Continuous fiber reinforced thermoplastic composite material forming system and process

Abstract

The invention discloses a continuous fiber reinforced thermoplastic composite material forming system and process, and relates to the technical field of thermoplastic composites.The continuous fiber reinforced thermoplastic composite material forming system comprises a working platform, a conveying assembly, a local heating assembly, a parallel type hot pressing mold set, a cooling assembly, a storage assembly and a transplanting type circulating assembly; the local heating assembly, the parallel type hot-pressing die set, the cooling assembly and the storage assembly are sequentially arranged on the path of the conveying assembly, and a workpiece to be machined is clamped on the conveying assembly through the workpiece clamping tray and sequentially penetrates through the local heating assembly, the parallel type hot-pressing die set, the cooling assembly and the storage assembly. The workpiece clamping tray is conveyed back to the initial position of the conveying assembly through clamping of the transplanting type circulating assembly. According to the production line, a plurality of procedures such as local heating, hot press molding, cooling shaping and finished product storage are integrated on one automatic production line, so that efficient, accurate and low-cost manufacturing of the continuous fiber reinforced thermoplastic composite product is realized.

Description

Technical Field

[0001] This invention relates to the field of thermoplastic composite materials technology, and in particular to a continuous fiber reinforced thermoplastic composite molding system and process. Background Technology

[0002] Continuous fiber reinforced thermoplastic composites are widely used in automotive parts, aerospace structural components and other fields due to their excellent properties such as being lightweight, high-strength and recyclable.

[0003] Currently, the molding process for this material is mainly divided into two methods: overall heating molding and partial contact heating. The overall heating molding process is prone to core material collapse and fiber orientation disorder when processing sandwich structure panels, and it also has high energy consumption and long production cycle. On the other hand, the partial contact heating method has problems such as low heating efficiency, the need for repeated operations, and reliance on Teflon auxiliary materials, which not only increases production costs, but also leads to increased wear due to frequent mold cleaning.

[0004] Most existing molding equipment adopts an independent station segmented operation mode, requiring workpieces to be transferred between different devices, making continuous production difficult. This intermittent production method not only increases manual intervention and workpiece positioning errors, but also significantly reduces production efficiency, especially when dealing with work requiring local molding in multiple areas, where problems such as poor process connection and inconsistent production rhythm are particularly prominent.

[0005] Therefore, how to develop a continuous fiber reinforced thermoplastic composite molding system and process that integrates multiple processes such as local heating, hot pressing, cooling and shaping, and finished product storage into an automated production line to achieve efficient, precise, and low-cost manufacturing of continuous fiber reinforced thermoplastic composite products has become a technical problem that urgently needs to be solved by people in this field. Summary of the Invention

[0006] The purpose of this invention is to provide a continuous fiber reinforced thermoplastic composite molding system and process that integrates multiple processes such as local heating, hot pressing, cooling and shaping, and finished product storage into an automated production line, so as to achieve efficient, precise and low-cost manufacturing of continuous fiber reinforced thermoplastic composite products.

[0007] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: This invention discloses a continuous fiber-reinforced thermoplastic composite molding system and process, comprising a working platform, a conveying component, a local heating component, a parallel hot press mold assembly, a cooling component, a storage component, and a transfer-type circulation component. The conveying component is integrated on the working platform. The local heating component, the parallel hot press mold assembly, the cooling component, and the storage component are sequentially arranged on the path of the conveying component. The workpiece to be processed is clamped on the conveying component by a workpiece clamping tray and passes through the local heating component, the parallel hot press mold assembly, the cooling component, and the storage component in sequence to complete the local heating, hot pressing, cooling, and storage operations of the workpiece in sequence. After the storage operation is completed, the workpiece clamping tray is clamped and transported back to the initial position of the conveying component by the transfer-type circulation component.

[0008] Preferably, the conveying assembly includes a first drive motor, a synchronous pulley, a driven pulley, an auxiliary support pulley, and a synchronous belt. Two first drive motors are symmetrically arranged on both sides of the loading end of the working platform. Two driven pulleys are correspondingly arranged on the other end of the working platform. A plurality of auxiliary support pulleys are installed at intervals on the working platform. The synchronous pulley is fixedly connected to the rotating end of the first drive motor. The synchronous belt is sleeved on the synchronous pulley and the driven pulley on the same side and is supported by the auxiliary support pulley. Multiple positioning blocks are installed at intervals on the synchronous belt. Each positioning block has a limiting hole. The bottom of the workpiece clamping tray is provided with a limiting post that matches the limiting hole. The workpiece clamping tray is positioned and connected to the synchronous belt through the insertion and cooperation of the limiting post and the limiting hole. The workpiece clamping tray is configured as a frame structure with openings at the top and bottom. The workpiece is positioned and installed on the workpiece clamping tray.

