Automatic impregnation equipment and impregnation method for composite material reinforcing fabric

Abstract

This invention discloses an automatic impregnation device and method for reinforcing composite fabrics, relating to the field of composite shell manufacturing equipment technology. This invention aims to solve the technical problems of poor uniformity, easy fiber damage, low efficiency, and resin waste inherent in the manual impregnation of end cap reinforcing carbon cloth in existing technologies. This invention provides an automatic impregnation device, comprising: a frame, a mobile material carrier located at the bottom of the frame, and a resin collection system with a heated impregnation tank; an impregnation worktable driven by a lifting module is provided on the frame; a traveling module is provided at the top of the frame, driving a roller pressing assembly suspended below it to reciprocate along the worktable surface. This invention achieves fully automatic, highly uniform impregnation of the fabric through a dynamic reciprocating roller pressing mechanism immersed in the compound liquid under the worktable, eliminating defects such as creases and fabric breakage; the special sloping bottom plate and valved material carrier design greatly improve the recycling rate of expensive epoxy resin.

Description

Technical Field

[0001] This invention relates to the field of composite material pressure shell manufacturing equipment technology, and in particular to an automatic impregnation equipment and method for reinforcing fabrics (such as carbon cloth) for composite material shell end caps. Background Technology

[0002] Composite material shells (such as carbon fiber wound high-pressure hydrogen storage cylinders and solid rocket motor shells) are widely used in aerospace, new energy vehicles, and special industrial equipment due to their lightweight and high strength characteristics. During the fiber winding molding process of composite material shells, the end caps of the shells, due to their complex geometry and concentrated stress, usually require pre-laying of reinforcing fabrics (such as end cap reinforcing carbon cloth) to enhance their structural strength.

[0003] To ensure the interlaminar shear strength and overall curing effect of the reinforcing carbon fiber and the overall winding layer of the shell, the reinforcing carbon fiber must be completely and uniformly impregnated with a resin matrix (such as epoxy resin) before bonding. Currently, in actual production processes within the industry, the impregnation of the end cap reinforcing carbon fiber still largely relies on manual operation. Workers typically place the carbon fiber on a flat plate, manually pour the resin, and then repeatedly scrape and press it with a scraper.

[0004] This existing technology has the following significant drawbacks: First, it is difficult to maintain consistent pressure during manual coating, which easily leads to uneven resin distribution. Furthermore, during repeated scraping, the fragile carbon fiber is prone to creases, fiber breakage, or disintegration, creating significant structural defects. Second, the size of the carbon cloth used to reinforce the end caps varies greatly depending on the shell specifications. Manual impregnation of large-sized carbon cloth requires multiple workers, consuming a large amount of manpower and resources, resulting in a slow production cycle and extremely low efficiency. Third, manual operation cannot precisely control the amount of resin used. Excess resin is lost on the workbench and cannot be effectively recovered, leading to significant waste of expensive aerospace-grade or industrial-grade epoxy resin and greatly increasing production costs.

[0005] In summary, the industry urgently needs an automated device that can automatically impregnate reinforcing fabrics, ensure uniform impregnation, and effectively recover resin. Summary of the Invention

[0006] In view of the shortcomings of the above-mentioned background technology, such as poor impregnation uniformity, easy damage to fiber structure, high labor cost and serious resin waste, the present invention provides an automatic impregnation equipment and method for composite material reinforcing fabrics, aiming to solve the core technical problems of existing technology, such as the inability to achieve high-quality automated impregnation of reinforcing carbon cloth and low resin recycling rate.

[0007] To solve the above-mentioned technical problems, in a first aspect, the present invention provides the following technical solution:

[0008] An automatic impregnation device for composite material reinforcing fabrics includes: a frame; a mobile material carrier movably disposed below the frame; a resin collection system disposed on the mobile material carrier, the resin collection system including an impregnation tank for holding impregnation liquid; a lifting module disposed on the frame; an impregnation worktable connected to the power output end of the lifting module, the lifting module being configured to drive the impregnation worktable to move vertically up and down so that the composite material reinforcing fabric carried on it is immersed in or detached from the impregnation tank, the impregnation worktable being used to carry the composite material reinforcing fabric; a traveling module disposed on the top of the frame; and a roller pressing assembly connected to the traveling module, the traveling module being configured to drive the roller pressing assembly to reciprocate linearly along the surface of the impregnation worktable to roller press the composite material reinforcing fabric immersed in the impregnation liquid.

