Automatic paving system and method for composite prepreg

Abstract

The invention belongs to the technical field of mechanical manufacturing and processing, and particularly discloses an automatic paving system and method for composite prepreg. Comprising a main tail end and an auxiliary tail end which are mutually independent and cooperative, the main tail end comprises a main tail end frame, a first prepreg material disc is used for winding a prepreg material belt with release molds / paper attached to the two sides, and an extrusion roller is used for stripping the release molds / paper, close to one side of a second prepreg material disc, of the prepreg material belt conveyed by the first prepreg material disc; the main pressing roller is used for pressing and laying a prepreg tape on the stripping side and the mold, the slave tail end comprises a slave tail end frame, a rolling mechanism and a film tearing mechanism, the rolling mechanism and the film tearing mechanism are arranged on the slave tail end frame, the rolling mechanism is used for compacting the prepreg tape laid on the surface of the mold, and the film tearing mechanism is used for tearing the prepreg tape on the surface of the mold. And the film tearing mechanism is used for stripping the release film / paper on the other side of the prepreg tape. According to the method, the efficiency of the composite material paving task is remarkably improved, and the method adapts to the batch production task of complex components.

Description

Technical Field

[0001] This invention belongs to the field of mechanical manufacturing technology, and more specifically, relates to an automated laying system and method for composite material prepregs. Background Technology

[0002] In the current aerospace manufacturing field, carbon fiber composite parts are widely used to further optimize structure and weight. Longspans, serving as load-bearing components, are often formed by laying and curing carbon fiber prepreg sheets. Carbon fiber prepreg is a high-performance semi-finished material pre-impregnated with carbon fiber reinforcement and a resin matrix, possessing advantages such as high strength, high modulus, low density, superior heat / corrosion resistance, and good fatigue performance. The laying process involves separating the prepreg from the release paper, then laying and bonding it to the tooling surface. The manufacturing process involves several operations that are difficult to perform using traditional machinery, such as prepreg laying, rolling, and film removal; currently, these are mainly done manually. In manual production lines, laying molds need to be designed and manufactured according to the geometric characteristics of the component. Carbon fiber prepreg sheets of different lengths and fiber orientation angles are manually cut and layered onto the mold in a specific order. After each layer is laid, it needs to be rolled to remove interlayer gaps and air bubbles generated during the laying process. In the current manufacturing process, the installation parameters are adjusted by on-site workers based on their experience, which results in problems such as low manufacturing efficiency, high manufacturing costs, and difficulty in ensuring product consistency.

[0003] Based on the above-mentioned defects and shortcomings, there is an urgent need in this field to propose a robotic end effector for automated laying of composite prepregs, to construct a modular design for the collaborative laying task of robotic composite prepreg tapes, and to avoid the problems of high manufacturing and maintenance costs and difficulty in guaranteeing accuracy and quality of the device itself during the laying process. Summary of the Invention

[0004] To address the aforementioned deficiencies or improvement needs of existing technologies, this invention provides an automated prepreg laying system and method for composite materials. Combining the material characteristics of composite prepreg tape requiring precise tension control and multi-layer continuous laying, as well as its process characteristics in the molding of large and complex curved surface components, a modular end-effector system based on a master-slave collaborative architecture is designed. The structure and specific configuration of its key components, such as the constant tension feeding and receiving mechanism, the prepreg extrusion and separation mechanism, the compliant floating roller pressing module, and the multi-dimensional automatic film-tearing mechanism, are studied and designed. This effectively solves the problems of low laying efficiency, poor interlayer bonding quality, and weak adaptability to complex curved surfaces in existing technologies. It also possesses the advantages of compact and lightweight structure, agile action response, and minimal material damage, making it particularly suitable for high-precision automated manufacturing applications of large composite material components in the aerospace field.

[0005] To achieve the above objectives, according to one aspect of the present invention, an automated prepreg laying system for composite materials is provided, comprising a main end 110 and a slave end 210 that cooperate independently, wherein, The main end 110 includes a main end frame, and a first prepreg tray, a second prepreg tray, a shearing mechanism, two extrusion rollers 1116 and a main pressure roller 1112 disposed on the main end frame. The first prepreg tray is used to wind a prepreg strip with release dies / paper attached to both sides. The two extrusion rollers 1116 are arranged side by side with a small interval and are used to peel off the release dies / paper on the side of the prepreg strip conveyed from the first prepreg tray that is close to the second prepreg tray. The main pressure roller 1112 is used to press and lay the prepreg strip on the peeled side with the die. The peeled release dies / paper are transferred to the second prepreg tray for recycling. The shearing mechanism is used to cut the prepreg strip located between the extrusion rollers 1116 and the main pressure roller 1112 as needed. The end 210 includes an end frame, and a rolling mechanism and a film-tearing mechanism disposed on the end frame. The rolling mechanism is used to compact the prepreg tape laid on the surface of the mold 500, and the film-tearing mechanism is used to peel off the release film / paper 700 on the other side of the prepreg tape.

[0006] As a further preferred embodiment, the main end frame includes an upper baffle 1104, a front baffle 1119 disposed in front of the upper baffle 1104, and a rear baffle 1103 disposed behind the upper baffle 1104, wherein the front baffle 1119, the upper baffle 1104, and the rear baffle 1103 form a frame structure. Preferably, the upper baffle 1104 is further provided with a first connector 1101 for connection with the main robot.