[0009] Preferably, it also includes multiple sets of positioning detection units, each of which includes a first sensor and a second sensor. The multiple sets of positioning detection units are respectively disposed at the corresponding workstations of the local heating component, the parallel hot pressing mold group, the cooling component, and the storage component. The first sensor is located at the station entrance to sense when the workpiece clamping tray begins to enter the processing area. The second sensor is located at the station exit to sense when the workpiece clamping tray has fully entered the processing area. When the first sensor senses the workpiece clamping tray and the second sensor subsequently senses the workpiece clamping tray, and the first sensor stops sensing, the system determines that the workpiece clamping tray is accurately positioned at the processing location.

[0010] Preferably, the local heating assembly includes a first gantry frame, a first electric telescopic rod, a second electric telescopic rod, a first double-layer clamp, a second double-layer clamp, a heating plate, and a baffle. The first gantry frame is horizontally mounted above the work platform. The first electric telescopic rod is fixedly installed on the crossbeam of the first gantry frame. The first double-layer clamp is fixedly connected to the telescopic end of the first electric telescopic rod. The work platform is provided with a first mounting slot, the second electric telescopic rod is fixedly installed at the bottom of the inner cavity of the first mounting slot, the second double-layer clamp is fixedly connected to the telescopic end of the second electric telescopic rod, and a plurality of heating plates and baffles are respectively clamped in the first double-layer clamp and the second double-layer clamp, and the heating plate is located on the side of the baffle away from the workpiece.

[0011] Preferably, multiple sets of heating units are equidistantly arranged on the heating plate. The heating units are one or more of ceramic plates, quartz plates, and quartz halogen lamps. The heating units are used to heat a local forming area of ​​the plate to be formed on one or both sides. The baffle has multiple sets of holes, which are used to distinguish between the heating zone and the non-heating zone; The workpiece includes an outer layer, a sandwich layer, and a core layer. The sandwich layer covers the outside of the core layer, and the outer layer covers the outside of the sandwich layer. Multiple sets of metal parts are embedded in the sandwich layer.

[0012] Preferably, the parallel hot press mold group includes multiple hot press molds arranged sequentially along the path of the conveying component. Each hot press mold includes a second gantry frame, a third electric telescopic rod, a fourth electric telescopic rod, an upper mold, and a lower mold. The second gantry frame is horizontally erected above the working platform. The third electric telescopic rod is fixedly installed on the crossbeam of the second gantry frame. The upper mold is fixedly connected to the telescopic end of the third electric telescopic rod. A second mounting groove is correspondingly provided on the working platform. The fourth electric telescopic rod is fixedly installed at the bottom of the inner cavity of the second mounting groove. The lower mold is fixedly connected to the telescopic end of the fourth electric telescopic rod.

[0013] Preferably, the cooling assembly includes a third gantry frame and multiple cooling fans. The third gantry frame is horizontally mounted above the work platform, and the multiple cooling fans are fixedly installed at the bottom of the crossbeam of the third gantry frame in a matrix arrangement and are positioned towards the workpiece being conveyed downwards, for forced air cooling of the surface of the workpiece after hot pressing.

[0014] Preferably, the storage assembly includes a storage frame, a fifth electric telescopic rod, a lifting plate, a second drive motor, a threaded rod, a fourth gantry frame, a sixth electric telescopic rod, a guide rod, and a push plate. The fourth gantry frame is horizontally mounted above the work platform, and the storage frame is located on one side of the work platform. The second drive motor is mounted on the upright of the fourth gantry frame on the corresponding side. One end of the threaded rod is fixedly connected to the rotating end of the second drive motor via a coupling, and the other end is threadedly connected to the storage frame. The guide rod is fixedly connected to the side of the fourth gantry frame near the storage frame, and the storage frame is slidably sleeved on the guide rod. A third mounting slot is correspondingly provided on the work platform. The fifth electric telescopic rod is fixedly mounted at the bottom of the inner cavity of the third mounting slot. The lifting plate is fixedly connected to the telescopic end of the fifth electric telescopic rod. The sixth electric telescopic rod is mounted on the upright of the fourth gantry frame on the other side. The push plate is fixedly connected to the telescopic end of the sixth electric telescopic rod and is used to push the workpiece into the storage frame for collection and residual heat cooling.

[0015] Preferably, the transfer-type circulation assembly includes a fifth gantry frame, a seventh electric telescopic rod, and a mechanical gripper. The fifth gantry frame is positioned above the work platform, and the axial direction of the crossbeam of the fifth gantry frame is aligned with the long side direction of the work platform. The seventh electric telescopic rod is slidably connected to the bottom of the crossbeam of the fifth gantry frame via a servo motor drive mechanism. The mechanical gripper is installed at the telescopic end of the seventh electric telescopic rod and is used to clamp the empty workpiece clamping tray.

