Alignment method for precise forming tool of large composite wallboard type structure

Abstract

The invention belongs to the technical field of profile machining, and particularly relates to an alignment method for a precise forming tool of a large composite wallboard type structure. The method comprises the following steps: firstly, processing a high-precision reference plane on a mold bottom plate; then measuring datum hole machining and die semi-finish machining are completed on a machine tool platform; a global coordinate system is established through a laser tracker, and finish machining is carried out; after a multi-point adjustable support is installed, a quadrilateral optical monitoring network comprising a plurality of observation lines is constructed above the mold; and finally, on the basis of the observation lines, posture adjustment is conducted on the mold comprising the composite wall plate at key process positions such as fiber laying, tape laying and hot press forming. The forming precision of the large composite wallboard is improved.

Description

Technical Field

[0001] This application belongs to the field of profile processing technology, specifically relating to a method for adjusting a tooling for precise forming of large composite wall panel structures. Background Technology

[0002] Composite material wall panels are increasingly used in the aerospace field, and their molding accuracy directly affects the aerodynamic performance and structural safety of aircraft. Large composite wall panels (typically structural components exceeding 10 meters in length and 2 meters in width) require multiple processes during manufacturing, including mold processing, mold calibration, mold inspection, AGV transportation, ground support, fiber and tape laying, AGV transportation, in-tank platform support, thermoforming, AGV transportation, post-forming processing, and inspection. During these processes, the mold is prone to uncontrollable elastic deformation due to its own weight, changes in support conditions, thermal stress, and residual stress. This deformation is particularly problematic in the critical stages of fiber and tape laying and thermoforming, where mold deformation can directly cause the cured composite product to deviate from its theoretical shape, leading to assembly difficulties or performance degradation.

[0003] In existing technologies, the inconsistent flatness of the support platforms of various process equipment (such as machine tools, wire and tape laying equipment, autoclaves, etc.) and the difficulty in setting up high-precision support structures in confined spaces such as autoclaves lead to the accumulation of reference transfer errors between different positions of the mold. Especially during the hot pressing process, local warping or overall tilting of the mold can cause irreparable surface deviations in the cured composite panel. Currently, there is a lack of a unified reference and deformation control method in China that can be applied throughout the entire process, making it difficult to effectively guarantee the forming accuracy of ultra-large composite panels. Summary of the Invention

[0004] To address the aforementioned issues, this application provides a method for adjusting the tooling for precise forming of large composite panel structures. This method is suitable for precisely adjusting the reference and shape of the mold during multi-station switching in the forming process of large composite panels or skin structures. Specifically, it is applied to the precision control in the forming process of large composite panels with a length exceeding 10m and a width exceeding 2m.

[0005] The method for adjusting the precision forming tooling for large composite wall panel structures provided in this application mainly includes:

[0006] Step S1: Machin a reference plane on the bottom of the mold to be processed for composite panel structures;

[0007] Step S2: On the machining tool, perform semi-finishing on the mold to be machined, and machine the measuring reference hole on the mold to be machined;

[0008] Step S3: Based on the measurement reference point structure installed on the measurement reference hole, construct a global coordinate system for measuring the mold, and perform finishing on the mold to be processed based on the global coordinate system;

[0009] Step S4: Remove the finished mold from the machine tool and place it on the multi-point adjustable support structure. Adjust the multi-point adjustable support structure so that the mold is consistent with its tilt angle on the machine tool.

[0010] Step S5: A monitoring plane is set at the first spacing above the reference plane of the mold. Multiple observation holes are set at the intersection of the monitoring plane and the mold to form at least four first observation lines around the outer contour of the mold. The four first observation lines enclose a quadrilateral. Each first observation line passes through at least three observation holes. A cross plane is set at the second spacing above the monitoring plane. Multiple observation holes are also set at the intersection of the cross plane and the mold to form at least two second observation lines. In the top view, the second observation lines serve as the diagonals of the quadrilateral. Each second observation line passes through at least three observation holes.