[0009] By employing the above-mentioned technical solution of this invention, and by combining the impregnation worktable with the impregnation lifting mechanism and introducing an automated reciprocating roller pressing assembly suspended from the top, this invention can achieve automated immersion extrusion penetration of reinforcing fabrics under the resin liquid surface. This not only completely avoids creases and disintegration caused by manual coating, ensuring extremely high impregnation uniformity, but also integrates the resin collection system onto a mobile material carrier, achieving separation of the impregnation area and the material turnover area, greatly improving operational efficiency.

[0010] In a preferred embodiment of the present invention, the resin collection system further includes a heating unit disposed at the bottom or side wall of the impregnation tank for heating and maintaining the temperature of the impregnation liquid; a reflux hole is provided at the bottom of the impregnation tank, and a control valve for controlling the discharge of the impregnation liquid is installed at the reflux hole. By further employing the configuration of a heating unit and a reflux hole with a control valve at the bottom, the present invention can also achieve dynamic adjustment of resin viscosity, using heating to keep the impregnation liquid such as epoxy resin in an optimal wetting fluidity state, thereby accelerating the fiber capillary penetration process; the reflux hole design allows for the one-click, pollution-free recovery of a large amount of pure residual resin after impregnation, significantly improving resin utilization.

[0011] In a preferred embodiment of the present invention, the impregnation worktable includes a frame with a U-shaped groove structure. The frame includes a horizontal section connected to the lifting module, vertical sections fixed to both ends of the horizontal section, and a base plate connected between the bottom ends of the two vertical sections. The top surface of the base plate is a sloping surface that slopes downward from the middle area to the two side edges, and the height of the middle part of the base plate is greater than the height of its two side edges. By further adopting a U-shaped groove frame and a sloping base plate design with a high middle and low side edges, the present invention can also achieve efficient extrusion of air bubbles and excess resin along the slope when the roller pressing assembly applies pressure from the middle to both sides, and allow them to drip back into the impregnation tank below, avoiding local accumulation of resin on the base plate and improving recycling efficiency.

[0012] In a preferred embodiment of the present invention, the lifting module includes two sets of lifting motors respectively fixed to both sides of the frame, and the power output ends of the two sets of lifting motors are respectively connected to both ends of the horizontal section; a vertical guide rail is provided between the horizontal section and the frame, and the horizontal section slides with the vertical guide rail via a slider. By further adopting a dual-point balanced drive structure with dual-sided lifting motors and vertical guide rails, the present invention can also achieve absolute stability in the lifting process of the impregnation worktable, avoiding mechanical jamming or uneven load caused by single-sided drive, and ensuring stable liquid entry of large-area reinforcing fabrics.

[0013] In a preferred embodiment of the present invention, a set of parallel travel rails are provided on both sides of the top of the frame. The travel module includes a mounting frame slidably mounted on the travel rails and a travel motor that drives the mounting frame to move along the travel rails. The roller pressing assembly is suspended below the mounting frame. By further adopting a top gantry-type travel rail design, the present invention can also achieve precise control of the running trajectory of the roller pressing assembly, avoid the transmission mechanism from being contaminated by the bottom resin, and ensure the long-term operational reliability of the equipment.

[0014] In a preferred embodiment of the present invention, the roller pressing assembly includes a lifting bracket and a pressing roller. The lifting bracket is fixed to the mounting frame, and a lifting groove is formed in the vertical direction of the lifting bracket. The two ends of the pressing roller have rotating shafts inserted into the lifting groove and can float freely in the vertical direction along the lifting groove. A counterweight unit is provided above the pressing roller, and the counterweight unit is used to apply downward pressure to the pressing roller. By further adopting a suspended roller design with a free-floating lifting groove and a counterweight unit, the present invention can also achieve adaptive floating bonding of the pressing roller according to the fabric thickness and the slope of the base plate. The constant downward pressure provided by the counterweight unit makes the roller pressure uniform and consistent, eliminating the damage to the carbon fiber caused by rigid mechanical interference.

[0015] In a preferred embodiment of the present invention, a controller and a safety light curtain unit are also included; the walking module, the lifting module, and the resin collection system are all electrically connected to the controller; the safety light curtain unit is disposed on the periphery of the frame and is communicatively connected to the controller, used to trigger an emergency stop of the equipment when an intrusion signal is detected. By further integrating the controller and the safety light curtain, the present invention can also achieve automated and precise control of the entire process flow and industrial-grade human-machine safety protection, preventing operators from accidentally touching the equipment and incurring the risk of pinching injuries during operation.

