-stability vertical untwisting frame capable of being automatically regulated and controlled

Abstract

The invention discloses a high-stability automatic-regulation vertical untwisting frame, which breaks through the technical bottlenecks of the industry through four innovations: firstly, a passive traction structure is replaced by an active rotating motor array, speed oscillation is inhibited from a dynamic source, tension fluctuation is stably controlled within + / -5%, and the requirement of a high-speed untwisting working condition is met; secondly, the vertical matrix type layout is fused with a self-locking suspension mechanism and a damping design, parallel operation of multiple rope bundles is achieved on the premise of space compression, and power consumption of unit productivity is reduced; thirdly, the intelligent synchronous control system is synchronized with millisecond start and stop through dynamic torque compensation, so that the wire stranding failure rate is reduced, and the stop time is greatly shortened; fourthly, a rope divider system supported by an inner support achieves spatial isolation of a guide rope path and auxiliary movement of a rotating shaft through rope holes arranged at intervals, and the risk that multiple ropes are wound in parallel is eliminated; according to the technology, the problems of wire breaking and winding in prepreg production are solved, a production line is promoted to unattended continuous operation and evolution, and core equipment support is provided for efficient manufacturing of composite material components.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of composite material prepreg production equipment, and particularly relates to a vertical untwisting frame with high stability and automatic regulation. BACKGROUND

[0002] In the production of high-performance composites, the untwisting machine bears the core function of relieving the twisted state of the fibers, and its performance directly affects the consistency of fiber orientation and the stability of mechanical properties of the prepreg. According to the industry analysis of "Composite Manufacturing Technology Review", the modern prepreg production line puts forward two rigid requirements for the untwisting process: first, the fiber tension fluctuation should be maintained within ±5% under continuous production conditions to avoid material defects caused by broken filaments or loose twists; second, the high-speed untwisting operation should be realized at a speed of more than 30 meters per minute, and the failure rate of the twisting line should be controlled below 5%, which requires the equipment to have precise cooperative driving capability and space intensive design.

[0003] The current mainstream untwisting equipment generally adopts a wall-mounted structure, with the guide rope bundle vertically suspended on the side wall of the installation frame, and the fiber bundle is drawn out from the top end of the rope bundle to the traction unit. This structure has some defects:

[0004] 1. Kinetic instability problem: the rotation of the rope bundle completely depends on the one-way traction of the end tension motor (see "Textile Machinery Dynamics", Li, 2020). During the start and stop stage, speed oscillation occurs due to inertia lag. The actual test data shows the following table. When the acceleration exceeds 0.5 m / s 2 , the tension fluctuation of the traditional equipment reaches ±15%-20%, which is far beyond the requirement of the prepreg process.

[0005] Operating condition Tension fluctuation range Breakage rate per 1000 hours Constant speed 2 m / s ±12％ 3.2 Variable speed 0.5 m / s 2 ]] ±18％ 8.7

[0006] 2. Frequent winding failure: the passive rotation mode causes the speed difference between the inner and outer layers of the rope bundle (as disclosed in patent

[0007] CN202010578XX), and the difference in friction coefficient between the layers when multiple fiber bundles are parallel causes twisting. Industry reports show that the downtime due to winding failure accounts for 15%-20% of the total working hours of traditional equipment.

[0008] 3. Low space efficiency: the wall-mounted design requires a lateral maintenance channel, and a single device occupies an area of 1.8 m2, which seriously restricts the layout of high-density production lines.

[0009] Currently, the expansion of large-scale composite component production is driving the prepreg production towards unattended and high-speed continuous development. However, the existing untwisting technology cannot meet the new requirements, and there are some technical drawbacks as follows:

[0010] The market requires that when the untwisting speed is ≥35 m / min, the tension fluctuation should be ≤±5%, but the actual test value of the traditional equipment is only ±15%.

[0011] Automated production line requires monthly downtime < 2 hours, and wall-mounted device loses 48 man-hours per month due to manual untwisting operation.

[0012] These technical disadvantages give rise to the core idea of the present application, which replaces the passive traction mode with active driving architecture, achieves dynamic balance through motor coordination control, and breaks through the space limit by using vertical matrix layout. SUMMARY

[0013] According to the traditional wall-mounted untwisting device proposed in the background art, there are significant defects in the passive traction mode;

[0014] Firstly, the rope bundle rotation depends on the end-on end one-way tension, and the inertia lag in the start-stop stage causes a tension fluctuation of ±15% or more, far exceeding the rigid standard of ±5% for prepreg process;

[0015] Secondly, the speed difference between the inner and outer layers of the rope bundle leads to frequent wire twisting failure, with an average downtime of 48 man-hours per month;

[0016] Thirdly, the design of the lateral maintenance channel makes the single unit occupy an area of up to 1.8 square meters, restricting the intensive development of the production line.