[0011] Step S6: Transfer the mold to the laying equipment, monitor the first observation line and the second observation line with an optical observation instrument, and adjust the multi-point adjustable support structure to ensure that each observation hole is within the coaxial tolerance range of its corresponding observation line.

[0012] Step S7: Perform wire and tape laying for the wall panel structure within the mold;

[0013] Step S8: Move the mold and its wire laying and tape laying wall panel structure together into the autoclave, monitor the first observation line and the second observation line with an optical observation instrument, and adjust the multi-point adjustable support structure to ensure that each observation hole is within the coaxial tolerance range of its corresponding observation line.

[0014] Step S9: Hot-press the mold and its wire-laying and tape-laying wall panel structure.

[0015] Preferably, in step S1, the flatness of the reference plane is processed to be less than 2 / 3 of the processing accuracy required for the shape of the mold.

[0016] Preferably, step S2 further includes:

[0017] Before rough machining the mold to be processed, the first finishing process is completed to retain the machining allowance of the measuring reference hole; after semi-finishing the mold to be processed, the second finishing process is performed on the measuring reference hole.

[0018] Preferably, the machining allowance is set to be less than 1 / 2 of the machining accuracy required for the shape of the mold.

[0019] Preferably, in step S3, the measuring reference point structure is installed in the measuring reference hole via a transition fit.

[0020] Preferably, in step S5, the first spacing is not less than 50 mm, and the second spacing is configured such that the structures to which the observation holes of the first observation line and the second observation line belong do not interfere with each other and have at least 50 mm of clearance space.

[0021] Preferably, in step S5, the distance between multiple observation holes located on the same observation line is not less than 5m.

[0022] Preferably, in step S5, the observation hole is a through hole opened on the ear plate structure with a corner plate or a folded plate. A filling space is reserved between the ear plate structure and the mold for fine-tuning its position. After adjusting each observation hole to be coaxial to form a corresponding observation line, cement is filled in the filling space to solidify and connect the ear plate structure and the mold.

[0023] Preferably, the height of the filling space is not less than 10mm and the area is not less than 3cm². 2 .

[0024] Preferably, adjusting the coaxiality of each observation hole includes ensuring that the installation deviation tolerance of the axis of each observation hole relative to the axis is less than 1 / 5 of the machining accuracy required by the shape of the mold.

[0025] This application unifies all processes in the molding of composite wall panels through a reference plane, a measurement reference structure, and a mesh observation line, thereby achieving precise control of the overall deformation of large composite wall panel molds and improving the molding accuracy of large composite wall panels. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the process of a preferred embodiment of the method for adjusting the tooling for precise forming of large composite wall panel structures according to this application.

[0027] Figure 2 This is a schematic diagram of the installation of the measurement reference point structure.

[0028] Figure 3 This is a schematic diagram showing the positional relationship between the monitoring plane and the intersecting plane.

[0029] Figure 4 This is a schematic diagram of an optical observation instrument.

[0030] Among them, 1-mold; 2-machine tool; 3-datum plane; 4-outline; 5-measuring datum hole; 6-layout equipment; 7-autoclave; 8-foundation; 9-ground plane; 10-transportation bracket; 11-platform; 12-measuring datum point structure; 13-shoulder surface; 14-hole axis; 15-multi-point adjustable support structure; 16-monitoring plane; 17a-first observation line; 17b-second observation line; 18-intersecting plane; 19-ear plate structure; 20-observation hole; 21-optical observation instrument. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions in the embodiments of this application will be described in more detail below with reference to the accompanying drawings. In the drawings, the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The described embodiments are only some, not all, of the embodiments of this application. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without creative effort are within the scope of protection of this application. The embodiments of this application will be described in detail below with reference to the accompanying drawings.

[0032] This application addresses the challenge of precisely controlling the deformation of composite panels and skin structures related to large aircraft fuselages and wings. Specifically, it studies methods for achieving precise adjustment of molds and tooling during panel or skin forming. The research focuses on unified methods for testing benchmarks in mold processing, wire and tape laying, thermoforming, and inspection processes. In particular, it provides solutions for the precise leveling and positioning process of large molds with non-precision support structures in the confined space of autoclaves.