[0016] A molding process for a continuous fiber-reinforced thermoplastic composite molding system includes the following steps: Step 1: The workpiece to be processed is clamped onto the conveying assembly using the workpiece clamping tray. The conveying assembly is then started to transport the workpiece to each processing station in sequence. Step 2: When the positioning detection unit confirms that the workpiece clamping tray is accurately positioned at the processing position of the local heating component, the first electric telescopic rod and the second electric telescopic rod drive the first double-layer clamp and the second double-layer clamp to move towards each other, so that the heating plate and the baffle are close to the workpiece, and the heating unit is started to locally heat the workpiece. Step 3: After heating is completed, the local heating component is reset, and the conveying component transports the workpiece to the parallel hot press mold group; after the positioning detection unit confirms that it is in place, the third and fourth electric telescopic rods of each hot press mold drive the upper and lower molds to close, and perform hot pressing on the workpiece. Step 4: After hot pressing is completed, the mold is opened and reset. The conveying component transports the workpiece to the cooling component, and the cooling fan is started to force-cool the surface of the workpiece. Step 5: After cooling, the workpiece is transported to the storage assembly. The fifth electric telescopic rod drives the lifting plate to rise and lift the workpiece, separating it from the workpiece clamping tray. The sixth electric telescopic rod drives the push plate to push the workpiece into the storage frame for collection and residual heat cooling. Step six: The empty workpiece clamping pallet is held by the mechanical gripper of the transfer-type circulation component, lifted by the seventh electric telescopic rod, and then transported back to the initial position of the conveying component by the servo motor driven mechanism, completing one processing cycle.

[0017] Compared with the prior art, the beneficial technical effects of the present invention are as follows: 1) This invention integrates multiple processes such as local heating, hot pressing, cooling and shaping, and finished product storage onto a single automated production line, achieving continuous production from material loading to finished product unloading. The collaborative work of the conveying components and the transfer-type circulation components allows the workpiece clamping pallet to automatically return to its starting position after completing all processing steps, forming a complete production cycle. This integrated production line design significantly reduces transfer time and manual intervention between processes, not only improving production efficiency but also effectively ensuring the consistency of product molding quality, making it particularly suitable for large-scale standardized production needs. 2) This invention employs symmetrically arranged local heating components, combined with a baffle structure featuring multiple sets of perforated holes, enabling precise heating of specific areas of the workpiece. The coordinated operation of the infrared heating unit and the hot pressing mold ensures that only the areas requiring molding are softened by heat, while other areas remain in their original state. This local heating method not only avoids the problems of sheet deformation and fiber orientation confusion caused by traditional overall heating, but also significantly reduces energy consumption and eliminates the need for auxiliary materials such as Teflon belts, effectively reducing production costs. 3) The various functional components of this system adopt a modular design. The parallel hot pressing mold assembly can be flexibly configured according to product requirements, enabling sequential or synchronous processing of different areas of the same workpiece. The coordination between the positioning and detection unit and the precision positioning mechanism ensures the accuracy of each processing step, while the automated control system guarantees the continuity and stability of the entire production process. This modular and automated design allows the system to adapt to the production needs of products with different specifications, improving equipment utilization and production flexibility while ensuring processing accuracy. Attached Figure Description

[0018] The present invention will be further described below with reference to the accompanying drawings.

[0019] Figure 1 This is a front view of a continuous fiber-reinforced thermoplastic composite molding system according to the present invention; Figure 2 This is a top view of a continuous fiber-reinforced thermoplastic composite molding system according to the present invention; Figure 3For the present invention Figure 1 A magnified view of a section at point A in the middle; Figure 4 This is a schematic diagram of the heating plate in this invention; Figure 5 This is a schematic diagram of the baffle structure in this invention; Figure 6 This is a schematic cross-sectional view of the workpiece in this invention; Figure 7 This is a schematic diagram of the workpiece clamping tray in this invention.

[0020] Explanation of reference numerals in the attached drawings: 1. Working platform; 2. Conveying assembly; 201. First drive motor; 202. Synchronous pulley; 203. Driven pulley; 204. Auxiliary support pulley; 205. Synchronous belt; 206. Positioning block; 207. Limiting hole; 3. Local heating assembly; 301. First gantry frame; 302. First electric telescopic rod; 303. Second electric telescopic rod; 304. First double-layer clamp; 305. Second double-layer clamp; 306. Heating plate; 3061. Heating unit; 307. Baffle; 3071. Hole; 4. Parallel hot press mold assembly; 401. Hot press mold; 402. Second gantry frame; 403. Third electric telescopic rod; 404. Fourth electric... 405. Electric telescopic rod; 406. Upper mold; 407. Lower mold; 5. Cooling assembly; 501. Third gantry frame; 502. Cooling fan; 6. Storage assembly; 601. Storage frame; 602. Fifth electric telescopic rod; 603. Lifting plate; 604. Second drive motor; 605. Threaded rod; 606. Fourth gantry frame; 607. Sixth electric telescopic rod; 608. Guide rod; 609. Push plate; 7. Transfer-type circulation assembly; 701. Fifth gantry frame; 702. Seventh electric telescopic rod; 703. Mechanical gripper; 8. Workpiece; 801. Outer layer; 802. Clamping layer; 803. Core material layer; 804. Metal parts; 9. Workpiece clamping tray; 901. Limiting post. Detailed Implementation

[0021] To make the technical problems to be solved, the technical solutions, and the beneficial effects of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0022] like Figure 1-7As shown, a continuous fiber-reinforced thermoplastic composite molding system and process includes a working platform 1, a conveying component 2, a local heating component 3, a parallel hot pressing mold group 4, a cooling component 5, a storage component 6, and a transfer-type circulation component 7. The conveying component 2 is integrated on the working platform 1. The local heating component 3, the parallel hot pressing mold group 4, the cooling component 5, and the storage component 6 are sequentially arranged on the path of the conveying component 2. The workpiece 8 to be processed is clamped on the conveying component 2 by the workpiece clamping tray 9 and passes through the local heating component 3, the parallel hot pressing mold group 4, the cooling component 5, and the storage component 6 in sequence to complete the local heating, hot pressing, cooling, and storage operations of the workpiece 8 in sequence. After the storage operation is completed, the workpiece clamping tray 9 is clamped and transported back to the initial position of the conveying component 2 by the transfer-type circulation component 7.