[0017] To break through the above technical bottlenecks, we urgently need a new untwisting architecture with active collaborative driving capability and high space utilization, based on which the present application proposes a high-stability automatic control vertical untwisting frame, which realizes the synchronous leap of dynamic performance and space efficiency by reconstructing the driving mechanism and space layout.

[0018] A high-stability automatic control vertical untwisting frame is composed of a three-dimensional frame supported by a solid alloy support.

[0019] The frame is divided into multiple independent bearing areas, each of which is equipped with a horizontally arranged bearing platform.

[0020] Each bearing area is provided with a door-shaped inner support, which is composed of two vertical supports and a horizontal support, and a rope divider is installed on each side of each support of the door-shaped inner support. The rope divider is a metal strip with multiple rope holes.

[0021] The bearing platform is made of high-strength alloy plate, and its thickness is designed to be 1.2 times the diameter of the mounting hole, which significantly enhances the bending stiffness and bearing stability of the platform.

[0022] On the bearing platform, mounting holes are precisely machined in an equidistant matrix arrangement, and wear-resistant insulating bushings are embedded in the inner wall of the holes.

[0023] This matrix arrangement design not only provides a basis for the subsequent precise positioning of the rotating motor, but also effectively avoids static damage and equipment wear caused by direct friction of metal parts.

[0024] Compared with the limitations of the single-row layout of traditional wall-mounted demilling machines, the modular matrix layout of the device significantly improves the processing capacity of the device per unit floor area, while integrating the necessary maintenance channels inside the frame, significantly reducing the floor area occupied by a single device.

[0025] The installation method of the rotating motor as the core driving unit has the following innovations:

[0026] The motor housing extends a ring-shaped bearing platform at the top, with an outer diameter greater than the inner diameter of the mounting hole on the bearing platform. By suspending and embedding the ring-shaped bearing platform in the mounting hole, stable self-locking installation of the motor is achieved, and the motor axis is strictly perpendicular to the bearing platform plane.

[0027] The lower surface of the ring-shaped bearing platform is specially provided with a shock-absorbing rubber layer to effectively absorb high-frequency vibrations during device operation, and the upper surface integrates a rotary encoder for real-time and accurate monitoring of the motor speed. The output shaft of the rotating motor is coaxially fixed to the tray.

[0028] The tray surface is carefully designed with anti-slip patterns and equipped with removable positioning retaining rings, providing double protection for the stability of the guide rope bundle during vertical placement and completely eliminating radial slipping.

[0029] After the rope head of the guide rope bundle is introduced from the side, it first passes through the rope hole of the corresponding door-type inner support, and then is guided to the tension motor by the rope distributor.

[0030] The spacing between the rope holes of the rope distributor is greater than the diameter of the guide rope, ensuring that each guide rope does not contact each other in the path, and the rope hole is provided with a rotating shaft that can freely rotate when the guide rope is pulled, assisting the smooth movement of the guide rope, significantly reducing friction resistance and preventing mutual entanglement of the guide ropes.

[0031] The design of this complete active driving system fundamentally changes the passive traction mode of traditional devices relying on end tension, achieving active rotation of the rope bundle, thereby solving the tension fluctuation problem caused by inertia lag during the start and stop stages at the source, and effectively solving the entanglement problem of multiple ropes running in parallel through the rope distributor structure.

[0032] The key innovation of the high-stability automatic control vertical demilling frame mentioned in this paper lies in the intelligent collaborative operation between the tension motor and the rotating motor through the synchronous controller.

[0033] The synchronous controller implements a triple-core control strategy:

[0034] First, precisely control the rotation direction of the rotating motor to ensure that it always matches the rope exit direction of the guide rope bundle, thus completely eliminating the difference in linear velocity between the inner and outer layers of the rope bundle;

[0035] Secondly, the rope winding linear speed of the tension motor and the rope unwinding angular speed of the rotation motor are matched in real time to ensure that the winding and unwinding speeds are strictly synchronized.

[0036] Furthermore, closed-loop dynamic adjustment based on real-time monitored torque difference precisely compresses the fluctuation range of rope tension to within ±5%, which is significantly better than the level of traditional equipment.

[0037] Finally, the synchronous start and stop response of the rotary motor and the tension motor at the millisecond level was achieved, completely avoiding speed oscillation. Actual tests showed that the wire breakage rate was successfully reduced to below 0.5 times / thousand hours.

