Flexible weaving forming method and equipment for composite material prefabricated body

Abstract

The invention discloses a flexible weaving forming method and equipment for a composite material preform, and the method can select weaving, sewing and / or needling sequence collaborative operation for a weaving area, or select weaving, sewing and / or needling alternative collaborative operation for the weaving area. The continuous processing of the prefabricated body on a complex curved surface and a large bending area is realized, and the production efficiency is improved; according to the equipment, the modular weaving device, the flexible array needling device and the sewing device are integrated on the same platform, and continuous processing of a prefabricated body on a complex curved surface and a large bending area can be achieved under the condition that multi-equipment sequence turning and manual carrying are not needed.

Description

Technical Field

[0001] This invention relates to the field of composite material preform forming technology, specifically to a flexible weaving forming method and equipment for composite material preforms. Background Technology

[0002] Composite preforms are widely used in aerospace, shipbuilding, and automotive industries, placing higher demands on the forming accuracy and reliability of large-size, irregularly shaped, and variable-thickness components. Traditional processes typically involve separate weaving, sewing, needle punching, and laminating equipment, requiring frequent manual handling and secondary positioning. This makes it difficult to achieve process continuity and online quality control, resulting in uneven interlayer bonding, large dimensional deviations, and low production efficiency. Flexible weaving, through programmable yarn paths, local reversal, and multi-axis synchronous control, enables multiple processes such as weaving, local sewing, and directional needle punching to be integrated and operated collaboratively on the same platform as needed. Combined with online visual inspection and adaptive closed-loop control, flexible weaving can achieve displacement compensation, local directional reinforcement, and real-time optimization of process parameters on complex curved surfaces. This significantly reduces intermediate handling, improves interlayer bonding strength and mechanical consistency, and enhances the equipment's rapid changeover and customization capabilities. However, current forming methods and equipment that deeply integrate flexible weaving with distributed control, online inspection, and multi-process linkage are still immature. Summary of the Invention

[0003] Purpose of the invention: This invention provides a flexible weaving forming method for composite material preforms, with the aim of achieving multi-process linkage forming of preforms involving weaving, sewing, and needle punching.

[0004] The present invention also provides equipment for a flexible weaving forming method of composite material preforms, the purpose of which is to integrate the weaving, sewing and needle punching of preforms on the same platform, so as to realize the multi-process linkage forming of preforms without the need for multiple equipment transfers and manual handling.

[0005] Technical Solution: To achieve the above objectives, the present invention provides a flexible weaving forming method for composite material preforms, which can adopt the following technical solution, including:

[0006] (1) Set the forming process parameters for the preform to be formed;

[0007] (2) The central control unit processes the input parameters and sends the process to each actuator through the lower-level PLC device; the actuator includes the knitting process actuator, the needle punching process actuator and the sewing process actuator;

[0008] (3) In the central control unit, the prefabricated body is initially processed by selecting the sequence of weaving, sewing and / or needle punching in the weaving area or by selecting the alternating sequence of weaving, sewing and / or needle punching. When the sequence of weaving, sewing and / or needle punching is selected for the weaving area, the weaving area is continuously woven to the preset number of layers to obtain the overall structure, and then the overall structure is reinforced by sewing and / or thick needle punching. When the alternating sequence of weaving, sewing and / or needle punching is selected for the weaving area, the weaving action is paused after the first weaving to the first preset number of layers is completed, and the weaving area is reinforced by the first sewing and / or the first needle punching. Then the weaving area is continued to be woven to the second preset number of layers, and then the weaving area is reinforced by the second sewing and / or the second needle punching. That is, the alternating sequence of weaving, sewing and / or needle punching is carried out until all the preset weaving, sewing and / or needle punching operations are completed.

[0009] (4) After receiving the servo signals during the initial processing, the central control unit feeds back the parameters that need to be adjusted to the knitting process execution mechanism, the needle punching process execution mechanism and the sewing process execution mechanism in real time.

[0010] (5) Complete the flexible weaving forming operation of composite material preforms.

[0011] The parameters in step (1) include:

[0012] Yarn weaving angle, number of weaving cycles, and yarn tension during the weaving process;

[0013] The stitch spacing and suture tension during the stitching process;

[0014] Needle density and needle insertion frequency during the acupuncture process.

[0015] The parameters that need to be adjusted in step (4) include the needle punching force, yarn tension, and suture tension in the sewing process.

[0016] Beneficial effects: The flexible weaving forming method for composite material preforms provided by the present invention can select the sequential or alternating operation of weaving, sewing, and needle punching according to the structural requirements of the preform, so as to realize the continuous processing of the preform in complex curved surfaces and large bending areas and improve production efficiency.