[0023] Specifically, the work platform 1 is welded from steel structure and covered with wear-resistant steel plate. The bottom of the platform is equipped with leveling feet to adapt to different ground conditions and ensure the stability and levelness of the entire system during operation. As the basic mounting surface for various functional components, the robust structure of the work platform 1 provides reliable support for the continuous production line.

[0024] Specifically, the conveying assembly 2 includes a first drive motor 201, a synchronous pulley 202, a driven pulley 203, an auxiliary support pulley 204, and a synchronous belt 205. Two first drive motors 201 are symmetrically arranged on both sides of the loading end of the working platform 1. Two driven pulleys 203 are correspondingly arranged on the other end of the working platform 1. A plurality of auxiliary support pulleys 204 are spaced apart and installed on the working platform 1. The synchronous pulley 202 is fixedly connected to the rotating end of the first drive motor 201. The synchronous belt 205 is sleeved on the synchronous pulley 202 and the driven pulley 203 on the same side and is supported by the auxiliary support pulleys 204. Multiple positioning blocks 206 are installed at intervals on the synchronous belt 205. The positioning blocks 206 have limiting holes 207. The bottom of the workpiece clamping tray 9 is provided with a limiting post 901 that matches the limiting hole 207. The workpiece clamping tray 9 is positioned and connected to the synchronous belt 205 through the insertion and cooperation of the limiting post 901 and the limiting hole 207. The workpiece clamping tray 9 is configured as a frame structure with openings at the top and bottom. The workpiece 8 is positioned and installed on the workpiece clamping tray 9.

[0025] Specifically, the conveying assembly 2 adopts a double-sided synchronous belt 205 drive method. The synchronous rotation of two first drive motors 201 drives the synchronous pulleys 202 and the synchronous belt 205, thereby driving the workpiece clamping pallet 9 to be smoothly conveyed along a straight path. Multiple auxiliary support pulleys 204 set on the platform effectively support the synchronous belt 205, preventing it from sagging under load and ensuring conveying accuracy. This design ensures that the workpiece 8 will not deviate during conveying, laying the foundation for precise positioning at subsequent workstations.

[0026] Specifically, the workpiece clamping tray 9 adopts a frame design with openings at both the top and bottom, facilitating processing of the workpiece 8 from both directions. The limiting post 901 at its bottom engages with the limiting hole 207 of the positioning block 206 on the synchronous belt 205, forming a fast and accurate positioning connection. This facilitates the assembly and disassembly of the workpiece clamping tray 9 and ensures that the workpiece clamping tray 9 maintains a fixed relative position with the synchronous belt 205 during transport and processing, preventing slippage.

[0027] Specifically, it also includes multiple sets of positioning detection units, each of which includes a first sensor and a second sensor. The multiple sets of positioning detection units are respectively set at the corresponding workstations of the local heating component 3, the parallel hot pressing mold group 4, the cooling component 5, and the storage component 6. The first sensor is located at the station entrance to sense when the workpiece clamping tray 9 begins to enter the processing area. The second sensor is located at the station exit to sense when the workpiece clamping tray 9 has fully entered the processing area. When the first sensor senses the workpiece clamping tray 9 and the second sensor subsequently senses the workpiece clamping tray 9, and the first sensor stops sensing, the system determines that the workpiece clamping tray 9 is accurately stopped at the processing position.

[0028] Specifically, the positioning detection unit achieves accurate judgment of the position of the workpiece clamping tray 9 through the coordinated operation of the first and second sensors. When the workpiece clamping tray 9 enters the workstation, the first sensor is triggered first, and when it continues to move until it completely covers the processing area, the second sensor is triggered, and at the same time, it leaves the sensing area of ​​the first sensor. Based on this logic, the system determines that the workpiece clamping tray 9 has been accurately positioned. This detection method effectively avoids positioning inaccuracies caused by inertia or transmission errors, ensuring that each processing step starts in the correct position.

[0029] Specifically, the local heating assembly 3 includes a first gantry frame 301, a first electric telescopic rod 302, a second electric telescopic rod 303, a first double-layer clamp 304, a second double-layer clamp 305, a heating plate 306, and a baffle 307. The first gantry frame 301 is horizontally mounted above the work platform 1. The first electric telescopic rod 302 is fixedly installed on the crossbeam of the first gantry frame 301. The first double-layer clamp 304 is fixedly connected to the telescopic end of the first electric telescopic rod 302. The working platform 1 is provided with a first mounting slot. The second electric telescopic rod 303 is fixedly installed at the bottom of the inner cavity of the first mounting slot. The second double-layer clamp 305 is fixedly connected to the telescopic end of the second electric telescopic rod 303. A plurality of heating plates 306 and baffles 307 are respectively clamped in the first double-layer clamp 304 and the second double-layer clamp 305, and the heating plate 306 is located on the side of the baffle 307 away from the workpiece 8.