[0016] In a preferred embodiment of the present invention, the counterweight unit is a detachable counterweight block, or the counterweight unit is a pneumatic servo cylinder, the output end of which is connected to the two rotating shafts of the pressure roller to provide dynamically adjustable downward pressure. By further employing a detachable counterweight block or a pneumatic servo cylinder, the present invention can also achieve flexible adjustment of the extrusion pressure to adapt to the impregnation process requirements of fabrics with different areal densities and weights, thus broadening the applicability of the equipment.

[0017] To solve the above-mentioned technical problems, in a second aspect, the present invention provides the following technical solution:

[0018] A method for impregnating composite material using the aforementioned automatic impregnation equipment includes the following steps: S1, preparation stage: injecting impregnation liquid into an impregnation tank located on a mobile material carrier, and controlling the temperature of the impregnation liquid to a preset process temperature; S2, laying stage: laying the composite material reinforcing fabric to be impregnated flat on the impregnation worktable in an initial high position; S3, feeding stage: moving the mobile material carrier equipped with a resin collection system to the impregnation station below the frame; S4, automatic impregnation and rolling stage: controlling the lifting module to drive the impregnation worktable to descend, so that the composite material reinforcing fabric is loaded onto the roller. The fabric impregnation worktable is immersed in the impregnation liquid in the impregnation tank; then the controller controls the walking module to drive the roller pressing assembly to move above the composite material reinforcing fabric and perform a preset number of reciprocating squeezes along its surface, so that the impregnation liquid penetrates evenly into the interior of the composite material reinforcing fabric; during the squeezing process, air bubbles inside the fabric and excess impregnation liquid are squeezed out along the impregnation worktable and flow back into the impregnation tank; S5, material discharge and recycling stage: after the impregnation is completed, the lifting module drives the impregnation worktable to reset and rise, removes the mobile material carrier, and obtains the impregnated composite material reinforcing fabric.

[0019] By employing the above-mentioned technical solution of the present invention, and by using a phased, submerged immersion process combined with underwater dynamic rolling, the present invention can change the traditional unidirectional surface coating process. By utilizing the coupling effect of liquid static pressure and roller dynamic pressure, the resin's penetration into high-density carbon fiber bundles is greatly improved, and a high-quality reinforcing layer without dry fibers or creases is prepared.

[0020] In a preferred embodiment of the present invention, a residual liquid recovery step is further included after step S5: the control valve at the bottom of the impregnation tank is opened to discharge the remaining impregnation liquid in the impregnation tank into the recovery container below for recycling. By further employing the residual liquid recovery step, the present invention can also achieve closed-loop management of expensive resins, significantly reducing the manufacturing cost of a single housing.

[0021] In a preferred embodiment of the present invention, the controller pre-stores a database of process formulas corresponding to different models of composite material reinforcing fabrics. Before step S4, the operator inputs or calls the model code of the fabric to be impregnated through a human-machine interface. The controller automatically matches and executes the corresponding temperature setpoint, roller reciprocating frequency, and traveling speed of the walking module based on the called model. By further introducing a database and a one-click model recall function, the present invention can also achieve flexible manufacturing, quickly switching between the production of different models of end cap reinforcing carbon cloth without rewriting cumbersome programs on-site, realizing one-click automated operation at the boundary.

[0022] As a preferred embodiment of the present invention, when processing small batches or irregularly shaped composite material reinforcing fabrics, a semi-automatic auxiliary mode is adopted: the composite material reinforcing fabric is laid flat in the middle of the impregnation worktable, and the impregnation liquid is manually applied to the surface of the fabric; the walking module is manually controlled to move the roller pressing assembly above the fabric, and the lifting module is manually controlled to make the roller pressing assembly press the fabric; the semi-automatic roller pressing command is triggered, and the walking module drives the roller pressing assembly to automatically perform reciprocating walking and pressing, and after completion, the lifting assembly is manually controlled for cleaning. By further providing a semi-automatic auxiliary mode, the present invention can also accommodate the production needs of small-batch prototyping or special irregularly shaped parts, taking into account both the high efficiency of mass production and the flexibility of R&D prototyping.

[0023] In a preferred embodiment of the present invention, in step S4, since the bottom plate of the impregnation workbench is a sloping surface inclined from the middle to both sides, when the roller pressing assembly moves from the middle of the bottom plate to both sides to squeeze, air bubbles inside the fabric and excess impregnation liquid are squeezed out along the sloping surface and flow back into the impregnation tank. By further clarifying the guiding effect of the bottom plate slope in the physical extrusion process, the present invention can also achieve directional flow of air and glue discharge, effectively preventing resin turbulence and improving impregnation quality.