[0017] The equipment used in the flexible weaving forming method for composite material preforms provided by this invention can adopt the following technical solutions:

[0018] It includes a central control unit, a modular knitting device, a flexible array needle punching device, a sewing device, a guide rail, and a mandrel clamp; the mandrel clamp is located on the guide rail and moves along the guide rail, the modular knitting device is located at one end of the guide rail, the sewing device is located at the other end of the guide rail, the flexible array needle punching device is located beside the guide rail, and the flexible array needle punching device is located between the modular knitting device and the sewing device; the mandrel clamp is moved to the workstation of the modular knitting device, the flexible array needle punching device, or the sewing device according to a preset operation sequence via the guide rail.

[0019] Furthermore, the modular weaving device is equipped with several yarn carriers arranged in a ring. Each yarn carrier is equipped with a yarn tension sensor and an active yarn release mechanism. The yarn tension is collected by the yarn tension sensor, and the release speed is adjusted by the active yarn release mechanism according to the set yarn tension value to keep the yarn under stable tension throughout the weaving process.

[0020] Furthermore, the flexible array needle acupuncture device is equipped with rows of needles, a drive device that drives the needles to reciprocate along the needle axis, and a force sensor for detecting the needle acupuncture force; the central control unit monitors the needle acupuncture force during the needle insertion process in real time, and when the detected force exceeds the set threshold, it adjusts the insertion speed or stops the current needle acupuncture action.

[0021] Furthermore, the suturing device is equipped with a suture tension sensor for detecting suture tension. The suture passes through the suture tension sensor during the suture feeding process, and the central control unit adjusts the feeding speed or braking force according to the suture tension signal to keep the suture stable when forming the stitch.

[0022] Furthermore, the modular knitting device also includes a corner wheel motion unit, a dial motion unit, a gear transmission unit, and a motor drive unit. The gear transmission unit is rigidly coupled to the motor drive unit via a transmission shaft. The corner wheel motion unit and the dial motion unit are mechanically coupled to the gear transmission unit via flat shafts. The yarn carrier unit achieves mechanical positioning and guidance with the corner wheel motion unit via an independent base. By calculating the rotation angle and displacement trajectory of the corner wheel and synchronously driving the corner wheel to rotate by the motor drive unit and the gear transmission unit, the spatial direction of the yarn entering the knitting area is changed to achieve control of the knitting angle.

[0023] Furthermore, the flexible array needle-punching device includes a robotic arm and a needle-punching unit installed at the execution end of the robotic arm; the needle-punching unit includes an upper support installed at the execution end of the robotic arm, an upper cylinder and a cylinder guide rod located on the support, the output ends of the upper cylinder and the cylinder guide rod are connected to a lower support, the lower support is provided with a pressure regulating cylinder, a short fiber introduction mechanism connected to the output end of the pressure regulating cylinder, a needle installed on the short fiber introduction mechanism, limiting plates on both sides of the short fiber introduction mechanism, and a pressure plate located below the needle, the pressure plate having an opening for the needle to pass through.

[0024] Furthermore, the sewing device includes a displacement compensation unit, a thread guide unit, a compaction unit, a bend needle guide unit, and a hook thread unit. The thread guide unit, the compaction unit, and the bend needle guide unit are connected to the main body of the device, and the hook thread unit is connected to the main body of the device via a drive shaft.

[0025] Beneficial effects: This invention integrates a modular weaving device, a flexible array needle punching device, and a sewing device onto a single platform, enabling continuous processing of prefabricated bodies on complex curved surfaces and areas with large bends without requiring multiple equipment transfers or manual handling. Real-time monitoring of operational data by sensors provides the data to a central control unit, which dynamically adjusts the weaving angle, sewing path, and needle punching parameters, improving process stability and repeatability. Attached Figure Description

[0026] Figure 1 This is a flowchart of the flexible weaving forming method for composite material preforms in this invention;

[0027] Figure 2 This is a schematic diagram of the overall structure of the flexible weaving equipment in this invention;

[0028] Figure 3 This is a structural diagram showing the locations of the modular weaving device, flexible array needle punching device, sewing device, guide rail, mandrel clamp, and feed mechanism in a flexible weaving equipment.