[0030] Specifically, multiple sets of heating units 3061 are equidistantly arranged on the heating plate 306. The heating unit 3061 adopts one or more of ceramic plates, quartz plates, and quartz halogen lamps. The heating unit 3061 is used to heat the local forming position of the plate to be formed on one or both sides. The baffle 307 has multiple sets of holes 3071, which are used to distinguish between the heating zone and the non-heating zone. The workpiece 8 includes an outer layer 801, a sandwich layer 802, and a core material layer 803. The sandwich layer 802 covers the outside of the core material layer 803, and the outer layer 801 covers the outside of the sandwich layer 802. The sandwich layer 802 has multiple sets of metal parts 804 embedded in it.

[0031] Specifically, the local heating component 3 employs a symmetrically arranged heating plate 306 and baffle 307, driven by a first electric telescopic rod 302 and a second electric telescopic rod 303, allowing simultaneous approach or departure from both the upper and lower sides of the workpiece 8. The holes 3071 on the baffle 307 precisely define the infrared heating area, ensuring that only the portion requiring shaping is heated and softened, while other areas remain unchanged. This localized heating method significantly reduces energy consumption and prevents overall workpiece deformation due to heat.

[0032] Specifically, the heating unit 3061 preferably uses a quartz halogen lamp in the mid-infrared band. This band is close to the resonance frequency of the molecular bonds of thermoplastic composite materials, which can achieve rapid and uniform heating at the molecular level and has high thermal efficiency.

[0033] Specifically, the workpiece 8 has a sandwich structure. The core layer 803 is typically a lightweight honeycomb or foam material, while the outer layer 801 and the sandwich layer 802 are continuous fiber-reinforced thermoplastic composite materials. The metal part 804 embedded in the sandwich layer 802 can be used as a connector or functional component in subsequent processes. This structure provides excellent specific strength and stiffness while ensuring the workpiece is lightweight.

[0034] Specifically, the parallel hot press mold group 4 includes multiple hot press molds 401 arranged sequentially along the path of the conveying component 2. Each hot press mold 401 includes a second gantry frame 402, a third electric telescopic rod 403, a fourth electric telescopic rod 404, an upper mold 405, and a lower mold 406. The second gantry frame 402 is horizontally mounted above the working platform 1. The third electric telescopic rod 403 is fixedly installed on the crossbeam of the second gantry frame 402. The upper mold 405 is fixedly connected to the telescopic end of the third electric telescopic rod 403. A second mounting groove is correspondingly provided on the working platform 1. The fourth electric telescopic rod 404 is fixedly installed at the bottom of the inner cavity of the second mounting groove. The lower mold 406 is fixedly connected to the telescopic end of the fourth electric telescopic rod 404.

[0035] Specifically, the parallel hot press mold group 4 consists of multiple independent hot press molds 401 arranged in a straight line along the production line. Each mold can independently complete the mold closing, pressure holding, and mold opening actions. This layout allows different areas of the same workpiece 8 to be pressed and formed sequentially or simultaneously, which is particularly suitable for workpieces with multiple discrete forming characteristics, greatly improving production efficiency and equipment utilization.

[0036] Specifically, the upper mold 405 and lower mold 406 of each hot press mold 401 are driven by independent third electric telescopic rods 403 and 404, respectively, ensuring the uniformity and controllability of the mold closing pressure. The mold surface can be customized according to the product shape to meet the forming requirements of different workpieces.

[0037] Specifically, the cooling assembly 5 includes a third gantry frame 501 and multiple cooling fans 502. The third gantry frame 501 is horizontally mounted above the work platform 1. The multiple cooling fans 502 are fixedly installed at the bottom of the crossbeam of the third gantry frame 501 in a matrix arrangement and are positioned towards the workpiece 8 being conveyed downwards, for forced air cooling of the surface of the workpiece after hot pressing.

[0038] Specifically, the cooling assembly 5 adopts a matrix arrangement of multiple high-power cooling fans 502 on the third gantry frame 501 to form a forced cooling air curtain covering the entire width of the workpiece. This design enables the surface of the workpiece 8 after hot pressing to cool and solidify quickly and uniformly, effectively shortening the production cycle and preventing deformation or internal stress caused by uneven cooling.

