Multi-station cooperative efficient production process for automatic weaving of carbon fiber pipes

Abstract

The invention discloses a multi-station cooperative efficient production process for carbon fiber pipe automatic weaving, and the process comprises the following modules: a multi-dimensional tension monitoring module which is used for deploying a fiber grating sensor array along a fiber path, and collecting the axial / transverse tension data of a fiber bundle in real time; the environment compensation module integrates a temperature and humidity sensor and an air pressure monitoring device, and constructs an environment disturbance model according to the following specific formula: Finv = 0.05 deltaT + 0.03 deltaH + 0.02 deltaP; the dynamic regulation and control actuator adopts a micro-displacement platform driven by piezoelectric ceramics; and the intelligent decision control module is used for controlling the dynamic regulation and control actuator to carry out tension control by obtaining the measurement data of the environment compensation module and the monitoring data of the multi-dimensional tension monitoring module, and the control formula is G = 0.2 mu m / N. Through four innovations of multi-dimensional perception, environment compensation, high-speed execution and intelligent decision making, precision and self-adaption of carbon fiber tension control are achieved, and the method is particularly suitable for carbon fiber pipe production work with strict mechanical property requirements.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of carbon fiber composite material manufacturing, in particular to a multi-station coordinated efficient production process for automatic weaving of carbon fiber pipes. BACKGROUND

[0002] As a core breakthrough in the field of advanced composite material manufacturing, the automatic weaving technology of carbon fiber pipes realizes a leap from traditional manual weaving to digital and intelligent production by precisely controlling the spatial direction and interlacing density of carbon fiber bundles through mechanical devices. This technology deeply integrates material science, precision mechanical automation, and multi-axis computer control technology, and its weaving precision can reach 0.05mm level, with production efficiency improved by more than 300% compared with traditional processes. It has become a key supporting technology for aerospace vehicle structures, new energy vehicle lightweight components, and high-end industrial equipment manufacturing. However, the existing carbon fiber weaving process still has four systemic defects in the tension control link, which seriously restricts the stability of product quality and the further improvement of production efficiency:

[0003] Fixed parameter control: The traditional tension control system uses open-loop control, and the parameters cannot be adjusted after being set to adapt to environmental changes or material batch differences, resulting in a tension fluctuation range of ±8N.

[0004] Single detection method: Only a tension sensor is installed at the fiber inlet, which cannot monitor the dynamic tension changes of the fiber bundle during the weaving process, and the defect detection is lagging.

[0005] Insufficient adjustment speed: The response time of the mechanical adjustment mechanism is ≥50ms, which cannot meet the real-time regulation and control requirements of high-speed weaving (>300mm / s).

[0006] Ignoring environmental interference: The influence of temperature, humidity, and air pressure changes on the mechanical properties of the fiber is not considered, and the scrap rate increases by 20%-30% when used in the southern plum rain season or highland areas.

[0007] Therefore, a multi-station coordinated efficient production process for automatic weaving of carbon fiber pipes is needed to solve the above problems. SUMMARY

[0008] The purpose of the present application is to provide a multi-station coordinated efficient production process for automatic weaving of carbon fiber pipes to solve the problems raised in the background.

[0009] To achieve the above purpose, the present application provides the following technical scheme: a multi-station coordinated efficient production process for automatic weaving of carbon fiber pipes, comprising the following modules, characterized by: a multi-dimensional tension monitoring module: a fiber grating sensor array is arranged along the fiber path to collect axial / lateral tension data of the fiber bundle in real time.