[0038] To ensure the overall stability of the equipment and the ease of operation, the bottom of the support frame for the three-dimensional frame is equipped with height-adjustable feet and a high-precision level.

[0039] This design allows the levelness error of the frame mounting plane to be precisely controlled within ≤0.1mm / m. At the same time, the positioning retaining ring on the tray adopts a quick-release design. Combined with the optimized operation process, the replacement of a single guide rope bundle can be completed in 30 seconds. This maintenance efficiency is significantly improved compared to traditional wall-mounted equipment, greatly reducing unplanned downtime.

[0040] Beneficial effects:

[0041] This vertical untwisting frame breaks through industry technical bottlenecks through four major innovations: First, it replaces the passive traction structure with an active rotating motor array, suppressing speed oscillations from the source of dynamics and keeping tension fluctuations stable within ±5%, meeting the requirements of high-speed untwisting conditions; Second, the vertical matrix layout integrates a self-locking suspension mechanism and shock absorption design, enabling parallel operation of multiple rope bundles under space compression, reducing power consumption per unit capacity; Third, the intelligent synchronous control system significantly reduces the strand failure rate and greatly shortens the average monthly downtime through dynamic torque compensation and millisecond-level start-stop synchronization; Fourth, the addition of a portal-type internal support and rope separator structure isolates the guide rope path through the rope hole spacing and uses the internal rotating shaft of the rope hole to assist movement, completely eliminating friction and entanglement between guide ropes, further improving the reliability of system operation. This technology not only solves the persistent problems of wire breakage and entanglement in prepreg production, but also promotes the evolution of production lines towards unattended continuous operation, providing core equipment support for the efficient manufacturing of large composite material components. Attached Figure Description

[0042] Fig. 1 This is a schematic diagram of a highly stable, automatically adjustable vertical untwisting frame;

[0043] Fig. 2 This is a schematic diagram of the installation of guide rope bundles for a highly stable, automatically adjustable vertical untwisting frame;

[0044] Fig. 3 This is a schematic diagram of the operation of a tension motor in a highly stable, automatically adjustable vertical untwisting frame;

[0045] Fig. 4 This is a schematic diagram of a traditional wall-mounted untwisting device, which is a highly stable, automatically adjustable vertical untwisting frame.

[0046] Fig. 5 This is a schematic diagram of the operation of a traditional wall-mounted untwisting device, which is a highly stable and automatically adjustable vertical untwisting frame.

[0047] In the diagram, 1. Guide rope bundle, 2. Tray, 3. Rotating motor, 4. Untwisting frame, 5. Tension motor, 6. Traditional wall-mounted untwisting device, 7. Rope separator. Detailed Implementation

[0048] To enhance understanding of the present invention, the invention will be further described in detail below with reference to embodiments and accompanying drawings. These embodiments are only for explaining the invention and do not constitute a limitation on the scope of protection of the invention.

[0049] 1. Guide rope bundle, 2. Tray, 3. Rotary motor, 4. Untwisting frame, 5. Tension motor, 6. Traditional wall-mounted untwisting device, 7. Rope separator.

[0050] The following will introduce the structural composition and spatial layout of a highly stable, automatically adjustable vertical untwisting frame 4, such as... Fig. 1 , 2 As shown in Figure 3, this highly stable, automatically adjustable vertical untwisting frame 4 is composed of the following core components:

[0051] Three-dimensional frame: It is formed by several alloy brackets. The frame is divided into multiple independent load-bearing areas. Each load-bearing area is equipped with a horizontal load-bearing platform and a portal frame.

[0052] Matrix mounting holes: arranged in an equally spaced array on the support platform, with wear-resistant insulating bushings embedded in the inner wall of the holes to avoid electrostatic damage caused by metal friction.

[0053] Rotary motor 3: It is suspended and embedded in the mounting hole via an annular support platform on the top of the housing, ensuring that the motor axis is strictly perpendicular. The lower surface of the support platform is equipped with a shock-absorbing rubber layer, and the upper surface integrates a rotary encoder.

[0054] Tray 2: Coaxially fixed to the output shaft of the rotating motor 3, located above the support platform, its surface is provided with anti-slip texture and a detachable positioning retaining ring, used to fix the vertical position of the guide rope bundle 1.

[0055] Guide rope bundle 1: Guide rope bundle 1 is a rope bundle to be untwisted formed by winding guide rope. Its rope end is led out from the side, first passing through the rope hole of the rope separator 7 on the corresponding portal frame, and then pulled to the tension motor 5 through the rope hole. The guide rope bundle is vertically placed on the tray 2.