[0024] Compared with the prior art, the present invention has the following significant advantages:

[0025] 1. This invention transforms the traditional open-type manual coating process into a semi-closed, automatic underwater roller pressing process by combining the immersion mechanism of the impregnation worktable with the roller pressing assembly suspended from the top. The negative pressure effect generated by the roller extrusion and exhaust guides the resin to penetrate deeply, effectively ensuring the extremely high uniformity of the carbon fiber fabric impregnation, eliminating creases and disintegration, and fundamentally improving the interfacial bonding strength of the composite material shell.

[0026] 2. The innovative mobile material carrier, combined with the heated impregnation tank and reflux control valve design, allows pure resin that has not been absorbed by the fabric to flow smoothly back into the impregnation tank by gravity, and is quickly and centrally discharged and recycled after the process is completed. Compared to the traditional manual operation where the resin cures and is wasted on the table, this greatly improves the utilization rate of epoxy resin and significantly reduces economic costs.

[0027] 3. Combined with the controller's formula database function, the equipment has a strong capacity for large-scale mixed-line production. Workers only need to call the corresponding model through the human-machine interface, and the equipment can automatically complete all actions such as constant temperature, immersion, and preset number of extrusions, reducing the single-piece dipping time by more than 70% and greatly liberating human resources. Attached Figure Description

[0028] To more clearly illustrate the technical solutions of the embodiments disclosed in this invention, the accompanying drawings of the embodiments will be briefly described below. These drawings are for illustrative purposes only and are not intended to limit the scope of protection of this invention.

[0029] Figure 1 This is a three-dimensional schematic diagram of the overall structure of an automatic impregnation device according to an embodiment of the present invention.

[0030] Figure 2 This is a schematic diagram of the structure of a mobile material carrier and resin collection system according to an embodiment of the present invention.

[0031] Figure 3 This is an enlarged schematic diagram of the installation structure of the roller pressing assembly according to an embodiment of the present invention.

[0032] Figure 4 This is a process flow diagram of the automatic impregnation method described in this invention.

[0033] In the diagram: 100, frame; 200, walking module; 210, walking slide rail; 220, mounting bracket; 230, walking motor; 300, lifting module; 310, lifting motor; 320, vertical guide rail; 400, impregnation worktable; 410, horizontal section; 420, vertical section; 430, base plate; 500, roller pressing assembly; 510, pressure roller; 520, hoisting bracket; 530, hoisting slot; 540, counterweight; 600, mobile material carrier; 700, resin collection system; 710, heating plate; 720, impregnation tank; 730, reflux hole; 740, control valve. Detailed Implementation

[0034] The technical solutions (including preferred technical solutions) of the present invention will be further described in detail below with reference to the accompanying drawings and by way of listing some optional embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0035] Example 1

[0036] This embodiment provides an automated impregnation device for composite material reinforcing fabrics. For example... Figure 1 , Figure 2 and Figure 3 As shown.

[0037] The automatic impregnation equipment of this embodiment includes a frame 100, a traveling module 200, a lifting module 300, an impregnation worktable 400, a roller pressing assembly 500, a mobile material carrier 600, and a resin collection system 700. These mechanical components, under the unified and coordinated command of a controller (e.g., a programmable logic controller, PLC), complete the highly complex impregnation process.

[0038] The frame 100 is the basic skeleton of the entire equipment, typically welded from high-strength carbon steel square tubing to provide sufficient rigidity to withstand the dynamic loads of each module during operation. A mobile material carrier 600 (equipped with bottom rollers, it can be manually or electrically pushed into the impregnation station below the frame 100) provides physical separation between the loading / unloading area and the work area. A resin collection system 700 is mounted on the top platform of the mobile material carrier 600. The core of the resin collection system 700 is the impregnation tank 720, a corrosion-resistant tank of a certain depth used to hold impregnation liquids such as epoxy resin. This ensures that the thermosetting resin maintains optimal flowability (typically epoxy resin...). (The viscosity decreases significantly at 40℃ to -60℃). A heating plate 710 (i.e., heating unit) is tightly attached to the bottom of the impregnation tank 720. The heating plate 710 is equipped with an electric heating wire or a fluid circulation pipe to provide a suitable and uniform surface heat source according to process requirements. A reflux hole 730 is opened at the lowest point of the bottom of the impregnation tank 720, and an explosion-proof manual or electric control valve 740 is connected below the reflux hole 730. After batch production is completed, opening the control valve 740 can accurately discharge the expensive and uncured residual adhesive into the recycling bin below.