[0007] As a further preferred embodiment, the first prepreg tray includes a first cylinder 1106 and first acrylic side plates 1107 disposed at both axial ends of the first cylinder 1106. The first cylinder 1106 and the two first acrylic side plates 1107 form an I-shaped structure. The inner wall of the first cylinder 1106 is also provided with a first motor flange seat 1108. The first motor flange seat 1108 is connected to a first servo motor 1105 disposed on the main end frame and rotates under the driving action of the first servo motor 1105 to drive the first cylinder 1106 to rotate. Preferably, the second prepreg tray includes a second cylinder 1121 and second acrylic side plates 1122 disposed at both axial ends of the second cylinder 1121. The second cylinder 1121 and the two second acrylic side plates 1122 form an I-shaped structure. The inner wall of the second cylinder 1121 is also provided with a second motor flange seat 1123. The second motor flange seat 1123 is connected to a second servo motor 1120 disposed on the main end frame and rotates under the driving action of the second servo motor 1120 to drive the second cylinder 1121 to rotate. As a further preferred embodiment, the shearing mechanism includes a blade holder 1114, a blade 1115 corresponding to the blade holder 1114, a blade swing arm 1117 for driving the blade 1115 to move, and a servo motor 1118 for driving the blade swing arm 1117 to move. The servo motor 1118 is fixedly mounted on the main end frame. The blade swing arm 1117 is arranged around the lower part of the extrusion roller 1116. The servo motor 1118 drives the blade 1115 to move to the blade holder 1114 through the swing arm 1117. There is an angle between the blade 1115 and the prepreg strip. Preferably, the main end frame is further provided with a plurality of first guide rollers 1109 for guiding the prepreg strip between the first prepreg tray and the extrusion roller 1116; Preferably, the main end frame is further provided with a plurality of second guide rollers 1124 for guiding the release mold / paper between the extrusion roller 1116 and the second prepreg tray; Preferably, the main end frame is further provided with a linear fine-tuning mechanism 1110, which is rigidly connected to a compression roller 1116 via a connector 1111, and is used to precisely adjust the compression force of the two compression rollers 1116 on the prepreg strip.

[0008] As a further preferred embodiment, the end frame includes a second upper baffle 2102, a second front baffle 2101 disposed in front of the second upper baffle 2102, and a second rear baffle 2105 disposed behind the second upper baffle 2102. The second front baffle 2101, the second upper baffle 2102, and the second rear baffle 2105 together constitute a frame structure. Preferably, the second upper baffle 2102 is further provided with a second connector 2103 for connection with the robot.

[0009] As a further preferred embodiment, the roller pressing mechanism includes a roller pressing drive motor 2112, a linear module, and a driven pressure roller 2115 disposed on the second rear baffle 2105. The linear module includes a timing belt 2109 and a slider 2111 that slides along a linear guide rail. The driven pressure roller 2115 is connected to the slider 2111. The roller drive motor 2112 controls the linear module to drive the driven pressure roller 2115 to move in a direction perpendicular to the mold surface and apply a compliant pressing force. As a further preferred embodiment, the film-tearing mechanism includes a multi-degree-of-freedom moving assembly, a contact wheel 2127, and a clamping assembly; the surface of the contact wheel 2127 is provided with an adhesive medium for adhering the release film; the clamping assembly is used to clamp the release film separated by the contact wheel 2127; the multi-degree-of-freedom moving assembly is used to drive the contact wheel 2127 and the clamping assembly to move relative to the end frame; As a further preferred embodiment, the clamping assembly includes an electric gripper 2120 and a gripper end 2121; the contact wheel 2127 is mounted on the horizontal motion module via a contact wheel mounting base 2126, and the electric gripper 2120 is mounted on the vertical motion module; during the film peeling process, the electric gripper 2120 is configured to move below the contact wheel 2127 to receive the release film.

[0010] As a further preferred embodiment, the main end 110 and the slave end 210 are respectively mounted on the end flanges of the main robot 100 and the slave robot 200, the main robot 100 and the slave robot 200 are arranged on a common track on a moving guide rail 300, and the moving guide rail 300 is arranged parallel to the worktable 400 where the mold 500 is placed.

[0011] According to another aspect of the present invention, an automated method for laying composite prepregs is also provided, comprising the following steps: S1. System initialization: Wrap the prepreg tape around the feeding assembly at the main end 110, pass it through the prepreg extrusion mechanism and fix it to the receiving assembly, and adjust the pressure of the prepreg extrusion mechanism. S2, Laying operation: Control the main end effector 110 to move with the main robot, use the main pressure roller 1112 to attach the prepreg tape to the mold surface, and at the same time, the feeding component and the receiving component work together to control the tension, and cut the prepreg tape at the designated position through the shearing mechanism. S3, Compliant Rolling: Controlling the movement of the follower robot from the end 210, and using the driven pressure roller 2115 of the rolling mechanism to roll the laid prepreg strip to eliminate interlayer gaps; S4. Film Removal Operation: Control the film removal mechanism at the end 210 to work. First, control the contact wheel 2127 to contact and roll the release film on the surface of the prepreg tape, using an adhesive medium to separate the release film from the prepreg tape. Then, control the clamping assembly to move to the position of the contact wheel 2127 to clamp the release film. Finally, control the robot to move away from the mold at the end 210 to complete the complete peeling and recycling of the release film.

[0012] In summary, compared with the prior art, the above-described technical solutions conceived by this invention mainly possess the following technical advantages: 1. The robotic end effector for automated prepreg laying of composite materials of the present invention divides the current complex prepreg tape laying and forming task of large composite material components into sub-tasks such as laying, rolling, and film tearing, and designs a dedicated master and slave end effector to complete the above sub-tasks. At the same time, the robot and guide rail complete the laying task of large and complex curved surface components, which significantly improves the efficiency of composite material laying task and adapts to the mass production task of complex components.

[0013] 2. The robotic end effector for automated application of composite prepregs of the present invention adopts a lightweight structural design, which greatly reduces the load requirements on the robot and can adapt to more production environments and application tasks. At the same time, it adopts a modular design, which greatly reduces the manufacturing and maintenance costs of the device itself.

[0014] 3. The robotic end effector for automated prepreg laying of composite materials of the present invention achieves compliant operation of prepreg tape in different environments through the coordinated control of motor and robot, reduces the material damage to the prepreg tape caused by device operation, improves the yield and quality consistency of molded components, and is suitable for large-scale composite material laying production.