[0056] Portal internal support: Located within the load-bearing area, it consists of two vertical supports and one horizontal support connected together.

[0057] Rope separator 7: A metal strip with multiple rope holes, fixedly installed on the side of each bracket of the portal frame. The rope holes are equipped with a freely rotatable shaft. The guide rope leading from the guide rope bundle 1 first passes through the rope hole of the rope separator 7 and then is guided to the tension motor 5. The spacing between the rope holes ensures that the guide ropes do not contact each other.

[0058] Synchronous controller: Real-time linkage control of rotary motor 3 and tension motor 5 to achieve speed matching, steering synchronization and millisecond-level start and stop.

[0059] Bracket adjustment mechanism: The bottom of the bracket is equipped with height adjustment feet and a level to ensure that the horizontal error of the frame installation plane is ≤0.1mm / m.

[0060] Furthermore, the following will compare the operation of the untwisting frame 4 in the traditional wall-mounted untwisting device 6 with the new technology, such as... Fig. 4 , 5 As shown:

[0061] The guide rope bundle 1 is vertically suspended from the side wall support and has no active drive device.

[0062] The rotation of the rope bundle relies entirely on the unidirectional traction force of the end tension motor 5, resulting in:

[0063] Inertial hysteresis: During the start-up and shutdown phases, the speed oscillations caused by the inertia of the rope bundle result in measured tension fluctuations far exceeding the ±5% process requirement.

[0064] Linear speed difference: The fibers in the inner and outer layers of the rope bundle have a speed difference due to passive rotation, with the inner layer being slower and the outer layer being faster, which can cause twisting failure.

[0065] Space inefficiency: The lateral maintenance access makes a single unit occupy an area of ​​1.8㎡.

[0066] The innovative operation and advantages of a highly stable, automatically adjustable vertical untwisting frame 4, such as... Fig. 1 , 2 As shown in Figure 3, the above-mentioned drawbacks are addressed through four major refactoring methods:

[0067] Active drive replaces passive traction: The rotating motor 3 directly drives the tray 2 to rotate actively, so that the rope bundle is released synchronously, eliminating start-stop inertia;

[0068] Vertical matrix layout: Multiple load-bearing areas are vertically stacked within a three-dimensional frame, integrating maintenance access within the frame, significantly reducing the footprint of a single unit;

[0069] Dynamic synchronization control: The synchronization controller matches the rope release angular velocity of the rotating motor 3 and the rope take-up linear velocity of the tension motor 5 in real time, and dynamically adjusts the torque difference to completely eliminate the speed difference between the inner and outer layers;

[0070] Rope separating and anti-tangling structure: The rope separator 7 precisely isolates the paths of each guide rope, and the rotating shaft inside the rope hole assists the smooth movement of the guide rope, effectively preventing the tangling of multiple ropes when working in parallel.

[0071] Furthermore, a synchronous controller for a highly stable, automatically adjustable vertical untwisting frame 4 executes the following closed-loop control strategy:

[0072] Steering control: The rotation direction of the rotating motor 3 is always consistent with the direction of rope exiting the rope bundle;

[0073] Speed ​​matching: Based on the rotational speed feedback from the rotary encoder, the linear speed v of the rope winding motor 5 is dynamically adjusted to satisfy v=ω*r, where ω is the angular velocity of the rotary motor 3 and r is the radius of the rope bundle;

[0074] Tension stability: The torque difference between the two motors is calculated in real time, and the motor output is adjusted through a PID algorithm to control the rope tension fluctuation within ±5%.

[0075] Start-stop synchronization: Both motors receive the same start-stop signal with a response delay of ≤10ms, avoiding speed oscillation.

[0076] Implementation example: Taking a carbon fiber prepreg production line as an example, the equipment operation process is illustrated as follows:

[0077] Step 1: Device Initialization

[0078] Place the eight guide ropes bundle 1 vertically inside the positioning retaining ring of the tray 2;

[0079] Adjust the support feet to ensure the overall levelness of the frame, as shown by the level indicator, is ≤0.1mm / m.

[0080] The rope ends of each guide rope bundle 1 are pulled along a predetermined path and threaded into the designated rope holes of the rope distributor 7 on the corresponding portal frame.

[0081] Step 2: Start the job

[0082] The synchronous controller sends a start command, and the rotary motor 3 and the tension motor 5 start synchronously within 10ms;

[0083] The rotating motor 3 actively rotates the tray 2 at an angular velocity ω = 120 r / min;

[0084] The tension motor 5 synchronously winds up the rope at 1.26 m / s, pulling the guide rope to slide smoothly on the rotating shaft inside the rope hole of the rope distributor 7.