[0039] Specifically, the storage assembly 6 includes a storage frame 601, a fifth electric telescopic rod 602, a lifting plate 603, a second drive motor 604, a threaded rod 605, a fourth gantry frame 606, a sixth electric telescopic rod 607, a guide rod 608, and a push plate 609. The fourth gantry frame 606 is horizontally mounted above the working platform 1. The storage frame 601 is located on one side of the working platform 1. The second drive motor 604 is mounted on the upright on the corresponding side of the fourth gantry frame 606. One end of the threaded rod 605 is fixedly connected to the rotating end of the second drive motor 604 via a coupling, and the other end is threadedly connected to the storage frame 601. The guide rod 608 is fixedly connected to one side of the four-gantry frame 606 near the storage frame 601. The storage frame 601 is slidably sleeved on the guide rod 608. A third mounting slot is correspondingly provided on the working platform 1. The fifth electric telescopic rod 602 is fixedly installed at the bottom of the inner cavity of the third mounting slot. The lifting plate 603 is fixedly connected to the telescopic end of the fifth electric telescopic rod 602. The sixth electric telescopic rod 607 is installed on the upright on the other side of the fourth gantry frame 606. The push plate 609 is fixedly connected to the telescopic end of the sixth electric telescopic rod 607 and is used to push the workpiece 8 into the storage frame 601 for collection and residual heat cooling.

[0040] Specifically, the storage component 6 lifts the formed workpiece 8 using the lifting plate 603, separating it from the workpiece clamping tray 9, thus creating conditions for the push plate 609 to push the workpiece into the storage frame 601. The second drive motor 604 drives the storage frame 601 to rise and fall along the guide rod 608 via the threaded rod 605, thereby realizing the layered stacking of workpieces within the storage rack, improving space utilization. The workpieces pushed into the storage frame 601 can utilize ambient air for final residual heat cooling.

[0041] Specifically, the transplanting circulation assembly 7 includes a fifth gantry frame 701, a seventh electric telescopic rod 702, and a mechanical gripper 703. The fifth gantry frame 701 is located above the work platform 1, and the axial direction of the crossbeam of the fifth gantry frame 701 is consistent with the long side direction of the work platform 1. The seventh electric telescopic rod 702 is slidably connected to the bottom of the crossbeam of the fifth gantry frame 701 through a servo motor drive mechanism. The mechanical gripper 703 is installed at the telescopic end of the seventh electric telescopic rod 702 and is used to clamp the empty workpiece clamping tray 9.

[0042] Specifically, the transfer-type circulation component 7, driven by a servo motor, controls the seventh electric telescopic rod 702 and its mechanical gripper 703 to move precisely on the fifth gantry frame 701. This reliably grips empty workpieces on the pallet 9 and directly returns them to the starting point of the conveyor line across multiple workstations. This automated circulation process replaces traditional manual handling or complex return lines, significantly saving manpower, optimizing the workshop layout, and ensuring the continuity of production rhythm.

[0043] A molding process for a continuous fiber-reinforced thermoplastic composite molding system includes the following steps: Step 1: The workpiece 8 to be processed is clamped on the conveying assembly 2 via the workpiece clamping tray 9, and the conveying assembly 2 is started to transport the workpiece 8 to each processing station in sequence; Step 2: When the positioning detection unit confirms that the workpiece clamping tray 9 is accurately positioned at the processing position of the local heating component 3, the first electric telescopic rod 302 and the second electric telescopic rod 303 drive the first double-layer clamp 304 and the second double-layer clamp 305 to move towards each other, so that the heating plate 306 and the baffle 307 are close to the workpiece 8, and the heating unit 3061 is started to locally heat the workpiece 8. Step 3: After heating is completed, the local heating component 3 is reset, and the conveying component 2 conveys the workpiece 8 to the parallel hot press mold group 4. After the positioning detection unit confirms that the workpiece is in place, the third electric telescopic rod 403 and the fourth electric telescopic rod 404 of each hot press mold 401 drive the upper mold 405 and the lower mold 406 to close the mold and perform hot pressing on the workpiece 8. Step 4: After hot pressing is completed, the mold is opened and reset. The conveying component 2 conveys the workpiece 8 to the cooling component 5, and the cooling fan 502 is started to force the surface of the workpiece 8 to be cooled by air. Step 5: After cooling, workpiece 8 is transported to the storage component 6. The fifth electric telescopic rod 602 drives the lifting plate 603 to rise and lift workpiece 8, so that it is separated from the workpiece clamping tray 9. The sixth electric telescopic rod 607 drives the push plate 609 to push workpiece 8 into the storage frame 601 for collection and residual heat cooling. Step six: The empty workpiece clamping tray 9 is held by the mechanical gripper 703 of the transfer circulation assembly 7, lifted by the seventh electric telescopic rod 702, and then transported back to the initial position of the conveying assembly 2 by the servo motor driven mechanism, completing one processing cycle.

[0044] Specifically, this invention integrates multiple processes such as local heating, hot pressing, cooling and shaping, and finished product storage onto a single automated production line. These processes are connected in series via a conveyor assembly 2 and a transfer-type circulation assembly 7, achieving fully automated cyclical production from raw material loading to finished product unloading and empty pallet return. This assembly line operation mode significantly reduces transfer time and manual intervention between processes, ensuring consistent product molding quality. It is particularly suitable for the mass production of standardized continuous fiber-reinforced thermoplastic composite products.