[0015] 4. The robotic end effector for automated prepreg laying of composite materials of the present invention adopts an innovative structural design for prepreg tape laying, realizes agile production requirements through a detachable prepreg tape tray, realizes the calibration of prepreg tape and multi-layer prepreg tape laying tasks through an innovative prepreg tape cutting mechanism design, and ensures laying accuracy and reduces material wrinkles by squeezing the prepreg tape before laying. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of a robot end effector for automated laying of composite prepregs according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the main end structure involved in an embodiment of the present invention; Figure 3 This is a schematic diagram of the main terminal workflow involved in an embodiment of the present invention; Figure 4 This is a schematic diagram of the overall structure of the end unit according to an embodiment of the present invention; Figure 5 This is a schematic diagram of the end-roller pressing device according to an embodiment of the present invention; Figure 6 This is a schematic diagram of the end-tear film device according to an embodiment of the present invention; Figure 7 This is a schematic diagram illustrating the collaborative work of two mobile robots to lay prepreg tape, as described in an embodiment of the present invention. Figure 8 This is a flowchart illustrating the collaborative laying process of dual-robot composite prepreg tapes in an embodiment of the present invention.

[0017] In all the accompanying drawings, the same reference numerals denote the same technical features, specifically: 100-master robot, 200-slave robot, 300-moving guide rail, 400-worktable, 500-mold, 600-prepreg tape, 700-release film / paper, 800-adhesive, 900-prepreg tape core, 110-master end effector, 210-slave end effector, 1101-first connector, 1102-first corner bracket, 1103-rear baffle, 1104-first upper baffle, 11 05-First servo motor, 1106-First cylinder, 1107-First acrylic side plate, 1108-First motor flange seat, 1109-First guide roller, 1110-Linear fine-tuning mechanism, 1111-First connector, 1112-Pressure roller, 1113-Roller shaft, 1114-Knife holder, 1115-Blade, 1116-Prepreg extrusion roller, 1117-Blade swing arm, 1118-Servo motor, 1119-First front baffle, 1120-Second servo motor 1121-Second cylinder, 1122-Second acrylic side plate, 1123-Second motor flange seat, 1124-Second guide roller, 2101-Second front baffle, 2102-Second upper baffle, 2103-Second connector, 2104-Second angle bracket, 2105-Second rear baffle, 2106-Ball screw base, 2107-Linear slider, 2108-Synchronous belt base, 2109-Synchronous belt, 2110-Ball bearing, 2111-Linear slider, 2 112-Servo motor, 2113-Coupling, 2114-Pressure roller connector, 2115-Pressure roller, 2116-Thrust ring, 2117-Pressure roller shaft, 2118-First stepper motor, 2119-Electric gripper connector, 2120-Electric gripper, 2121-Gripper end, 2122-Second stepper motor, 2123-Ball screw base, 2124-Linear slider, 2125-Contact wheel connector, 2126-Contact wheel fixing seat, 2127-Contact wheel. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of this invention clearer, the 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 merely illustrative and not intended to limit the invention. Furthermore, the technical features involved in the various embodiments of this invention described below can be combined with each other as long as they do not conflict with each other.

[0019] like Figure 1 As shown, this embodiment of the invention provides a robotic end effector for automated prepreg laying of composite materials. The device consists of two independent robotic end effectsors. The first end effector lays the prepreg, while the second end effector performs operations such as rolling and removing release film / paper from the prepreg laid on the mold. The first end effector, called the main end effector, is the core equipment for controlling the laying speed and quality of the prepreg; the second end effector, called the slave end effector, is the core equipment for ensuring the quality of prepreg laying, ensuring efficient bonding between the prepreg and the mold. By arranging multiple auxiliary end effectors, the production line speed is further increased, the laying process is optimized, and thus the continuous prepreg laying and molding process for large-size composite material components is completed.

[0020] Specifically, such as mention 1 and Figure 2 As shown, a robotic end effector for automated application of composite prepreg includes a master robot 100 and a slave robot 200 mounted on a moving guide rail 300. Both the master robot 100 and the slave robot 200 can move linearly along the moving guide rail 300 (viewed from the direction shown in the figure). A worktable 400 is located in front of the moving guide rail 300, and the moving guide rail 300 and the worktable 400 are arranged parallel to each other. A mold 500 is placed on the worktable 400. The master robot 100 has a master end effector 110 at its end, and the slave robot 200 has a slave end effector 210 at its end.

[0021] like Figure 2As shown, the structure of the main end 110 includes an upper baffle 1104, a rear baffle 1103, and a front baffle 1119, which provide the structural skeleton of the main end. The baffles have numerous threaded holes distributed on their surfaces. The baffles are connected by bolts and a first angle bracket 1102 device. This method reduces the overall weight of the end and provides sufficient rigidity. The front baffle 1119 also has threaded holes and countersunk holes for mounting various necessary components such as motors, bearings, and rollers. A first cylinder 1106 and two first acrylic side plates 1107 are connected by bolts to form a prepreg tray. Before application, the prepreg tape is wrapped around the tray to prevent deformation and wrinkling of the prepreg tape. The first cylinder 1106, the first acrylic side plate 1107, the first motor flange seat 1108, and the second cylinder 1121, the second acrylic side plate 1122, and the second motor flange seat 1123 form two material trays, one on the left and one on the right. The left material tray, composed of the first cylinder 1106, the first acrylic side plate 1107, and the first motor flange seat 1108, is used for feeding, while the right material tray, composed of the second cylinder 1121, the second acrylic side plate 1122, and the second motor flange seat 1123, is used for discharging. The left and right material trays are connected to the first motor flange seat 1108 and the second motor flange seat 1123 respectively by four bolts, allowing for easy installation and replacement. The first motor flange seat 1108 is axially fixed to the front baffle 1119 via bearings and is connected to the motor shaft via a keyway for rotation. Multiple polyurethane first guide rollers 1109 and second guide rollers 24 of different diameters are installed on the front baffle to guide the prepreg tape and the released film / paper after release, respectively. The prepreg extrusion roller 1116 separates the carbon fiber prepreg from the release paper and delivers the prepreg at a stable angle to the pressure roller 1112 where it contacts the mold. The pressure roller 1112 ensures a stable fit between the prepreg and the mold. A linear fine-tuning mechanism 1110 is rigidly connected to the extrusion roller 1116 via a connector 1111. This mechanism precisely adjusts the extrusion force of the prepreg extrusion roller 1116, balancing guiding accuracy and material quality, while also facilitating the installation and removal of the prepreg. A servo motor 1118 drives the blade 1115 to the blade holder 1114 via a swing arm 1117. An angle exists between the blade and the prepreg, ensuring efficient and accurate prepreg cutting.