[0085] Step 3: Dynamic Adjustment

[0086] Based on the detected increase in the rotational speed of the rotating motor 3 and the preset initial radius of the rope bundle, the synchronous controller maintains the rope winding speed of the tension motor 5 at a constant 1.26 m / s.

[0087] During this period, fluctuations in torque difference triggered PID regulation, and the tension sensor reported a stable tension value of 49.8N±2.5N.

[0088] Step 4: Emergency Stop

[0089] The production line suddenly stopped, and both motors braked synchronously within 8ms.

[0090] The shock-absorbing rubber layer absorbs the impact of rotational inertia, and the instantaneous peak tension at the rope end is only 52N, with no broken strands or loose twists.

[0091] Step 5: Maintenance Operation

[0092] Remove the positioning retaining ring of tray 2 and replace the empty rope bundle within 30 seconds. No side passage is required. When replacing, the guide rope only needs to be pulled out from the rope hole of rope separator 7, which is convenient to operate.

[0093] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A highly stable, automatically adjustable vertical untwisting frame, characterized in that, include: Guide rope bundle, tray, rotary motor, untwisting frame, and tension motor; The untwisting frame is supported by several supports to form a three-dimensional frame, which has several load-bearing areas, each of which is equipped with a horizontal load-bearing platform; The bearing area is equipped with a portal-type internal support, which is composed of two vertical supports and one horizontal support connected together. The support platform has several array-arranged mounting holes. The top of the housing of the rotary motor extends into a ring-shaped support platform, the outer diameter of which is larger than the inner diameter of the mounting hole. The rotating motor is suspended and embedded in the mounting hole via the support platform, and the motor axis is perpendicular to the support platform. The tray is coaxially connected to the output shaft of the rotating motor and is located above the support platform; The tray is used to vertically support the guide rope bundle; Each support of the portal frame is equipped with a rope divider, which is a metal strip with multiple rope holes. The guide rope pulled out from the side of the guide rope bundle first passes through the rope holes of the rope divider, and then is guided by the rope divider to the tension motor. The spacing between the rope holes of the rope separator is greater than the diameter of the guide rope, and the guide ropes do not come into contact with each other during the passage. The tension motor is located at the end of the rope exit path of the rope bundle, and it is synchronized with the rotation motor through a synchronous controller to achieve matching of the winding and unwinding speeds and synchronous control of the direction.

2. The high-stability, automatically adjustable vertical untwisting frame according to claim 1, characterized in that: The synchronization controller is configured as follows: The rotation direction of the control motor is consistent with the rope output direction of the guide rope bundle; Make the rope-taking speed of the tension motor equal to the rope-releasing speed of the rotary motor; Synchronous start and stop of rotating motors and tension motors.

3. The high-stability, automatically adjustable vertical untwisting frame according to claim 1, characterized in that: The mounting holes are arranged in a matrix with equal spacing, and the inner walls of the holes are provided with wear-resistant insulating bushings.

4. The high-stability, automatically adjustable vertical untwisting frame according to claim 1, characterized in that: The upper surface of the tray is provided with anti-slip texture and a detachable positioning retaining ring.

5. A highly stable, automatically adjustable vertical untwisting frame according to claim 1, characterized in that: The supporting platform is an alloy plate with a thickness of 1.2 times the diameter of the mounting holes.

6. The high-stability, automatically adjustable vertical untwisting frame according to claim 1, characterized in that: The lower surface of the annular support platform of the rotating motor is provided with a shock-absorbing rubber layer, and the upper surface is provided with a rotary encoder to monitor the rotation speed.

7. The high-stability, automatically adjustable vertical untwisting frame according to claim 1, characterized in that: The bracket is equipped with a height-adjustable foot cup and a level at its bottom.

8. A highly stable, automatically adjustable vertical untwisting frame according to claim 1, characterized in that: The rope separator has a rotating shaft inside its rope hole. This rotating shaft rotates when the guide rope is pulled by the tension motor, thus assisting the guide rope to move smoothly.

9. A highly stable, automatically adjustable vertical untwisting frame according to claim 2, characterized in that: The synchronous controller dynamically adjusts the torque difference between the rotary motor and the tension motor to ensure that the tension fluctuation range of the guide rope bundle is ≤±5%.

10. A highly stable, automatically adjustable vertical untwisting frame according to claim 1, characterized in that: The rope separator is fixedly installed on the side of the bracket of the portal frame via its metal strip side.

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