[0010] Environmental compensation module: integrate temperature and humidity sensor with air pressure monitoring device, build environmental disturbance model, specific formula as follows: F env = 0.05ΔT + 0.03ΔH + 0.02ΔP, wherein ΔT is temperature deviation, ΔH is humidity deviation, ΔP is air pressure deviation; mechanical properties of carbon fiber are highly sensitive to environmental changes, for every 1℃ increase in temperature (ΔT), the elastic modulus of carbon fiber decreases by about 0.2%, for every 10% increase in humidity (ΔH), the surface friction coefficient of the fiber increases by 15%, resulting in tension fluctuation, for every 1kPa decrease in air pressure (ΔP), the contact pressure of the fiber bundle on the guide roller decreases by 0.5N, causing tension drift, the specific formula of the environmental disturbance model built by the present application quantifies environmental changes into tension deviation through coefficients (0.05, 0.03, 0.02), realizing decoupling of environmental factors and tension control;

[0011] Dynamic control actuator: micro-displacement platform driven by piezoelectric ceramic, adjustment range 0-50μm, response time ≤2ms;

[0012] Intelligent decision control module: through obtaining measurement data of the environmental compensation module and monitoring data of the multi-dimensional tension monitoring module, control the dynamic control actuator for tension control, its control formula is as follows: G = 0.2μm / N, wherein G is the displacement amount of the carbon fiber guide roller required to be controlled, when the temperature increases by 5℃ (ΔT = 5), the model predicts the tension deviation F env = 0.05×5 = 0.25N, triggering the actuator to adjust the guide roller position by 0.05μm (0.25N×0.2μm / N), offsetting the tension relaxation caused by temperature.

[0013] Preferably, the fiber grating sensor array of the multi-dimensional tension monitoring module is disposed along the fiber path, adopts wavelength division multiplexing technology, a single optical fiber integrates 16 sensing points with a spacing of 50mm, covering the fiber inlet, weaving area and outlet. The fiber grating sensor is based on the Bragg grating effect, and its core is the grating structure formed by the periodic refractive index modulation in the optical fiber; when tension acts on the carbon fiber, the strain of the optical fiber changes the period (Λ) and effective refractive index (n eff ) of the grating, thereby changing the reflected wavelength (λ B ); the specific relationship is λ B = 2n eff Λ, when the strain (ε) changes due to tension, the wavelength shift (Δλ B ) has a linear relationship with the strain: Δλ B = λ B (1-ρ)ε, wherein ρ is the photoelastic coefficient, which can be determined through calibration. By measuring Δλ B , the tension size can be deduced.

[0014] Preferably, the dynamic regulation executor adopts a micro-displacement platform driven by a double piezoelectric sheet, the driving voltage range is 0-150V, the maximum displacement is 50um, and the control accuracy is 0.1um. The dynamic regulation executor is designed in an integrated manner with the carbon fiber guide wheel, so that the dynamic regulation executor can drive the carbon fiber guide wheel to move when the dynamic regulation executor is powered on, so as to control the transmission tension of the carbon fiber. The surface of the carbon fiber guide wheel is sprayed with a diamond coating, and the friction coefficient is greater than or equal to 0.8.

[0015] Preferably, the dynamic regulation executor is also provided with a displacement feedback sensor, the displacement feedback sensor adopts a capacitive displacement sensor, the range is 0-50um, the resolution is 0.01um, the data transmission delay is less than or equal to 1ms, and the displacement of the carbon fiber guide wheel is detected in real time.

[0016] Preferably, the temperature and humidity sensor in the environment compensation module adopts a PT1000 thin film platinum resistance and a polymer capacitive humidity sensor, the range is -40~85℃ / 0~100%RH, and the accuracy is ±0.1℃ / ±2%RH. The pressure sensor adopts a piezoresistive chip, the range is 50~110kPa, and the accuracy is ±0.1kPa.

[0017] Preferably, the initial environment data of the environment compensation module is set as follows: temperature 20±1℃, humidity 45±3%RH, and air pressure 100±1kPa.

[0018] Compared with the prior art, the present application has the following beneficial effects:

[0019] 1. The present application constructs an environment disturbance model, quantifies the influence of temperature, humidity and air pressure on fiber tension, integrates an air pressure compensation device and a temperature and humidity sensor, realizes real-time monitoring and compensation of environment parameters, reduces the tension fluctuation from ±8N to ±2N through dynamic compensation in the plum rain season in the south or in the plateau low pressure area, reduces the scrap rate from 25% to 3%, and significantly improves the product yield.