[0029] Figure 4 This is a partial structural diagram of a modular weaving device;

[0030] Figure 5 This is a schematic diagram of the array needle puncture device;

[0031] Figure 6 A schematic diagram of the adaptive enhanced acupuncture unit structure of the array acupuncture device;

[0032] Figure 7 This is a schematic diagram of the suturing device. Detailed Implementation

[0033] This invention provides an experimental method for obtaining the salt deposition patterns in the airflow channels of an aero-engine, comprising:

[0034] Example 1

[0035] Please see Figure 1 As shown, this embodiment provides a method for flexible weaving and forming of composite material preforms, including the following steps:

[0036] (1) Set the forming process parameters for the preform to be formed; the parameters include:

[0037] Yarn weaving angle, number of weaving cycles, and yarn tension during the weaving process;

[0038] The stitch spacing and suture tension during the stitching process;

[0039] Needle density and needle insertion frequency during the acupuncture process.

[0040] (2) The central control unit processes the input parameters and sends the process to each actuator through the lower-level PLC device; the actuator includes the weaving process actuator, the needle punching process actuator and the sewing process actuator.

[0041] (3) In the central control unit, the weaving area is pre-selected to perform weaving, sewing and / or needle punching in sequence or to perform weaving, sewing and / or needle punching alternately to complete the preliminary processing of the preform.

[0042] When the knitting, sewing and / or needle punching sequence is selected to work together on the knitting area, the knitting area is continuously knitted to the preset number of layers to obtain the overall structure, and then the overall structure is reinforced by sewing and / or thick-direction needle punching.

[0043] When alternating weaving, sewing, and / or needle punching operations are selected for the woven area, after the first weaving to the first preset number of layers is completed, the weaving action is paused, and the woven area undergoes its first sewing and / or first needle punching reinforcement. Then, the woven area continues to be woven to the second preset number of layers, followed by a second sewing and / or second needle punching reinforcement. This alternating operation continues until all preset weaving, sewing, and / or needle punching operations are completed. In this alternating operation, a suitable collaborative operation method can be selected based on the interlayer bonding performance requirements of the woven area. For example, after weaving, only one of sewing or needle punching operations can be used to provide secondary reinforcement to the woven area, or a method of sewing first and then needle punching can be used to provide secondary reinforcement to the woven area. This collaborative operation method improves the flexibility for sewing areas at different locations on the precast body.

[0044] (4) After receiving the servo signals during the initial processing, the central control unit feeds back the parameters that need to be adjusted to the knitting process execution mechanism, the needle punching process execution mechanism, and the sewing process execution mechanism in real time. The parameters that need to be adjusted include the needle punching force, yarn tension, and sewing thread tension in the needle punching process.

[0045] (5) Complete the flexible weaving forming operation of composite material preforms.

[0046] After completion, the composite material preform is tested. If the composite material preform does not meet the predetermined performance requirements, return to step (2) to adjust the parameters and re-weave.

[0047] Example 2

[0048] This embodiment provides a flexible weaving equipment, which is applicable to the flexible weaving forming method of composite material preforms in Embodiment 1.

[0049] Please combine Figure 2 and Figure 3 As shown, the flexible weaving equipment includes a central control unit, a modular weaving device 1, a flexible array needle punching device 2, a sewing device 3, a guide rail 24, a mandrel clamp 26, and a feeding mechanism 28. A prefabricated mandrel 25 is mounted on the mandrel clamp 26. The sewing device 3 adjusts the distance between itself and the mandrel clamp 26 via the feeding mechanism 28 to adjust the sewing spacing during the sewing process.

[0050] The core mold clamp 26 is located on the guide rail 24 and moves along the guide rail 24. The modular knitting device 1 is located at one end of the guide rail 24, the sewing device 3 is located at the other end of the guide rail 24, and the flexible array needle punching device 2 is located beside the guide rail. The flexible array needle punching device 2 is located between the modular knitting device 1 and the sewing device 3. The core mold clamp 26 is moved to the work station of the modular knitting device 1, the flexible array needle punching device 2, or the sewing device 3 according to the preset operation sequence through the guide rail 24.

[0051] Please combine Figure 3 and Figure 4 As shown, the modular weaving device 1 is equipped with several yarn carriers 5 arranged in a ring, a corner wheel motion unit 6, a dial motion unit 7, a gear transmission unit 8, and a motor drive unit 9. The gear transmission unit 8 is rigidly coupled to the motor drive unit 9 via a transmission shaft; the corner wheel motion unit 6 and the dial motion unit 7 are mechanically coupled to the gear transmission unit 8 via flat shafts; the yarn carrier unit 5 is mechanically positioned and guided by the corner wheel motion unit 6 via an independent base; by calculating the rotation angle and displacement trajectory of the corner wheel 6 and synchronously driving the corner wheel 6 to rotate by the motor drive unit 9 and the gear transmission unit 8, the spatial direction of the yarn entering the weaving area is changed to achieve control of the weaving angle. During the weaving process, the number of weaving cycles is counted. Each time a complete dial 7 is interlaced and the yarn is laid, an effective weaving structure is formed until the preset thickness of the prefabricated weaving area is reached. This modular weaving device 1 is existing technology and can be replaced by other three-dimensional weaving devices, as long as the three-dimensional weaving process of the prefabricated body can be realized.