[0022] like Figure 3 As shown, the workflow of the main end effector of the composite prepreg laying process robot is as follows: Initial stage as... Figure 3As shown in (a), a certain width of prepreg tape is manually wound around the tray, and the tray is fixed to the flange. Simultaneously, one side of the prepreg tape with release paper / film is manually peeled off, and the peeled release paper / film is passed around the prepreg extrusion roller 1116, through the first guide roller 1109, and then fixed to the right tray with tape. After the prepreg installation is completed, the handwheel of the linear fine-tuning mechanism 1110 is rotated to bring the prepreg extrusion rollers 1116 into contact. The right servo motor is set to position control mode, and the left motor is set to torque control mode. A stable torque is applied through the controller to ensure the prepreg tape is fully tensioned. The shearing stage is as follows... Figure 3 As shown in (b), when the prepreg tape is ready to be laid, the drive motor 1118 moves clockwise, and the blade 1115 contacts the cutter holder 1114 to cut off the excess prepreg tape. Figure 3 As shown in (c), the worker retrieves the cut prepreg tape and drives the servo motor 1118 to move counterclockwise back to the starting state, preventing the blade from interfering with the prepreg tape laying process. Figure 2 As shown in (d), the robot executes the tape-laying trajectory to ensure stable contact between the pressure roller 1112 and the mold. The right-side motor 1105, linked to the robot's motion, moves the prepreg tape from between the two prepreg extrusion rollers 1116 to the pressure roller 1112 and the mold surface, where the pressure roller 1112 initially rolls and fixes the prepreg tape to the mold surface. Simultaneously, the left-side servo motor applies a stable torque to the prepreg tape in torque mode, maintaining stable tension during movement. Figure 3 As shown in (e), after the robot finishes laying the prepreg, the control servo motor 1118 rotates counterclockwise to cut the prepreg tape. The robot then continues to drive the end effector to roll the remaining prepreg tape onto the mold surface. Finally, as shown... Figure 3 As shown in (f), after the laying is completed, the robot drives the end to detach from the mold surface, so that the prepreg tape on the tray can be used for the next laying trajectory, ensuring that the prepreg laying is continuous and efficient.

[0023] like Figures 4-6As shown, the end-effector comprises a lightweight end-effector main structure consisting of a second front baffle 2101, a rear baffle 2105, a second upper baffle 2102, and a second corner bracket 2104, and is connected to the robot end-effector flange via a second connector 2103. Devices for compliant rolling and film tearing are respectively installed on the front and rear baffles of this end-effector. A synchronous belt base 2108, a synchronous belt 2109, a ball bearing 2110, and a linear slider 2111 form a synchronous belt linear module. The linear slider 2111 is connected to the pressure roller connector 2114 via bolts, and the pressure roller connector 2114 is connected to the pressure roller 2115 via a pressure roller shaft 2117 and a thrust ring 2116. The rolling device drives the synchronous belt linear module to move via a servo motor 2112, causing the polyurethane pressure roller 2115 to apply stable pressure to the surface of the complex mold through up-and-down movement. The ball screw base 2106, linear slider 2107, and... Figure 6 The structural components of the film-tearing mechanism are demonstrated. Ball screw base 2106 and linear slider 2107, and ball screw base 2123 and linear slider 2124 respectively form linear guides for vertical and horizontal movement, driven by a first stepper motor 2118 and a second stepper motor 22. Contact wheel 2127 is fixed to the horizontally arranged linear unit via contact wheel fixing seat 2126 and contact wheel connector 2125, while the electro-dynamically controlled gripper is connected to the vertically arranged linear unit via connector 2119, and completes the gripping of the deionized membrane / paper via the gripper end 2121. This device drives the electro-dynamically controlled gripper 2120 to move up and down and the contact wheel 2127 to move left and right via the first stepper motor 2118 and the second stepper motor 2122, respectively, to roll the prepreg tape laid on the mold surface and remove the release film / paper from the top of the prepreg tape.

[0024] The robot rolls the laid-out prepreg tape from the end to remove gaps between the prepreg tape and the mold, and between prepreg tapes, and to remove the release film / paper from the surface of the prepreg tape during the laying process. For composite prepreg tapes that have completed the initial laying, the robot controls the end effector to make stable contact between the pressure roller 2115 and the surface of the prepreg tape at a certain angle. At this time, the servo motor 2112 applies stable vertical roller pressure to the surface of the prepreg tape through the pressure roller connector 2114 via torque control. Then, the robot controls the end effector to move to achieve a large range of prepreg tape rolling, ensuring that there are no obvious wrinkles and bubbles between the layers of the prepreg tape. After the rolling is completed, the contact wheel 2124, which is coated with adhesive from the other side of the end effector, contacts and bonds the release film / paper on the surface of the prepreg tape. The robot controls the end effector to move upward to separate the release film / paper from the prepreg tape. Then, the robot drives the first stepper motor 2118 to move the electric gripper end effector 2121 below the contact wheel to stably grip the separated release film / paper. Finally, the robot moves its end effector extensively, causing the electric gripper 2120 to completely separate and recycle the release film / paper from the prepreg tape. From the end effector, subsequent operations such as rolling and tearing the prepreg tape are performed on the laid-out tape to prepare the main end effector for laying the next layer of prepreg tape.

[0025] like Figure 7 As shown, the specific principle of the end effector for rolling and tearing the prepreg tape is as follows: The compliant pressure roller 2115 rolls the prepreg tape 600 onto the mold 500 with a large curvature by contouring along a trajectory. The compliant pressure roller 2115 achieves one-dimensional compliance through a servo motor and synchronous belt device, avoiding pressure damage to the prepreg tape on the large curvature surface during the rolling process. The entire tearing process is as follows: The electric gripper 2110 is driven by an electric gripper, and a layer of adhesive 8 is attached to the contact wheel 7. When performing the tearing task, the contact wheel 2125 first contacts and rolls with the release film / paper 700. The adhesive 800 on the contact wheel 2125 separates the release film / paper 700 from the prepreg tape core 900. Then, the electric gripper 2110 clamps and fixes the release film / paper 700. Finally, the robot drives the end effector to move over a large range, separating the clamped release film / paper 700 from the prepreg tape.