[0039] In the resin impregnation process, the fabric not only needs to come into contact with the resin but also needs to be mechanically kneaded to remove tiny air bubbles between the fiber bundles. For this purpose, the equipment cleverly incorporates a lifting module 300 and an impregnation worktable 400. The impregnation worktable 400 is designed as a U-shaped trough frame, specifically including a horizontal section 410 at the top, vertical sections 420 extending vertically downwards from both ends of the horizontal section 410, and a base plate 430 horizontally connected between the bottom ends of the two vertical sections 420. The base plate 430 must be larger than the largest size of the end cap reinforcing carbon fiber fabric to be processed. The lifting module 300 is mounted on the two side columns of the frame 100 and includes two high-precision synchronously operating lifting motors 310. The two lifting motors 310 are connected to both ends of the horizontal section 410 of the impregnation worktable 400 via a screw-nut mechanism or a chain drive mechanism. To ensure absolute verticality and stability when the U-shaped frame is lowered and raised, a heavy-duty vertical guide rail 320 is installed between the uprights of the frame 100 and the horizontal section 410.

[0040] The design of the base plate 430 is one of the structural highlights of this embodiment. The base plate 430 is not a perfectly flat surface, but rather a sloping surface that slopes downwards at a certain angle from the central area towards the front and rear edges. This means that the central area of ​​the base plate 430 has the highest elevation. When the fabric is laid flat on it, and the impregnation worktable 400 is submerged in the impregnation tank 720, this "sloping" structure is extremely beneficial for the rapid drainage of excess resin to both sides during subsequent extrusion steps, preventing the formation of localized deep water zones on the worktable surface that would affect the uniformity of impregnation.

[0041] To provide power for automated compaction, a traveling module 200 is mounted on top of the frame 100. The traveling module 200 includes two parallel traveling rails 210 fixed to the two sides of the top of the frame 100, and a gantry-type mounting frame 220 spanning these two rails. A traveling motor 230 driven by a servo motor drives the entire mounting frame 220 to reciprocate back and forth along the traveling rails 210 via a rack and pinion or synchronous belt mechanism.

[0042] Connected to the mounting bracket 220 is the roll forming assembly 500. (Combined) Figure 3 As shown, the roller pressing assembly 500 includes a lifting bracket 520 and a pressing roller 510 with an elastic, wear-resistant coating on its surface. The lifting bracket 520 is vertically fixed to the mounting frame 220, and its lower part has an elongated lifting groove 530. The two ends of the pressing roller 510 are fitted into the lifting groove 530 with a clearance fit. The beneficial effect of this design is that it gives the pressing roller 510 the ability to "float freely" in the vertical direction (i.e., conformal ability). Several counterweights 540 are stacked on top of the pressing roller 510. In actual operation, the counterweights 540 provide a constant gravitational downward load, so that the pressing roller 510 is always in close contact with the surface of the base plate 430 (and carbon cloth). Since the base plate 430 is an inclined slope, when the mounting bracket 220 drives the lifting bracket 520 to move horizontally, the shaft of the pressure roller 510 can slide freely up and down in the lifting groove 530 according to the height change of the slope, ensuring that the contact pressure is consistent throughout the entire stroke.

[0043] Furthermore, due to mandatory considerations for safe production in industrial settings, multiple sets of safety light curtain units are arranged around the open side of the frame 100. Once an operator's arm or body is detected encroaching on the work area during automatic lifting or rolling operations, the controller will cut off the servo system's enable signal within milliseconds, forcing the equipment to stop abruptly, thus completely eliminating the safety hazards posed by heavy machinery.

[0044] Example 2

[0045] This embodiment provides a method for large-scale automated impregnation based on the aforementioned equipment, specifically corresponding to a fully automated production process. The steps of this method are as follows:

[0046] S1, Preparation Stage: The operator first turns on the heating plate 710 through the controller to heat up the impregnation tank 720. After the temperature sensor reports that the temperature has reached the set value (e.g., the optimal resin impregnation temperature of 50°C), the liquid epoxy resin (impregnation liquid) that has been mixed evenly in proportion is poured into the impregnation tank 720 on the mobile material carrier 600.

[0047] S2, Laying Stage: At this time, the impregnation worktable 400 is at its upper limit position (i.e., the initial high position) under the control of the lifting module 300. The operator lays the cut end-reinforcing carbon cloth flat on the highest point of the center of the base plate 430, ensuring that the carbon cloth is wrinkle-free.

[0048] S3, Feeding Stage: The operator pushes the mobile trolley 600, equipped with the complete resin collection system 700, into the predetermined station below the frame 100. Once in place, mechanical locking or magnetic adsorption is used to ensure that the trolley does not shift during subsequent processing.