[0020] 2. The present application solves the core pain points of environmental interference sensitivity and tension control lag in the carbon fiber weaving process through environment adaptive technology and high-precision intelligent control, and provides a high-performance and high-reliability pipe production solution for the fields of aerospace, automobile lightweight and the like.

[0021] 3. The present application controls the movement of the carbon fiber guide wheel through the piezoelectric ceramic executor, and the whole control speed is rapid, so as to make up for the core pain points of tension control lag and the like. BRIEF DESCRIPTION OF DRAWINGS

[0022] Figure 1 The system block diagram of the multi-station coordinated and efficient production process for the automatic weaving of the carbon fiber pipe of the present application. DETAILED DESCRIPTION

[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] Please see Figure 1 The present invention provides a technical solution: a multi-station collaborative and efficient production process for automated weaving of carbon fiber tubes, comprising the following modules, characterized in that: a multi-dimensional tension monitoring module: deploying a fiber optic grating sensor array along the fiber path to collect axial / transverse tension data of the fiber bundle in real time.

[0025] Environmental compensation module: Integrates temperature and humidity sensors and air pressure monitoring devices to construct an environmental disturbance model. The specific formula is as follows: F env =0.05ΔT+0.03ΔH+0.02ΔP, where ΔT is the temperature deviation, ΔH is the humidity deviation, and ΔP is the air pressure deviation; the mechanical properties of carbon fiber are highly sensitive to environmental changes. For temperature (ΔT), the elastic modulus of carbon fiber decreases by about 0.2% for every 1°C increase in temperature; for humidity (ΔH), the surface friction coefficient of the fiber increases by 15% for every 10% increase in humidity (RH), resulting in tension fluctuations; for air pressure (ΔP), the contact pressure of the fiber bundle on the guide wheel decreases by 0.5N for every 1kPa decrease in air pressure, causing tension drift. The specific formula for constructing the environmental disturbance model in this application quantifies environmental changes into tension deviations through coefficients (0.05, 0.03, 0.02), thereby decoupling environmental factors from tension control.

[0026] Dynamic control actuator: Employs a micro-displacement platform driven by piezoelectric ceramics, with an adjustment range of 0-50μm and a response time ≤2ms;

[0027] Intelligent decision control module: By obtaining measurement data from the environmental compensation module and monitoring data from the multi-dimensional tension monitoring module, it controls the dynamic control actuator to perform tension control. The control formula is as follows: G = 0.2 μm / N, where G is the required displacement of the carbon fiber guide wheel. When the temperature increases by 5℃ (ΔT = 5), the model predicts the tension deviation F. env =0.05×5=0.25N, triggering the actuator to adjust the guide wheel position by 0.05μm (0.25N×0.2μm / N) to counteract the tension relaxation caused by temperature.

[0028] The fiber grating sensor array of the multi-dimensional tension monitoring module is disposed along the fiber path, adopts wavelength division multiplexing technology, integrates 16 sensing points in a single optical fiber with a spacing of 50 mm, and covers the fiber inlet, the weaving area and the outlet. The fiber grating sensor is based on the Bragg grating effect, and the core is a grating structure formed by periodic refractive index modulation in the optical fiber; when the tension acts on the carbon fiber, the strain of the optical fiber changes the period (Lambda) and the effective refractive index (n eff ) of the grating, thereby changing the reflected wavelength (lambda B ); the specific relationship is lambda B =2n eff Lambda, when the tension changes to cause the strain (epsilon), the wavelength shift (delta lambda B ) is linearly related to the strain: delta lambda B = lambda B (1-p) epsilon, wherein p is the photoelastic coefficient, and the specific value can be determined by calibration. By measuring delta lambda B , the tension can be inversely deduced.