[0026] like Figure 8The present invention utilizes dual robots and an end effector to automate the entire process of prepreg application. First, the system is initialized and the robot end effector and mold coordinate systems are calibrated. Then, the pre-cut prepreg tape is manually wound onto the first set of end effector trays for application. Next, the main robot, carrying the main end effector, applies the prepreg tape and release film / paper onto the mold. Then, the slave robot, carrying the slave end effector, ensures the prepreg tape is tightly adhered to the mold, and after rolling, the release film / paper is removed from the prepreg tape by a film-tearing mechanism. After completing these steps, the robots return to their origin and begin the next layer of prepreg tape application, rolling, and film-tearing process until the number of prepreg tape layers meets the design requirements.

[0027] This embodiment proposes a robotic end effector and system for automated laying of composite prepregs. To enable those skilled in the art to better understand the invention, a detailed description of this embodiment is provided below with reference to the accompanying drawings. The overall architecture of the device is based on a platform for collaborative operation of two robots. As shown in Figures 1 and 2, the system mainly includes a laying execution unit, a post-processing execution unit, and a shared motion reference unit. The motion reference unit includes a movable guide rail fixed to the ground, which constitutes the X-axis linear motion reference of the system. The laying execution unit includes a master robot slidably mounted on the movable guide rail and a master end effector installed at the end of the master robot. The post-processing execution unit includes a slave robot sharing the same rail with the master robot and slidably mounted independently on the movable guide rail, and a slave end effector installed at the end of the slave robot. The master robot and the slave robot are preferably six-degree-of-freedom multi-joint industrial robots, arranged in series along the movable guide rail and operating parallel to the worktable and the mold it carries.

[0028] In this architecture, the main end focuses on the precise conveying, tension control, and bonding of the prepreg tape, while the auxiliary end focuses on the post-layout compaction and automated peeling of the release film. Physically independent, they are coordinated sequentially via a host computer, achieving decoupling between "layout" and "processing" in composite material molding processes, significantly improving manufacturing efficiency for large, complex curved components.

[0029] Modular structure and connection relationship of the main end device. Referring to Figures 1 and 2, the main end device adopts a highly integrated modular design, specifically including a main end frame module, a prepreg feeding module, a release paper receiving module, a guiding and separating module, a fixed-length cutting module, and a main laying and compaction module.

[0030] The main end-effector frame module constitutes the supporting skeleton of the entire device, employing a lightweight and highly rigid box-type structure design. Specifically, the main end-effector frame includes a robot connector, a first upper baffle, a rear baffle, and a first front baffle. The first upper baffle is horizontally positioned, with the robot connector circumferentially fixed to its upper surface center by bolts. The robot connector is used to achieve a rigid mechanical connection with the sixth-axis flange of the main robot. The rear edge of the first upper baffle extends vertically downward and is fixed to the upper edge of the rear baffle by bolts. The rear baffle and the first front baffle are arranged in parallel intervals. To enhance the overall rigidity of the frame, multiple first angle brackets are provided at the connection angle between the first upper baffle and the rear baffle, as well as at the connection between the first upper baffle and the first front baffle. The two right-angled sides of the first angle brackets are respectively bolted to the corresponding baffle surfaces. The first front baffle serves as the main load-bearing panel, and has multiple precision holes for installing bearings, motor shafts, and locating pins. This structural form, which combines splicing of panels with reinforcement using corner brackets, ensures sufficient structural rigidity to resist the reaction force of the paving while greatly reducing the end-load weight and improving the robot's dynamic response performance.

[0031] The prepreg feeding module is located on the upper left side of the main end frame (see view direction) and is used to store and actively release prepreg tape with release paper. Referring to your requested description, the core component of the prepreg feeding module is a first prepreg tray. Specifically, the first prepreg tray includes a first cylinder and first acrylic side plates located at both axial ends of the first cylinder. The first cylinder, serving as the core for winding the prepreg tape, is a hollow cylindrical structure. The two first acrylic side plates are fixed to the left and right end faces of the first cylinder with screws, and the outer diameter of the first acrylic side plates is larger than the outer diameter of the first cylinder, thus forming an I-shaped structure. This I-shaped structure creates a trough capable of accommodating the prepreg tape roll and restricting its axial movement, and the transparent acrylic material facilitates observation of the remaining material. Furthermore, a first motor flange seat is circumferentially fixed to the inner wall of the first cylinder by bolts. A keyway is provided at the central shaft hole of the first motor flange seat for transmitting torque. A first servo motor is fixedly installed on the back side of the first front baffle of the main end frame, i.e., between the two baffles. The output shaft of the first servo motor passes through a shaft hole in the first front baffle and is rigidly connected to the first motor flange seat via a key connection or an expansion sleeve connection. In terms of operation, the first motor flange seat rotates under the drive of the first servo motor, thereby driving the first cylinder and the entire first prepreg reel to rotate synchronously. Preferably, the first servo motor is configured in torque control mode, providing a constant torque opposite to the unwinding direction during the laying process, thereby generating a constant tension on the prepreg tape and preventing material loosening.

[0032] The release paper collection module is located on the upper right side of the main end frame, symmetrically distributed with the feeding module, and is used to collect the waste release paper / film after peeling. Preferably, the release paper collection module includes a second prepreg tray. The second prepreg tray includes a second cylinder and second acrylic side plates located at both axial ends of the second cylinder. The second cylinder and the two second acrylic side plates also form an I-beam structure for winding the recycled waste. A second motor flange seat is also provided on the inner wall of the second cylinder, and the second motor flange seat is fixed to the inner wall of the cylinder by bolts. In terms of drive connection, a second servo motor is also provided on the main end frame, specifically on the back side of the first front baffle. The output shaft of the second servo motor passes through the front baffle and is connected to the second motor flange seat. The second motor flange seat rotates under the drive of the second servo motor to drive the second cylinder to rotate. In terms of operating mechanism, unlike the torque mode of the feeding motor, the second servo motor is usually configured in position or speed control mode. Its rotation speed is matched with the moving speed of the main robot and the linear speed of the first guide roller through electronic gear ratio, thereby ensuring that the waste is wound up in a timely and stable manner, avoiding the breakage of the release paper due to excessively fast winding or the entanglement due to excessively slow winding.