[0052] The yarn carrier 5 is equipped with a yarn tension sensor and an active yarn feeding mechanism. The yarn tension sensor collects the yarn tension, and the active yarn feeding mechanism adjusts the feeding speed according to the set yarn tension value to keep the yarn under stable tension throughout the weaving process.

[0053] Please combine Figure 3 , Figure 5 and Figure 6As shown, the flexible array needle-punching device 2 includes a robotic arm 11 and a needle-punching unit 10 mounted on the execution end of the robotic arm 11. The needle-punching unit 10 includes an upper support mounted on the execution end of the robotic arm 11, an upper cylinder 12 and a cylinder guide rod 13 located on the support. The output ends of the upper cylinder 12 and the cylinder guide rod 13 are connected to a lower support. The lower support is provided with a pressure regulating cylinder 14, a pressure regulating valve 15, a short fiber introduction mechanism 16 connected to the output end of the pressure regulating cylinder 14, needles 27 mounted on the short fiber introduction mechanism 16, a force sensor for detecting the needle-punching force, limiting plates 17 located on both sides of the short fiber introduction mechanism 16, and a pressure plate 18 located below the needles 27. The pressure plate 18 has an opening for the needles 27 to pass through. The structure of this flexible array needle-punching device 2 is existing technology and can be replaced by other three-dimensional needle-punching devices, as long as the needle-punching process on the preform can be achieved.

[0054] The central control unit monitors the acupuncture force during the insertion of the needle 27 in real time. When the force exceeds the set threshold, the insertion speed is adjusted or the current acupuncture action is stopped.

[0055] Please combine Figure 3 and Figure 7 As shown, the sewing device 3 includes a displacement compensation unit 19, a thread guide unit 20, a compaction unit 21, a bend needle guide unit 22, and a hook thread unit 23. The thread guide unit 20, the compaction unit 21, and the bend needle guide unit 22 are connected to the main body of the device, and the hook thread unit 23 is connected to the main body of the device via a drive shaft. This sewing device 3 is a prior art structure and can be replaced by other three-dimensional sewing devices, as long as it can perform the sewing process on the prefabricated body.

[0056] The suture device 3 is equipped with a suture tension sensor for detecting suture tension. The suture passes through the suture tension sensor during the suture feeding process. The central control unit adjusts the feeding speed or braking force according to the suture tension signal to keep the suture stable when forming the stitch.

[0057] Furthermore, there are many specific methods and approaches to implement this invention, and the above description is only a preferred embodiment of this invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of this invention, and these improvements and modifications should also be considered within the scope of protection of this invention.

Claims

1. A method for flexible weaving and forming of a composite material preform, characterized in that, Includes the following steps: (1) Set the forming process parameters for the preform to be formed; (2) The central control unit processes the input parameters and sends the process to each actuator through the lower-level PLC device; the actuator includes the knitting process actuator, the needle punching process actuator and the sewing process actuator; (3) In the central control unit, the prefabricated body is initially processed by selecting the sequence of weaving, sewing and / or needle punching in the weaving area or by selecting the alternating sequence of weaving, sewing and / or needle punching. When the sequence of weaving, sewing and / or needle punching is selected for the weaving area, the weaving area is continuously woven to the preset number of layers to obtain the overall structure, and then the overall structure is reinforced by sewing and / or thick needle punching. When the alternating sequence of weaving, sewing and / or needle punching is selected for the weaving area, the weaving action is paused after the first weaving to the first preset number of layers is completed, and the weaving area is reinforced by the first sewing and / or the first needle punching. Then the weaving area is continued to be woven to the second preset number of layers, and then the weaving area is reinforced by the second sewing and / or the second needle punching. That is, the alternating sequence of weaving, sewing and / or needle punching is carried out until all the preset weaving, sewing and / or needle punching operations are completed. (4) After receiving the servo signals during the initial processing, the central control unit feeds back the parameters that need to be adjusted to the knitting process execution mechanism, the needle punching process execution mechanism and the sewing process execution mechanism in real time. (5) Complete the flexible weaving forming operation of composite material preforms.