[0029] The dynamic control actuator adopts a micro-displacement platform driven by double piezoelectric sheets, the driving voltage range is 0-150V, the maximum displacement is 50um, and the control accuracy is 0.1um. The dynamic control actuator is integrated with the carbon fiber guide roller, so that the dynamic control actuator can drive the carbon fiber guide roller to move when powered on, so as to control the transmission tension of the carbon fiber. The surface of the carbon fiber guide roller is sprayed with a diamond coating, and the friction coefficient is greater than or equal to 0.8.

[0030] The displacement feedback sensor is also provided with a displacement feedback sensor, which adopts a capacitive displacement sensor, the range is 0-50um, the resolution is 0.01um, the data transmission delay is less than or equal to 1ms, and the displacement of the carbon fiber guide roller is detected in real time.

[0031] The temperature and humidity sensor in the environment compensation module adopts a PT1000 thin film platinum resistance and a polymer capacitive humidity sensor, the range is -40~85℃ / 0~100%RH, and the accuracy is ±0.1℃ / ±2%RH; the pressure sensor adopts a piezoresistive chip, the range is 50~110kPa, and the accuracy is ±0.1kPa.

[0032] The initial environment data of the environment compensation module is set to be temperature 20±1℃, humidity 45±3%RH and air pressure 100±1kPa.

[0033] Based on the existing process of the present application, the following examples are given; the carbon fiber pipe with a diameter of 50mm, a wall thickness of 3mm and a length of 2000mm is produced by the process of the present application, and the requirements are:

[0034] Weaving angle: ±55° (balance axial and hoop strength)

[0035] Resin system: Epoxy resin (viscosity 300 mPa-s)

[0036] Ambient conditions: Temperature 22±1°C, Humidity 50±2% RH, Pressure 101 kPa.

[0037] Station 1: Fiber spreading control

[0038] Real-time monitoring data: Tension 10.2 N (ΔλΒ = 1.2 pm)

[0039] Ambient disturbance: ΔΤ = 3°C (F_env = 0.15 N)

[0040] Control decision:

[0041] Actuator displacement: G = 0.15 N x 0.2 pm / N = 0.03 pm

[0042] Adjust guide wheel position to +0.03 pm

[0043] Feedback verification: Capacitive displacement sensor shows 0.03 pm (error < 0.01 pm)

[0044] Station 2: Cross-weaving control

[0045] Real-time monitoring data: Tension 14.8 N (ΔλΒ = 17.8 pm)

[0046] Ambient disturbance: ΔΗ = 8% RH (F_env = 0.24 N)

[0047] Control decision:

[0048] Actuator displacement: G = 0.24 N x 0.2 pm / N = 0.048 pm

[0049] Adjust guide wheel position to -0.048 pm (using double piezoelectric sheet reverse drive)

[0050] Feedback verification: Tension returns to 15.0 N (error < 0.1 N)

[0051] Station 3: Resin impregnation control

[0052] Real-time monitoring data: Tension 8.1 N (ΔλΒ = 9.7 pm)

[0053] Ambient disturbance: ΔΡ = 1 kPa (F_env = 0.02 N)

[0054] Control decision:

[0055] Actuator displacement: G = 0.02 N x 0.2 pm / N = 0.004 pm

[0056] Adjust guide wheel position to +0.004 pm

[0057] Feedback verification: the glue content of the glue scraping device is controlled at 40% ± 1%.

[0058] It is to be noted that, in the present document, relational terms such as first and second and the like can be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Moreover, the terms "comprises", "comprising", or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but can include other elements not expressly listed or inherent to such process, method, article, or apparatus.

[0059] While embodiments of the application have been shown and described, it is to be understood that the application is not limited to the details of the embodiments described, since numerous further modifications and changes can be apparent to one skilled in the art without departing from the spirit and scope of the application, which is defined by the appended claims and their equivalents.