[0033] This application proposes a method for adjusting the tooling for precise forming of large composite wall panel structures, mainly including:

[0034] Step S1: Machin the reference plane 3 on the bottom of the mold 1 to be processed in the composite wall panel structure;

[0035] Step S2: On the machining machine tool 2, perform semi-finishing on the mold 1 to be processed, and machine the measuring reference hole 5 on the mold 1 to be processed;

[0036] Step S3: Based on the measurement reference point structure 12 installed on the measurement reference hole 5, construct a global coordinate system for measuring the mold 1, and perform fine machining on the mold 1 to be machined based on the global coordinate system;

[0037] Step S4: Remove the finished mold 1 from the machine tool 2 and place it on the multi-point adjustable support structure 15. Adjust the multi-point adjustable support structure 15 so that the mold 1 is consistent with its tilt angle on the machine tool 2.

[0038] Step S5: A monitoring plane 16 is set at a first distance upward from the reference plane 3 of the mold 1. Multiple observation holes 20 are set at the intersection of the monitoring plane 16 and the mold 1 to form at least four first observation lines 17a around the outer contour of the mold 1. The four first observation lines 17a enclose a quadrilateral. Each first observation line 17a passes through at least three observation holes 20. A cross plane 18 is set at a second distance upward from the monitoring plane 16. Multiple observation holes 20 are also set at the intersection of the cross plane 18 and the mold 1 to form at least two second observation lines 17b. In a top view, the second observation lines 17b serve as the diagonals of the quadrilateral. Each second observation line 17b passes through at least three observation holes 20.

[0039] Step S6: Transfer the mold 1 to the laying device 6, monitor the first observation line and the second observation line through the optical observation instrument 21, and adjust the multi-point adjustable support structure 15 so that each observation hole 20 is within the coaxial tolerance range of its corresponding observation line.

[0040] Step S7: Perform wire and tape laying for the wall panel structure within the mold 1;

[0041] Step S8: Move the mold 1 and its wire laying and tape laying wall panel structure together into the autoclave 7. Monitor the first observation line and the second observation line through the optical observation instrument 21. Adjust the multi-point adjustable support structure 15 to ensure that each observation hole 20 is within the coaxial tolerance range of its corresponding observation line.

[0042] Step S9: Hot-press the mold 1 and its wire-laying and tape-laying wall panel structure.

[0043] First refer to Figure 1 The general process of forming composite wall panels is shown below. First, mold 1 is machined on machine tool 2 to form the reference plane 3, shape 4, and measuring reference holes 5. After machining, accuracy is checked at the inspection station. Then, it enters the laying equipment 6 for wire and tape laying and manual application. Next, it enters the autoclave 7 for thermoforming. After forming, it enters the inspection or reprocessing series. The machine tool 2, laying equipment 6, and autoclave 7 are all set on the foundation 8. Generally, the table of machine tool 2 is higher than the ground plane 9. Mold 1 enters machine tool 2 by hoisting. The inspection station and the table of laying equipment 6 are flush with the ground plane 9. Mold 1 enters laying equipment 6 by transport equipment. The placement plane of autoclave 7 is flush with the ground plane 9. Mold 1 enters autoclave 7 by transport bracket 10.

[0044] In step S1, the reference plane 3 needs to be machined on the machine tool 2.

[0045] In some alternative embodiments, in step S1, the flatness of the reference plane 3 is machined to less than 2 / 3 of the machining accuracy required for the shape 4 of the mold 1.

[0046] In step S2, the measuring reference hole 5, the semi-finished mold shape 4, and other structural features of the mold need to be machined on the platform 11 of the machining tool 2, with the reference plane 3 as the reference.

[0047] In some alternative implementations, step S2 further includes:

[0048] Before rough machining of the mold 1 to be processed, the first finishing machining of the measuring reference hole 5 is completed, leaving a machining allowance; after semi-finishing of the mold 1 to be processed, the measuring reference hole 5 is finished a second time.