2. The flexible weaving forming method for composite material preforms according to claim 1, characterized in that, The parameters in step (1) include: Yarn weaving angle, number of weaving cycles, and yarn tension during the weaving process; The stitch spacing and suture tension during the stitching process; Needle density and needle insertion frequency during the acupuncture process.

3. The flexible weaving forming method for composite material preforms according to claim 1, characterized in that, The parameters that need to be adjusted in step (4) include the needle punching force, yarn tension, and suture tension in the sewing process.

4. An apparatus used in the flexible weaving forming method for composite material preforms as described in any one of claims 1 to 3, characterized in that, It includes a central control unit, a modular knitting device (1), a flexible array needle punching device (2), a sewing device (3), a guide rail (24), and a core mold clamp (26); the core mold clamp (26) is located on the guide rail (24) and moves along the guide rail (24), the modular knitting device (1) is located at one end of the guide rail (24), the sewing device (3) is located at the other end of the guide rail (24), the flexible array needle punching device (2) is located beside the guide rail, and the flexible array needle punching device (2) is located between the modular knitting device (1) and the sewing device (3); the core mold clamp (26) is moved to the work station of the modular knitting device (1), the flexible array needle punching device (2), or the sewing device (3) according to the preset operation sequence through the guide rail (24).

5. The flexible weaving forming method for composite material preforms according to claim 4, characterized in that, The modular weaving device (1) is provided with several yarn carriers (5) arranged in a ring. The yarn carriers (5) are equipped with a yarn tension sensor and an active yarn release mechanism. The yarn tension is collected by the yarn tension sensor, and the yarn release speed is adjusted by the active yarn release mechanism according to the set yarn tension value so that the yarn maintains a stable tension throughout the weaving process.

6. The flexible weaving forming method for composite material preforms according to claim 5, characterized in that, The flexible array needle acupuncture device (2) is equipped with rows of needles (27), a driving device that drives the needles (27) to reciprocate along the needle (27) axis, and a force sensor for detecting the needle acupuncture force. The central control unit monitors the needle acupuncture force during the needle insertion process in real time. When the force exceeds the set threshold, the insertion speed is adjusted or the current needle acupuncture action is stopped.

7. The flexible weaving forming method for composite material preforms according to claim 6, characterized in that, The suturing device (3) is equipped with a suture tension sensor for detecting suture tension. The suture passes through the suture tension sensor during the suture feeding process. The central control unit adjusts the feeding speed or braking force according to the suture tension signal so that the suture remains stable when forming the stitch.

8. The flexible weaving forming method for composite material preforms according to claim 5, characterized in that, The modular knitting device (1) also includes a corner wheel motion unit (6), a dial motion unit (7), a gear transmission unit (8), and a motor drive unit (9). The gear transmission unit (8) is rigidly coupled to the motor drive unit (9) through a transmission shaft. The corner wheel motion unit (6) and the dial motion unit (7) are mechanically coupled to the gear transmission unit (8) through flat shafts, respectively. The yarn carrier unit (5) achieves mechanical positioning and guidance with the corner wheel motion unit (6) through an independent base. By calculating the rotation angle and displacement trajectory of the corner wheel (6) and synchronously driving the corner wheel (6) to rotate by the motor drive unit (9) and the gear transmission unit (8), the spatial direction of the yarn entering the knitting area is changed to achieve control of the knitting angle.

9. The flexible weaving forming method for composite material preforms according to claim 6, characterized in that, The flexible array needle puncture device (2) includes a robotic arm (11) and a needle puncture unit (10) installed on the execution end of the robotic arm (11). The needle puncture unit (10) includes an upper support installed on the execution end of the robotic arm (11), an upper cylinder (12) and a cylinder guide rod (13) located on the support. The output ends of the upper cylinder (12) and the cylinder guide rod (13) are connected to the lower support. The lower support is provided with a pressure regulating cylinder (14), a short fiber introduction mechanism (16) connected to the output end of the pressure regulating cylinder (14), a needle (27) installed on the short fiber introduction mechanism (16), a limiting plate (17) on both sides of the short fiber introduction mechanism (16), and a pressure plate (18) located below the needle (27). The pressure plate (18) has an opening for the needle (27) to pass through.

10. The flexible weaving forming method for composite material preforms according to claim 7, characterized in that, The suture device (3) includes a displacement compensation unit (19), a lead wire unit (20), a compaction unit (21), a bend needle guide unit (22), and a hook wire unit (23). The lead wire unit (20), the compaction unit (21), and the bend needle guide unit (22) are connected to the main body of the device, and the hook wire unit (23) is connected to the main body of the device through a drive shaft.

Images