Claims

1. A multi-station collaborative high-efficiency production process for automated braiding of carbon fiber tubes, comprising the following modules, characterized in that: Multidimensional tension monitoring module: Deploys a fiber optic grating sensor array along the fiber path to acquire axial / transverse tension data of the fiber bundle in real time. Environmental compensation module: Integrates temperature and humidity sensors and air pressure monitoring devices to construct an environmental disturbance model. The specific formula is as follows: F env =0.05ΔT+0.03ΔH+0.02ΔP, where ΔT is the temperature deviation, ΔH is the humidity deviation, and ΔP is the air pressure deviation; the mechanical properties of carbon fiber are highly sensitive to environmental changes. Temperature (ΔT): For every 1°C increase in temperature, the elastic modulus of carbon fiber decreases by about 0.2%. Humidity (ΔH): For every 10% increase in humidity (RH), the coefficient of friction on the fiber surface increases by 15%, leading to tension fluctuations; Air pressure (ΔP): For every 1 kPa decrease in air pressure, the contact pressure of the fiber bundle on the guide wheel decreases by 0.5 N, causing tension drift. The specific formula of the environmental disturbance model in this application quantifies environmental changes into tension deviations through coefficients (0.05, 0.03, 0.02), thereby decoupling environmental factors from tension control. When the temperature increases by 5℃ (ΔT = 5), the model predicts the tension deviation F. env =0.05×5=0.25N, triggering the actuator to adjust the guide wheel position by 0.05μm (0.25N×0.2μm / N) to counteract the tension relaxation caused by temperature; Dynamic control actuator: Employs a micro-displacement platform driven by piezoelectric ceramics, with an adjustment range of 0-50μm and a response time ≤2ms; The dynamic control actuator is integrated with a carbon fiber guide wheel, allowing the carbon fiber guide wheel to move when the dynamic control actuator is powered on. Intelligent decision control module: By obtaining measurement data from the environmental compensation module and monitoring data from the multi-dimensional tension monitoring module, the module controls the dynamic control actuator to perform tension control. The control formula is as follows: G = 0.2 μm / N, where G is the displacement of the carbon fiber guide wheel to be controlled.

2. The multi-station collaborative high-efficiency production process for automated braiding of carbon fiber tubes according to claim 1, characterized in that: The fiber grating sensor array of the multidimensional tension monitoring module is deployed along the fiber path and uses wavelength division multiplexing technology. A single fiber integrates 16 sensing points with a spacing of 50 mm, covering the fiber inlet, braiding area and outlet.

3. The multi-station collaborative high-efficiency production process for automated braiding of carbon fiber tubes according to claim 1, characterized in that: The dynamic control actuator adopts a micro-displacement platform driven by dual piezoelectric elements, with a driving voltage range of 0-150V, a maximum displacement of 50μm, and a control accuracy of 0.1μm. The dynamic control actuator is integrated with a carbon fiber guide wheel, so that the dynamic control actuator can drive the carbon fiber guide wheel to move when energized, thereby controlling the transmission tension of the carbon fiber. The surface of the carbon fiber guide wheel is coated with a diamond coating, with a friction coefficient ≥0.

8.

4. The multi-station collaborative high-efficiency production process for automated braiding of carbon fiber tubes according to claim 1, characterized in that: The dynamic control actuator is also equipped with a displacement feedback sensor, which is a capacitive displacement sensor with a range of 0-50μm, a resolution of 0.01μm, and a data transmission delay of ≤1ms, used to detect the displacement of the carbon fiber guide wheel in real time.

5. The multi-station collaborative high-efficiency production process for automated braiding of carbon fiber tubes according to claim 1, characterized in that: The temperature and humidity sensor in the environmental compensation module is a PT1000 thin-film platinum resistance and polymer capacitive humidity sensor with a range of -40~85℃ / 0~100%RH and an accuracy of ±0.1℃ / ±2%RH; the barometric pressure sensor is a piezoresistive chip with a range of 50~110kPa and an accuracy of ±0.1kPa.

6. The multi-station collaborative high-efficiency production process for automated braiding of carbon fiber tubes according to claim 1, characterized in that: The initial environmental data settings for the environmental compensation module are: temperature 20±1℃, humidity 45±3%RH, and air pressure 100±1kPa.

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