[0049] In some alternative embodiments, the machining allowance is set to be less than 1 / 2 of the machining accuracy required for the shape 4 of the mold 1.

[0050] It should also be noted that the flatness of the platform 11 in this application should be lower than the flatness of the reference plane 3 processed in step S1.

[0051] In step S3, the mold 1 needs to be precision machined with the help of the measuring reference point structure 12.

[0052] First, the measurement reference point structure 12 needs to be machined. The measurement reference point structure 12 generally includes a bushing or target holder, and is a structure that can be used with a laser tracker for positioning. Multiple measurement reference point structures 12 are used to determine the shape or other structural features of the mold 1, thus assisting in the machining of the mold 1. For example... Figure 2 As shown, the main control features of the machining of the measuring reference point structure 12 are the hole diameter accuracy, the flatness of the upper surface of the shoulder at the end of the hole, and the perpendicularity of the shoulder surface 13 to the hole axis 14. After machining, it is installed in the measuring reference hole 5. In some optional embodiments, in step S3, the measuring reference point structure 12 is installed in the measuring reference hole 5 through a small clearance transition fit.

[0053] Subsequently, based on the measurement reference point structure 12, a global coordinate system for measuring mold 1 is established. According to this global coordinate system, the coordinate values ​​of all measurement reference point structures 12 are calibrated. Based on the measurement reference point structure 12 and the global coordinate system, the shape 4 and other structural features of the mold are precision machined.

[0054] Finally, on the machining tool, based on the measurement reference point structure 12 and the global coordinate system, the shape 4 and structural features of the mold are inspected, and the inspection data is used as the basis for the shape change of the mold 1 in subsequent processes. Throughout the entire machining process of the mold 1, the positioning and clamping state of the mold 1 on the platform 11 of the machining tool 2 must not be changed.

[0055] In step S4, the finished mold 1 is removed from the shelf and placed on the multi-point adjustable support structure 15 so that its posture can be adjusted in subsequent processes. In this embodiment, the multi-point adjustable support structure 15 refers to a structure that can support the mold 1 and has multiple adjustable height positions. The simplest example is that the support plate is provided with multiple threaded holes and bolts are adapted to be installed. By rotating the bolts at different positions, the posture of the mold 1 located above the bolts can be adjusted.

[0056] like Figure 1 As shown, move mold 1 to the inspection position, and adjust the multi-point adjustable support structure 15 according to the measurement reference point structure 12 and the global coordinate system until the inspection is qualified.

[0057] In step S5, two planes and six observation lines are constructed. Specifically, a monitoring plane 16 is constructed equidistantly upwards along the outer contour of the reference plane 3 of the mold 1. Four first observation lines 17a surround the outer contour of the mold 1 on the monitoring plane 16. An intersecting plane 18 is constructed equidistantly upwards on the monitoring plane 16, and two diagonally opposite second observation lines 17b are set, as shown below. Figure 1 As shown, from a top-down perspective, a total of 6 mesh-like observation lines are formed on monitoring plane 16 and intersecting plane 18.

[0058] In some alternative implementations, in step S5, the first spacing is not less than 50 mm, and the second spacing is configured such that the structures to which the observation holes 20 of the first observation line 17a and the second observation line 17b belong do not interfere with each other and have at least 50 mm of clearance space.

[0059] refer to Figure 3 and Figure 4 The monitoring plane 16 needs to be at least 50 mm higher than the reference plane 3 so that various auxiliary measuring devices can be installed on the monitoring plane 16 to form an observation hole for constructing the first observation line 17a. Similarly, the intersecting plane 18 should be at least 50 mm higher than the monitoring plane 16 so as to construct an observation hole for the second observation line 17b and not interfere with the auxiliary measuring devices formed on the monitoring plane 16.

[0060] In some alternative implementations, in step S5, the multiple observation holes 20 located on the same observation line are at least 5m apart from each other.