[0033] The guiding and separating module is located between the feeding module and the main pressure roller, used to plan the path of the prepreg tape and achieve primary separation of the prepreg and release paper. This module mainly consists of multiple first guide rollers, second guide rollers, prepreg extrusion rollers, and a linear fine-tuning mechanism. Multiple first guide rollers are distributed along a specific path on the surface of the first front baffle. Each first guide roller is rotatably connected to a roller shaft via a built-in deep groove ball bearing, one end of which is threaded to the first front baffle. The surface of the first guide rollers is coated with a polyurethane layer to increase friction with the back of the prepreg tape and prevent fiber damage. The key separating mechanism includes two prepreg extrusion rollers arranged in pairs. These two extrusion rollers are located on opposite sides of the prepreg tape path, forming a counter-rolling structure. The lower extrusion roller is fixed to the first front baffle via a bearing seat, while the two bearing seats at both ends of the upper extrusion roller are connected to the movable end of the linear fine-tuning mechanism. The linear fine-tuning mechanism includes a fixed seat, an adjusting screw, and a sliding block. The fixed seat screw is connected to the first front baffle, and the sliding block is located in the guide rail of the fixed seat and is threadedly engaged with the adjusting screw. The bearing seat of the upper extrusion roller is fixed to the sliding block. In terms of operation mechanism, by rotating the adjusting knob of the linear fine-tuning mechanism, the sliding block is driven to produce a small linear displacement, thereby changing the center distance, i.e., the roller gap, between the two prepreg extrusion rollers. When the composite prepreg tape passes through the roller gap, it is subjected to normal extrusion force. Due to the difference in elastic modulus between the resin matrix and the release paper, the extrusion action destroys the bonding interface between the two. Subsequently, the prepreg tape enters the main pressure roller downwards, while the release paper is forcibly pulled upwards through the second guide roller to the take-up module, thereby achieving material separation by utilizing the bifurcation of the physical path and the shearing force of the rollers.

[0034] The fixed-length shearing module is located below the extrusion roller and is used to cut the prepreg at the end of the laying process. This module includes a servo motor, a blade arm, a blade, and a blade holder. The blade holder is a long strip of metal, bolted to the first front baffle and located on the back side of the prepreg tape's running path, providing rigid support for shearing. The servo motor is fixedly mounted on the first front baffle, with its output shaft perpendicular to the baffle surface. One end of the blade arm is fixed to the servo motor's output shaft by a spline or fastening screw, and the other end extends near the blade holder. The blade is detachably fixed to the end of the blade arm by screws, and the cutting edge plane of the blade forms a preset cutting angle with the feed direction of the prepreg tape, which is not perpendicular. The operating mechanism is as follows: During normal laying, the servo motor remains in its initial position, the blade arm is raised, and the blade is away from the prepreg tape. When a cutting signal is received, the servo motor quickly drives the blade arm to rotate, causing the blade to slide across the prepreg tape and press against the blade holder. Due to the presence of the cutting angle, the blade "slides" rather than "chops" the material, effectively reducing cutting resistance and ensuring a smooth cut.

[0035] The main laying and compaction module is located at the bottom of the main end and includes a first connector, a roller shaft, and a pressure roller. The upper end of the first connector is fixed to a frame near the extrusion roller mechanism, and the lower end has a shaft hole. The roller shaft passes through the shaft hole and the center of the pressure roller. The pressure roller is rotatably connected to the roller shaft via a bearing. This pressure roller is the first point of force application when the prepreg contacts the mold, and under the drive of the main robot, it rolls and adheres the separated prepreg strip to the mold surface.

[0036] The modular structure and connection relationship of the end device. Referring to Figures 1-2, the end device mainly consists of an end frame module, a compliant roller drive module, and a multi-dimensional film tearing module.

[0037] The end effector frame module adopts an inverted U-shaped or gantry-type structure, mainly including a second upper baffle, a second front baffle, a rear baffle, and a second connector. The second connector is flange-shaped, with its bottom surface bolted to the center of the upper surface of the second upper baffle, and its top surface used to connect to the end effector of the robot. The two side edges of the second upper baffle extend vertically downwards and connect to the second front baffle and the rear baffle, with the connection reinforced by a second angle bracket. The second front baffle and rear baffle provide mounting surfaces for functional components; this two-sided, separate structure helps balance the end effector's center of gravity.

[0038] The compliant roller pressing drive module is installed on the outer side of the rear baffle to provide constant compaction force. This module includes a synchronous belt base, a synchronous belt, a servo motor, a linear slider, and a driven pressure roller assembly. The synchronous belt base is vertically fixed to the rear baffle by bolts and has a linear guide rail inside. The synchronous belt is tensioned on synchronous pulleys located at the upper and lower ends of the base. The servo motor is horizontally mounted on the upper part of the base, and its output shaft is connected to the shaft of the upper synchronous pulley via a coupling to drive the synchronous belt. The linear slider slides on the linear guide rail of the base and is fixedly clamped to one side of the synchronous belt. A pressure roller connector is fixedly connected to the lower end face of the linear slider by bolts. The pressure roller connector has a fork-shaped structure with a pressure roller shaft at its end. The driven pressure roller is rotatably sleeved on the pressure roller shaft via ball bearings, and thrust rings are provided on both axial sides for limiting movement. The unique aspect of the operating mechanism and connection relationship is that the servo motor, coupling, synchronous belt, linear slider, and driven pressure roller form a force transmission chain. In use, the servo motor is set to torque control mode. Regardless of how the driven pressure roller undulates with the mold surface, causing the linear slider to move up and down passively, the motor always applies a constant torque through the synchronous belt, which is converted into a constant pressure of the pressure roller on the mold surface, thereby achieving a "compliant floating" compaction effect.