[0045] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0046] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A continuous fiber-reinforced thermoplastic composite molding system, characterized in that: The assembly includes a working platform (1), a conveying component (2), a local heating component (3), a parallel hot press mold group (4), a cooling component (5), a storage component (6), and a transfer circulation component (7). The conveying component (2) is integrated on the working platform (1). The local heating component (3), the parallel hot press mold group (4), the cooling component (5), and the storage component (6) are arranged sequentially on the path of the conveying component (2). The workpiece (8) to be processed is clamped on the conveying component (2) by the workpiece clamping tray (9) and passes through the local heating component (3), the parallel hot press mold group (4), the cooling component (5), and the storage component (6) in sequence to complete the local heating, hot pressing, cooling, and storage operations of the workpiece (8) in sequence. After the storage operation is completed, the workpiece clamping tray (9) is transported back to the initial position of the conveying component (2) by the clamping of the transfer circulation component (7).

2. The continuous fiber-reinforced thermoplastic composite molding system according to claim 1, characterized in that: The conveying assembly (2) includes a first drive motor (201), a synchronous pulley (202), a driven pulley (203), an auxiliary support pulley (204), and a synchronous belt (205). Two first drive motors (201) are symmetrically arranged on both sides of the loading end of the working platform (1). Two driven pulleys (203) are correspondingly arranged on the other end of the working platform (1). A plurality of auxiliary support pulleys (204) are spaced apart on the working platform (1). The synchronous pulley (202) is fixedly connected to the rotating end of the first drive motor (201). The synchronous belt (205) is sleeved on the synchronous pulley (202) and the driven pulley (203) on the same side and is supported by the auxiliary support pulleys (204). Multiple positioning blocks (206) are installed at intervals on the synchronous belt (205). The positioning blocks (206) have limiting holes (207). The bottom of the workpiece clamping tray (9) is provided with a limiting post (901) that matches the limiting hole (207). The workpiece clamping tray (9) is positioned and connected to the synchronous belt (205) through the insertion and cooperation of the limiting post (901) and the limiting hole (207). The workpiece clamping tray (9) is set as a frame structure with openings at the top and bottom. The workpiece (8) is positioned and installed on the workpiece clamping tray (9).

3. The continuous fiber-reinforced thermoplastic composite molding system according to claim 2, characterized in that: It also includes multiple sets of positioning detection units, each of which includes a first sensor and a second sensor. The multiple sets of positioning detection units are respectively set at the corresponding workstations of the local heating component (3), the parallel hot pressing mold group (4), the cooling component (5), and the storage component (6). The first sensor is located at the station entrance and is used to sense when the workpiece clamping tray (9) begins to enter the processing area. The second sensor is located at the station exit and is used to sense when the workpiece clamping tray (9) has fully entered the processing area. When the first sensor senses the workpiece clamping tray (9) and the second sensor subsequently senses the workpiece clamping tray (9), and the first sensor stops sensing, the system determines that the workpiece clamping tray (9) is accurately stopped at the processing position.

4. The continuous fiber-reinforced thermoplastic composite molding system according to claim 3, characterized in that: The local heating assembly (3) includes a first gantry frame (301), a first electric telescopic rod (302), a second electric telescopic rod (303), a first double-layer clamp (304), a second double-layer clamp (305), a heating plate (306), and a baffle (307). The first gantry frame (301) is horizontally mounted above the work platform (1). The first electric telescopic rod (302) is fixedly installed on the crossbeam of the first gantry frame (301). The first double-layer clamp (304) is fixedly connected to the telescopic end of the first electric telescopic rod (302). The working platform (1) is provided with a first mounting slot, the second electric telescopic rod (303) is fixedly installed at the bottom of the inner cavity of the first mounting slot, the second double-layer clamp (305) is fixedly connected to the telescopic end of the second electric telescopic rod (303), and multiple heating plates (306) and baffles (307) are respectively clamped in the first double-layer clamp (304) and the second double-layer clamp (305), and the heating plate (306) is located on the side of the baffle (307) away from the workpiece (8).

5. The continuous fiber-reinforced thermoplastic composite molding system according to claim 4, characterized in that: Multiple heating units (3061) are equidistantly arranged on the heating plate (306). The heating unit (3061) is one or more of ceramic plate, quartz stone plate, and quartz halogen lamp tube. The heating unit (3061) is used to heat the local forming position of the plate to be formed on one or both sides. The baffle (307) has multiple sets of holes (3071) for distinguishing between the heating zone and the non-heating zone; The workpiece (8) includes an outer layer (801), a sandwich layer (802) and a core material layer (803). The sandwich layer (802) covers the outside of the core material layer (803), and the outer layer (801) covers the outside of the sandwich layer (802). The sandwich layer (802) has multiple sets of metal parts (804) embedded in it.