[0049] S4, Automatic Impregnation and Rolling Stage: The operator selects the "Automatic Walking Program" on the upper computer touchscreen of the controller and presses the start button. First, the lifting motor 310 of the lifting module 300 starts, driving the impregnation worktable 400 to descend smoothly along the vertical guide rail 320. The descent stops when the base plate 430 is completely submerged below the resin surface in the impregnation tank 720, at which point the carbon cloth is completely immersed in the resin.

[0050] Next, the walking motor 230 of the walking module 200 starts, driving the mounting frame 220 and the roller pressing assembly 500 to move from the initial end to directly above the area where the carbon cloth is located. With the weight of the counterweight 540, the pressing roller 510 presses firmly against the surface of the carbon cloth. The walking module 200 drives the roller pressing assembly 500 to move back and forth in a straight line along the surface of the carbon cloth according to preset logic. Because the base plate 430 is a slope that is higher in the middle and lower on both sides, when the pressing roller 510 rolls from the middle to both sides, it not only expels the residual air between the carbon fiber bundles in the form of tiny bubbles, but also generates a pump-like dynamic pressure effect, forcing the highly fluid, warm epoxy resin to penetrate deeply into the weave gaps of the carbon fibers. Excess resin flows directly back into the impregnation tank 720 along the slope, never accumulating locally on the base plate 430.

[0051] S5, Discharge and Recycling Stage: After reaching the preset number of roller presses, the travel motor 230 controls the roller press assembly 500 to return to its initial position. Subsequently, the lifting motor 310 reverses, controlling the impregnation worktable 400 to automatically rise and detach from the liquid surface. The operator then removes the mobile material carrier 600. At this point, the carbon cloth surface is flat, the resin is evenly impregnated, and there is no excess resin flow, making it ready for direct removal for subsequent shell winding processes.

[0052] Repeat the above-described fabric laying and calling procedure steps until all end cap reinforcing carbon cloth for the current shift has been processed. Close the bottom heating plate 710, open the control valve 740 at the bottom of the impregnation tank 720, and discharge any unused cleaning resin in the tank through the return hole 730 into a dedicated sealed recovery container for frozen storage or reprocessing.

[0053] Example 3

[0054] This embodiment provides a semi-automatic / manual impregnation method. This method combines partially automated actions with manual intervention, aiming to simplify the operation process without changing complex procedures.

[0055] The operation process is as follows:

[0056] The first step is to evenly lay a small amount of carbon fiber reinforcing fabric to be tested on the center of the base plate 430 of the high-positioned impregnation workbench 400. Unlike the automatic mode, there is no need to pour a large amount of resin into the impregnation tank 720. Instead, the worker uses a hand-held glue brush to manually apply a very small amount of the prepared resin directly to the surface of the carbon fiber fabric.

[0057] The second step is for the operator to switch the controller to "manual mode" and start the walking motor 230 by pressing the control button to move the mounting bracket 220 with the adhesive roller 510 to the position aligned with the center of the carbon cloth.

[0058] Third, by jogging the motor 310 again, the dipping worktable 400 with the U-shaped frame is slightly raised, or the pressure roller is lowered to adjust the height of the pressure roller, so that the pressure roller 510 suspended in the lifting groove 530 fully presses the carbon cloth.

[0059] The fourth step is to trigger a local automatic operation command. The walking module 200 drives the pressure roller 510 to perform several automatic back-and-forth pressing operations above the carbon cloth. The mechanical power replaces the manual scraper to evenly press and penetrate the resin initially applied to the surface into the interior of the carbon cloth.

[0060] Fifth, after the impregnation is complete, manually control the operating interface to raise the impregnation worktable 400 or retract the pressing roller 510. The worker removes the impregnated carbon cloth and cleans the surface of the worktable 400 directly with cleaning agent and a cloth.

[0061] Example 4

[0062] This embodiment focuses on describing the data processing algorithm and formula management logic for process ratios and system storage number retrieval based on different models, further improving the technical details of this invention in the field of automation control.

[0063] Because composite material shells come in different volume specifications (such as 35MPa Type III bottles, 70MPa Type IV bottles, etc.), the reinforcing carbon cloth used for their two end caps varies greatly in terms of basis weight (such as 200g / m² to 400g / m²), weaving method (plain weave or twill weave), width, and number of layers. This directly determines the different resin absorption requirements and impregnation time for different carbon cloths.