[0061] This embodiment ensures that the overall posture of the mold 1 is controllable through multiple observation holes 20.

[0062] In some alternative embodiments, in step S5, the observation hole 20 is a through hole opened on the ear plate structure 19 with a corner plate or folding plate. The ear plate structure 19 and the mold 1 are reserved with a filling space for fine adjustment of their positions. After adjusting each observation hole 20 to be coaxial to form the corresponding observation line, the connection is solidified by filling with cement.

[0063] refer to Figure 3 and Figure 4 The auxiliary measuring equipment for each observation line is an ear plate structure 19, with a pre-reserved gap of not less than 10mm to 15mm and an area of ​​not less than 3cm² at the connection between it and the mold 1. 2 After adjusting the coaxial alignment, fill the space with high-strength grouting cement until it hardens.

[0064] In some alternative embodiments, adjusting the coaxiality of each observation hole 20 includes making the installation deviation tolerance of the axis of each observation hole 20 relative to the axis less than 1 / 5 of the machining accuracy required for the shape 4 of the mold 1.

[0065] This application uses optical observation instruments 21, such as collimators, for coaxial installation and adjustment. For each observation line, it should be ensured that the hole axes of the observation holes 20 it covers are on the same axis.

[0066] With the above auxiliary testing devices, the posture of mold 1 can be adjusted during the subsequent use of mold 1, including filament and tape laying, hot pressing and forming and various testing processes.

[0067] In step S6, the mold 1 is transferred to the laying device 6. Based on the optical observation instrument 21, such as a collimator, the optical observation lines of the six observation lines are monitored. The position of the observation holes 20 deviating from the observation lines is adjusted by the multi-point adjustable support structure 15 until each observation hole 20 is within the coaxial tolerance range of its corresponding observation line. After adjustment, the wire and tape laying is performed in step S7.

[0068] Similarly, in step S8, the mold 1 and the formed wall panel structure are moved to the autoclave 7 for hot pressing. In the autoclave 7, as shown in step S6, the height of the mold 1 is adjusted using the multi-point adjustable support structure 15 until all observation holes 20 are within the coaxial tolerance range of their corresponding observation lines. After adjustment, in step S9, hot pressing is performed until the mold is removed from the autoclave 7.

[0069] Subsequently, mold 1 and the wall panel structure are moved to the post-forming processing position, and the above-mentioned inspection and posture adjustment steps are repeated to perform post-forming shaping processing. After completion, they are moved to the inspection station, and the above-mentioned inspection and posture adjustment steps are repeated to inspect the wall panel mechanism until the inspection is completed.

[0070] This application employs a dot-matrix adjustable support system that supports mold loads and allows for height adjustment. It comprehensively utilizes the machine tool platform's reference plane, measurement reference holes, measurement reference point structure, and a laser tracker to establish a coordinate system. Through collimator optical observation of linear deflection and other reference positioning monitoring methods, the entire process of composite panel forming is fully unified. This allows for controlling the overall deformation of a 30m-sized large composite panel mold to within 0.2mm, and the overall deformation of the formed composite panel to within 0.5mm. This solution is suitable for forming large composite panels exceeding 10m in length and 2m in width, and has broad applicability to the forming and manufacturing of large composite panel structures for aircraft, rockets, and other applications.