6. The continuous fiber-reinforced thermoplastic composite molding system according to claim 5, characterized in that: The parallel hot press mold group (4) includes multiple hot press molds (401) arranged sequentially along the path of the conveying component (2). Each hot press mold (401) includes a second gantry frame (402), a third electric telescopic rod (403), a fourth electric telescopic rod (404), an upper mold (405), and a lower mold (406). The second gantry frame (402) is horizontally mounted above the working platform (1). The third electric telescopic rod (403) is fixedly installed on the crossbeam of the second gantry frame (402). The upper mold (405) is fixedly connected to the telescopic end of the third electric telescopic rod (403). A second mounting groove is correspondingly provided on the working platform (1). The fourth electric telescopic rod (404) is fixedly installed at the bottom of the inner cavity of the second mounting groove. The lower mold (406) is fixedly connected to the telescopic end of the fourth electric telescopic rod (404).

7. The continuous fiber-reinforced thermoplastic composite molding system according to claim 5, characterized in that: The cooling assembly (5) includes a third gantry frame (501) and multiple cooling fans (502). The third gantry frame (501) is horizontally mounted above the work platform (1). The multiple cooling fans (502) are fixedly installed at the bottom of the crossbeam of the third gantry frame (501) in a matrix arrangement and are positioned towards the workpiece (8) being conveyed downwards, for forced air cooling of the surface of the workpiece after hot pressing.

8. The continuous fiber reinforced thermoplastic composite molding system according to claim 5, characterized in that: The storage assembly (6) includes a storage frame (601), a fifth electric telescopic rod (602), a lifting plate (603), a second drive motor (604), a threaded rod (605), a fourth gantry frame (606), a sixth electric telescopic rod (607), a guide rod (608), and a push plate (609). The fourth gantry frame (606) is horizontally mounted above the work platform (1). The storage frame (601) is located on one side of the work platform (1). The second drive motor (604) is mounted on the upright on the corresponding side of the fourth gantry frame (606). One end of the threaded rod (605) is fixedly connected to the rotating end of the second drive motor (604) via a coupling, and the other end is threadedly connected to the storage frame (601). The fourth gantry frame (606) is fixedly connected to the guide rod (608) on the side near the storage frame (601). The storage frame (601) is slidably sleeved on the guide rod (608). The work platform (1) is provided with a third mounting slot. The fifth electric telescopic rod (602) is fixedly installed at the bottom of the inner cavity of the third mounting slot. The lifting plate (603) is fixedly connected to the telescopic end of the fifth electric telescopic rod (602). The sixth electric telescopic rod (607) is installed on the upright on the other side of the fourth gantry frame (606). The push plate (609) is fixedly connected to the telescopic end of the sixth electric telescopic rod (607) for pushing the workpiece (8) into the storage frame (601) for collection and residual heat cooling.

9. A continuous fiber-reinforced thermoplastic composite molding system according to claim 5, characterized in that: The transplanting circulation assembly (7) includes a fifth gantry frame (701), a seventh electric telescopic rod (702), and a mechanical gripper (703). The fifth gantry frame (701) is located above the work platform (1), and the axial direction of the crossbeam of the fifth gantry frame (701) is consistent with the long side direction of the work platform (1). The seventh electric telescopic rod (702) is slidably connected to the bottom of the crossbeam of the fifth gantry frame (701) through a servo motor drive mechanism. The mechanical gripper (703) is installed at the telescopic end of the seventh electric telescopic rod (702) and is used to clamp the empty workpiece clamping tray (9).

10. A molding process for a continuous fiber-reinforced thermoplastic composite molding system based on any one of claims 1 to 9, characterized in that: Includes the following steps: Step 1: The workpiece (8) to be processed is clamped on the conveying assembly (2) through the workpiece clamping tray (9), and the conveying assembly (2) is started to transport the workpiece (8) to each processing station in sequence; Step 2: When the positioning detection unit confirms that the workpiece clamping tray (9) is accurately positioned at the processing position of the local heating component (3), the first electric telescopic rod (302) and the second electric telescopic rod (303) respectively drive the first double-layer clamp (304) and the second double-layer clamp (305) to move towards each other, so that the heating plate (306) and the baffle (307) are close to the workpiece (8), and the heating unit (3061) is started to locally heat the workpiece (8); Step 3: After heating is completed, the local heating component (3) is reset, and the conveying component (2) conveys the workpiece (8) to the parallel hot press mold group (4); after the positioning detection unit confirms that it is in place, the third electric telescopic rod (403) and the fourth electric telescopic rod (404) of each hot press mold (401) drive the upper mold (405) and the lower mold (406) to close the mold and perform hot pressing on the workpiece (8); Step 4: After hot pressing is completed, the mold is opened and reset. The conveying component (2) conveys the workpiece (8) to the cooling component (5). The cooling fan (502) is started to force the surface of the workpiece (8) to be cooled by air. Step 5: After cooling, the workpiece (8) is transported to the storage assembly (6). The fifth electric telescopic rod (602) drives the lifting plate (603) to rise and lift the workpiece (8) so that it is separated from the workpiece clamping tray (9). The sixth electric telescopic rod (607) drives the push plate (609) to push the workpiece (8) into the storage frame (601) for collection and residual heat cooling. Step six: The empty workpiece clamping tray (9) is held by the mechanical gripper (703) of the transfer circulation assembly (7), lifted by the seventh electric telescopic rod (702), and then transported back to the initial position of the conveying assembly (2) by the servo motor driven mechanism to complete one processing cycle.

Images