[0064] Therefore, a "relationship table of reinforcement fabric process parameters" is pre-established in the memory of the controller of this invention. The logical structure of this table is as follows:

[0065] Input identifier: Fabric model number (e.g., Model-A, Model-B, etc.);

[0066] Output control parameter set:

[0067] (1) Target heating temperature T set ;

[0068] (2) Number of reciprocating roller presses, N;

[0069] (3) The running speed V of the walking servo motor;

[0070] (4) Immersion waiting delay time t delay .

[0071] Operators only need to enter a unique number on the host computer touch screen, and the controller will call the corresponding array parameters.

[0072] Taking the resin heating system as an example, since the viscosity μ of the impregnation liquid is extremely sensitive to changes in temperature T, a closed-loop PID temperature control algorithm is executed in the controller, and its control output power u(t) follows the following pattern:

[0073] Among them, K p K is the proportional control coefficient. i K is the integral control coefficient. d These are the differential control coefficients; , which is the deviation between the target process temperature and the real-time temperature sensor in the immersion tank 720.

[0074] By combining this algorithm with direct access to process data sheets, the equipment can automatically increase the heating temperature and decrease the walking speed V when impregnating high-basis-weight carbon cloth of different grades, thereby extending the time for mechanical pressing and thermal penetration to ensure complete impregnation of thick carbon cloth. When processing low-basis-weight thin carbon cloth, it automatically decreases the temperature and increases the walking speed, thereby ensuring penetration while greatly saving processing time and preventing excessive resin curing.

[0075] Example 5

[0076] Based on the mechanical structure of Example 1, this embodiment provides an optimized technical solution for equivalent replacement of the "counterweight unit" to adapt to the production needs of higher precision and digitalization.

[0077] In Example 1, the downward pressure of the pressure roller 510 comes from the gravity of the physical counterweight 540. Adjusting the pressure requires manual handling to add or remove the counterweight, which has the disadvantages of high labor intensity and discontinuous adjustment steps.

[0078] In this embodiment, the physical counterweight 540 above the lifting slot 530 is eliminated. Instead, two pneumatic servo cylinders (or miniature electric push rods) controlled by electro-proportional valves are vertically mounted downwards on the mounting frame 220. The output piston rods of the pneumatic servo cylinders are flexibly connected directly to the bearing seats of the rotating shafts at both ends of the pressure roller 510.

[0079] Meanwhile, the pressure control terminal of the pneumatic servo cylinder is electrically connected to the controller. When the operator calls different carbon cloth formulas on the interface, in addition to sending the temperature and speed parameters in Example 4, the controller will also directly output an analog voltage signal to the electric proportional valve. The proportional valve precisely adjusts the pressure in the cylinder's air chamber, thereby applying a dynamically adjustable, Newton-level precise downward pressure to the pressing roller 510.

[0080] By employing this equivalent technological substitution, the device of this invention not only completely eliminates manual intervention in replacing counterweights but also enables variable pressure extrusion processes (e.g., in areas where the carbon cloth is thicker in the middle and thinner at the edges, the cylinder pressure is automatically reduced in real time as the walking module moves towards the edge to prevent the fibers from being broken). This improvement further strengthens the fully automatic and highly adaptable technological advantages of this device, and falls entirely within the scope of protection claimed by this invention based on the aforementioned core architecture.

[0081] It should be noted that those skilled in the art will understand that the driving and pressure application methods mentioned in the above embodiments are merely illustrative. For example, in addition to motor drive, the lifting drive component and walking drive device can also employ other driving technologies known in the art, such as hydraulic cylinders, pneumatic cylinders, and linear modules. Similarly, in addition to counterweights or pneumatic servo cylinders, the pressure application unit can also employ any technical solution capable of applying controllable downward pressure to the pressure rollers, such as spring mechanisms, electric push rods, and hydraulic cylinders. These equivalent substitutions or modifications all fall within the scope of the concept claimed by this invention.

[0082] It will be readily understood by those skilled in the art that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, combinations, substitutions, improvements, etc., made under the spirit and principles of the present invention are included within the protection scope of the present invention.

Claims

1. An automatic impregnation device for composite material reinforcing fabrics, characterized in that, include: frame; A mobile material carrier is movably mounted below the frame; A resin collection system is installed on the mobile material carrier, and the resin collection system includes an impregnation tank for holding the impregnation liquid; A lifting module is mounted on the frame; The impregnation worktable is connected to the power output end of the lifting module. The lifting module is configured to drive the impregnation worktable to move up and down in the vertical direction so that the composite material reinforcing fabric carried on it is immersed in or detached from the impregnation tank. The impregnation worktable is used to carry the composite material reinforcing fabric. A walking module is mounted on the top of the frame; as well as A roller pressing assembly is connected to the walking module, which is configured to drive the roller pressing assembly to reciprocate linearly along the surface of the impregnation table to roller press the composite reinforcing fabric immersed in the impregnation liquid.