[0071] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A method for adjusting a precision forming fixture for large composite wall panel structures, characterized in that, Includes the following steps: Step S1: Machin the reference plane (3) on the bottom of the mold (1) to be processed in the composite wall panel structure. Step S2: On the machining machine tool (2), perform semi-finishing on the mold (1) to be processed, and machine the measuring reference hole (5) on the mold (1) to be processed. Step S3: Based on the measurement reference point structure (12) installed on the measurement reference hole (5), construct a global coordinate system for measuring the mold (1), and perform finishing on the mold (1) to be processed based on the global coordinate system; Step S4: Remove the finished mold (1) from the machine tool (2) and place it on the multi-point adjustable support structure (15). Adjust the multi-point adjustable support structure (15) so that the mold (1) is aligned with its tilt angle on the machine tool (2). Step S5: A monitoring plane (16) is set at the first spacing above the reference plane (3) of the mold (1). Multiple observation holes (20) are set at the intersection of the monitoring plane (16) and the mold (1) to form at least four first observation lines (17a) around the outer contour of the mold (1). The four first observation lines (17a) enclose a quadrilateral. Each first observation line (17a) passes through at least three observation holes (20). A cross plane (18) is set at the second spacing above the monitoring plane (16). Multiple observation holes (20) are also set at the intersection of the cross plane (18) and the mold (1) to form at least two second observation lines (17b). In the top view, the second observation lines (17b) serve as the diagonals of the quadrilateral. Each second observation line (17b) passes through at least three observation holes (20). Step S6: Transfer the mold (1) to the laying device (6), monitor the first observation line and the second observation line through the optical observation instrument (21), and adjust the multi-point adjustable support structure (15) so that each observation hole (20) is within the coaxial tolerance range of its corresponding observation line. Step S7: Perform wire and tape laying for the wall panel structure within the mold (1); Step S8: Move the mold (1) and its wire laying and tape laying wall panel structure together into the autoclave (7), monitor the first observation line and the second observation line through the optical observation instrument (21), and adjust the multi-point adjustable support structure (15) so that each observation hole (20) is within the coaxial tolerance range of its corresponding observation line. Step S9: Hot press the mold (1) and its wire-laying and tape-laying wall panel structure.

2. The method for adjusting the precision forming tooling of large composite wall panel structures according to claim 1, characterized in that, In step S1, the flatness of the reference plane (3) is processed to be less than 2 / 3 of the processing accuracy required for the shape (4) of the mold (1).

3. The method for adjusting the precision forming tooling of large composite wall panel structures according to claim 1, characterized in that, Step S2 further includes: Before rough machining of the mold (1) to be processed, the first finishing machining of the measuring reference hole (5) with the remaining machining allowance is completed; after semi-finishing of the mold (1) to be processed, the second finishing machining of the measuring reference hole (5) is performed.

4. The method for adjusting the precision forming tooling of large composite wall panel structures according to claim 3, characterized in that, The machining allowance is set to be less than 1 / 2 of the machining accuracy required for the shape (4) of the mold (1).

5. The method for adjusting the precision forming tooling of large composite wall panel structures according to claim 1, characterized in that, In step S3, the measurement reference point structure (12) is installed in the measurement reference hole (5) by a transition fit.

6. The method for adjusting the precision forming tooling of large composite wall panel structures according to claim 1, characterized in that, In step S5, the first spacing is not less than 50 mm, and the second spacing is configured such that the structures to which the observation holes (20) of the first observation line (17a) and the second observation line (17b) belong do not interfere with each other and have at least 50 mm of clearance space.

7. The method for adjusting the precision forming tooling of large composite wall panel structures according to claim 1, characterized in that, In step S5, the distance between multiple observation holes (20) located on the same observation line is not less than 5m.

8. The method for adjusting the precision forming tooling of large composite wall panel structures according to claim 1, characterized in that, In step S5, the observation hole (20) is a through hole opened on the ear plate structure (19) with corner plate or fold plate. A filling space is reserved between the ear plate structure (19) and the mold (1) for fine adjustment of its position. After adjusting each observation hole (20) to be coaxial to form the corresponding observation line, cement is filled in the filling space to solidify and connect the ear plate structure (19) and the mold (1).

9. The method for adjusting the precision forming tooling of large composite wall panel structures according to claim 8, characterized in that, The height of the filling space shall not be less than 10mm, and the area shall not be less than 3cm². 2 .

10. The method for adjusting the precision forming tooling of large composite wall panel structures according to claim 8, characterized in that, Adjusting the coaxiality of each observation hole (20) includes ensuring that the installation deviation tolerance of the axis of each observation hole (20) relative to the axis is less than 1 / 5 of the machining accuracy required by the shape (4) of the mold (1).

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