[0039] The multi-dimensional film-removing module is installed on the side of the second front baffle and is used to remove the release film. This module includes a vertical motion unit and a horizontal motion unit. The vertical motion unit includes a ball screw base, a first screw, and a first stepper motor fixed to the second front baffle. The first stepper motor drives the first screw to rotate, causing a vertical linear slider sleeved on the screw to move up and down. An electric gripper is fixed to the vertical linear slider via an electric gripper connector, and the front end of the electric gripper has a gripper end. The horizontal motion unit also includes a ball screw base, a second screw, and a second stepper motor. This horizontal unit is mounted on a specific bracket or arranged in an L-shape with the vertical unit, as shown in the figure. The second stepper motor drives the horizontal screw, causing the horizontal linear slider to move left and right. The horizontal linear slider is connected to a contact wheel via a contact wheel connector and a contact wheel fixing seat. The surface of the contact wheel is coated with an adhesive layer. The action mechanism is as follows: When tearing the film, the horizontal motion unit first drives the contact wheel to move and press against the release film, and uses adhesive to stick the film edge; then the vertical motion unit drives the electric gripper to descend, and the end of the gripper extends under the film edge and closes to clamp it; finally, the robot drives the end to move and tear off the entire release film.

[0040] Collaborative Working Mechanism. Based on the detailed structural connections described above, the overall workflow of this device is as follows: First, the prepreg tape is loaded onto the first cylinder of the main end, passing through the first guide roller and the prepreg extrusion roller. The separated release paper is then wound back onto the second cylinder. At the start of the operation, the main robot carries the main end along the mold trajectory. At this time, the first servo motor applies torque in the opposite direction to control the tension, the second servo motor synchronously winds up the waste paper, and the pressure roller adheres the pure prepreg tape to the mold. Upon reaching the endpoint, the servo motor drives the blade to cut the material. Immediately afterwards, the slave robot carries the follow-up from the end. The servo motor drives the driven pressure roller through the synchronous belt to perform a secondary roll pressing on the freshly laid prepreg at a constant pressure, expelling air bubbles. After the roll pressing is completed, the end adjusts its posture, uses the contact wheel to adhere the release film on the surface, and then uses an electric gripper to hold and tear it off, completing the single-layer laying process.

[0041] Combination Figure 8 The flowchart illustrates the operation process of the device of the present invention in practical applications, which is as follows: Step S1: System Initialization and Preparation Before starting the operation, the operator first performs the material feeding operation. The rolled prepreg tape is loaded into the first cylinder 1106 of the main end 110, and the tape head is manually pulled out, peeling off approximately half a meter of release paper. The pure prepreg tape head is passed under the extrusion roller 1116 and led to the main pressure roller 1112; the peeled release paper is then routed around the upper guide roller and fixed onto the second cylinder 1121 on the receiving side. Next, the handwheel of the linear fine-tuning mechanism 1110 is rotated until the extrusion roller exerts a suitable gripping force on the tape. Simultaneously, the system is powered on, the master and slave robots perform origin return, and the coordinate system of the mold 500 is calibrated based on vision or laser sensors to ensure that the offline programmed trajectory coincides with the actual physical environment.

[0042] Step S2: The main robot laying system receives the laying instruction. The main robot 100 begins to move according to the preset stringer geometry path. The main pressure roller 1112 of the main end 110 presses the prepreg tape head against the mold. As the robot moves forward, the left motor provides reverse tension, and the right motor synchronously winds up the waste paper. During the laying process, the prepreg is continuously squeezed, separated, and bonded. When approaching the end of the path, the shearing mechanism activates to cut the prepreg tape, but the robot continues to move a distance to completely roll the cut tail material onto the mold, completing the laying of a single tape.

[0043] Step S3: After the main robot moves away from the prepreg rolling operation, the slave robot 200 immediately follows. Its end-driven pressure roller 2115 presses down, and the servo motor 2112 enters torque mode. The slave robot repeats the laying path as before (or uses a specific spiral / reciprocating path depending on process requirements). The compliant mechanism absorbs minor unevenness on the mold surface, applying uniform normal pressure (e.g., adjustable from 50N to 200N) to ensure no air bubbles remain between prepreg layers.

[0044] Step S4: After the robot completes the film-tearing operation and roller pressing, if there is still backing film to be removed from the current layer surface, the robot switches its posture and uses the film-tearing module. Following the aforementioned "adhesion-gripping-tearing" logic, the protective film covering the newly laid material surface is removed. The torn waste film is moved to the waste bin for release.

[0045] Step S5: The cyclic operation system determines whether the designed layer thickness has been reached. If not, the main robot returns to the starting point and begins laying the next layer; if the thickness has been reached, the AGV (Automated Guided Vehicle) removes the mold, completing the entire process.

[0046] Those skilled in the art will readily understand that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An automated application system for composite prepregs, characterized in that, It includes a master terminal (110) and a slave terminal (210) that cooperate independently, wherein, The main end (110) includes a main end frame, and a first prepreg tray, a second prepreg tray, a shearing mechanism, two extrusion rollers (1116) and a main pressure roller (1112) disposed on the main end frame. The first prepreg tray is used to wind a prepreg strip with release dies / paper attached to both sides. The two extrusion rollers (1116) are arranged side by side with a small interval to peel off the release dies / paper on the side of the prepreg strip conveyed by the first prepreg tray that is close to the second prepreg tray. The main pressure roller (1112) is used to press and lay the prepreg strip on the peeled side with the die. The peeled release dies / paper are transferred to the second prepreg tray for recycling. The shearing mechanism is used to cut the prepreg strip located between the extrusion rollers (1116) and the main pressure roller (1112) as needed. The end (210) includes an end frame, a rolling mechanism and a film-tearing mechanism disposed on the end frame, the rolling mechanism being used to compact the prepreg tape laid on the surface of the mold (500), and the film-tearing mechanism being used to peel off the release film / paper (700) from the other side of the prepreg tape.

2. The automated prepreg laying system for composite materials according to claim 1, characterized in that, The main end frame includes an upper baffle (1104), a front baffle (1119) located in front of the upper baffle (1104), and a rear baffle (1103) located behind the upper baffle (1104). The front baffle (1119), the upper baffle (1104), and the rear baffle (1103) form a frame structure. Preferably, the upper baffle (1104) is further provided with a first connector (1101) for connection with the main robot.

3. The automated prepreg laying system for composite materials according to claim 1, characterized in that, The first prepreg tray includes a first cylinder (1106) and first acrylic side plates (1107) disposed at both ends of the first cylinder (1106) along the axial direction. The first cylinder (1106) and the two first acrylic side plates (1107) form an I-shaped structure. The inner wall of the first cylinder (1106) is also provided with a first motor flange seat (1108). The first motor flange seat (1108) is connected to a first servo motor (1105) disposed on the main end frame and rotates under the driving action of the first servo motor (1105) to drive the first cylinder (1106) to rotate. Preferably, the second prepreg tray includes a second cylinder (1121) and two second acrylic side plates (1122) disposed at both ends of the second cylinder (1121) along the axial direction. The second cylinder (1121) and the two second acrylic side plates (1122) form an I-shaped structure. The inner wall of the second cylinder (1121) is also provided with a second motor flange seat (1123). The second motor flange seat (1123) is connected to a second servo motor (1120) disposed on the main end frame and rotates under the driving action of the second servo motor (1120) to drive the second cylinder (1121) to rotate.

4. The automated prepreg laying system for composite materials according to claim 1, characterized in that, The shearing mechanism includes a blade holder (1114), a blade (1115) corresponding to the blade holder (1114), a blade swing arm (1117) for driving the blade (1115) to move, and a servo motor (1118) for driving the blade swing arm (1117) to move. The servo motor (1118) is fixed on the main end frame. The blade swing arm (1117) is arranged around the lower part of the extrusion roller (1116). The servo motor (1118) drives the blade (1115) to move to the blade holder (1114) through the swing arm (1117). There is an angle between the blade (1115) and the prepreg strip. Preferably, the main end frame is further provided with a plurality of first guide rollers (1109) for guiding the prepreg strip between the first prepreg tray and the extrusion roller (1116); Preferably, the main end frame is further provided with a plurality of second guide rollers (1124) for guiding the release mold / paper between the extrusion roller (1116) and the second prepreg tray; Preferably, the main end frame is further provided with a linear fine-tuning mechanism (1110), which is rigidly connected to a compression roller (1116) through a connector (1111) for precisely adjusting the compression force of the two compression rollers (1116) on the prepreg strip.

5. An automated prepreg laying system for composite materials according to any one of claims 1-4, characterized in that, The end frame includes a second upper baffle (2102), a second front baffle (2101) located in front of the second upper baffle (2102), and a second rear baffle (2105) located behind the second upper baffle (2102). The second front baffle (2101), the second upper baffle (2102), and the second rear baffle (2105) together constitute a frame structure. Preferably, the second upper baffle (2102) is further provided with a second connector (2103) for connection with the robot.

6. The automated prepreg laying system for composite materials according to claim 5, characterized in that, The roller pressing mechanism includes a roller pressing drive motor (2112), a linear module, and a driven roller (2115) mounted on the second rear baffle (2105). The linear module includes a timing belt (2109) and a slider (2111) that slides along a linear guide rail. The driven pressure roller (2115) is connected to the slider (2111). The roller drive motor (2112) controls the linear module to drive the driven pressure roller (2115) to move in a direction perpendicular to the mold surface and apply a compliant pressing force.

7. The automated prepreg laying system for composite materials according to claim 5, characterized in that, The film-tearing mechanism includes a multi-degree-of-freedom moving component, a contact wheel (2127), and a clamping component; the surface of the contact wheel (2127) is provided with an adhesive medium for adhering the release film; the clamping component is used to clamp the release film separated by the contact wheel (2127); the multi-degree-of-freedom moving component is used to drive the contact wheel (2127) and the clamping component to move relative to the end frame.

8. The automated prepreg laying system for composite materials according to claim 7, characterized in that, The clamping assembly includes an electric gripper (2120) and a gripper end (2121); the contact wheel (2127) is mounted on the horizontal motion module via a contact wheel mounting base (2126), and the electric gripper (2120) is mounted on the vertical motion module; during the film peeling process, the electric gripper (2120) is configured to move below the contact wheel (2127) to receive the release film.

9. The automated prepreg laying system for composite materials according to claim 1, characterized in that, The main end (110) and the slave end (210) are respectively installed on the end flanges of the main robot (100) and the slave robot (200). The main robot (100) and the slave robot (200) are arranged on a moving guide rail (300) and the moving guide rail (300) is parallel to the worktable (400) on which the mold (500) is placed.

10. A method for automated laying of composite prepregs, characterized in that, Includes the following steps: S1. System initialization: Wrap the prepreg tape around the feeding assembly at the main end (110), pass it through the prepreg extrusion mechanism and fix it to the receiving assembly, and adjust the pressure of the prepreg extrusion mechanism; S2, Laying operation: Control the main end (110) to move with the main robot, use the main pressure roller (1112) to attach the prepreg tape to the mold surface, and at the same time the feeding component and the receiving component work together to control the tension, and cut the prepreg tape at the designated position through the shearing mechanism; S3, Compliant Rolling: Control the movement of the robot from the end (210) and use the driven pressure roller (2115) of the rolling mechanism to roll the laid prepreg strip to eliminate interlayer gaps; S4. Film peeling operation: Control the film peeling mechanism from the end (210) to work. First, control the contact wheel (2127) to contact and roll the release film on the surface of the prepreg tape, and use the viscous medium to separate the release film from the prepreg tape. Then, control the clamping assembly to move to the position of the contact wheel (2127) to clamp the release film. Finally, control the robot to move away from the end (210) from the mold to complete the complete peeling and recycling of the release film.

Images