2. The automatic impregnation equipment according to claim 1, characterized in that, The resin collection system also includes a heating unit, which is disposed at the bottom or side wall of the impregnation tank and is used to heat and keep the impregnation liquid warm. The bottom of the impregnation tank is provided with a reflux hole, and a control valve for controlling the discharge of the impregnation liquid is installed at the reflux hole.

3. The automatic impregnation equipment according to claim 1, characterized in that, The impregnation workbench includes a frame with a U-shaped groove structure. The frame includes a horizontal part connected to the lifting module, vertical parts fixed to both ends of the horizontal part, and a base plate connected between the bottom ends of the two vertical parts. The top surface of the base plate is a sloping surface that slopes downward from the middle area to the two side edges. The height of the middle part of the base plate is greater than the height of its two side edges. The lifting module includes two sets of lifting motors fixed on both sides of the frame, and the power output ends of the two sets of lifting motors are respectively connected to the two ends of the horizontal part; a vertical guide rail is provided between the horizontal part and the frame, and the horizontal part slides with the vertical guide rail through a slider.

4. The automatic impregnation equipment according to claim 1, characterized in that, The top two sides of the frame are provided with a set of parallel walking slide rails. The walking module includes a mounting frame that is slidably mounted on the walking slide rails and a walking motor that drives the mounting frame to move along the walking slide rails. The roller pressing assembly is suspended below the mounting frame.

5. The automatic impregnation equipment according to claim 4, characterized in that, The roller pressing assembly includes a lifting bracket and a pressing roller. The lifting bracket is fixed on the mounting frame, and the lifting bracket has a lifting groove in the vertical direction. The two ends of the pressing roller are inserted into the lifting groove and can float freely in the vertical direction along the lifting groove; a counterweight unit is provided above the pressing roller, and the counterweight unit is used to apply downward pressure to the pressing roller; The counterweight unit is a detachable counterweight block, or the counterweight unit is a pneumatic servo cylinder, the output end of which is connected to the two rotating shafts of the pressure roller to provide dynamically adjustable downward pressure.

6. The automatic impregnation equipment according to any one of claims 1 to 5, characterized in that, It also includes a controller and a safety light curtain unit; the walking module, the lifting module and the resin collection system are all electrically connected to the controller; The safety light curtain unit is located on the periphery of the rack and is communicatively connected to the controller, used to trigger an emergency stop of the device when an intrusion signal is detected.

7. A method for impregnating resin using the automatic impregnation equipment as described in any one of claims 1 to 6, characterized in that, Includes the following steps: S1, Preparation stage: The impregnation liquid is injected into the impregnation tank located on the mobile material carrier, and the temperature of the impregnation liquid is controlled to the preset process temperature. S2, Laying stage: Lay the composite reinforcing fabric to be impregnated flat on the impregnation worktable which is in an initial high position. S3, Feeding stage: The mobile material carrier equipped with the resin collection system is moved to the impregnation station below the frame; S4, Automatic Impregnation Roller Pressing Stage: The control lifting module drives the impregnation worktable to descend, so that the impregnation worktable carrying the composite material reinforcing fabric is immersed in the impregnation liquid of the impregnation tank. Subsequently, the controller controls the walking module to move the roller pressing assembly above the composite material reinforcing fabric and performs a preset number of reciprocating squeezes along its surface, so that the impregnating liquid can evenly penetrate into the interior of the composite material reinforcing fabric. S5, Discharge and Recycling Stage: After impregnation is completed, the lifting module drives the impregnation worktable to reset and rise, removes the mobile material carrier, and obtains the impregnated composite material reinforcement fabric.

8. The impregnation method according to claim 7, characterized in that, The residual liquid recovery step is included after step S5: Open the control valve at the bottom of the impregnation tank to discharge the remaining impregnation liquid in the impregnation tank into the recycling container below for recycling and reuse.

9. The impregnation method according to claim 7, characterized in that, The controller contains a pre-stored database of process formulas for different types of composite material reinforcing fabrics. Before step S4, the operator inputs or calls the model code of the fabric to be impregnated through the human-machine interface. The controller automatically matches and executes the corresponding temperature setting, number of roller reciprocations, and travel speed of the walking module according to the called model.

10. The impregnation method according to claim 7, characterized in that, When processing small batches or irregularly shaped composite reinforcement fabrics, a semi-automatic auxiliary mode is used: The composite reinforcing fabric is laid flat in the middle of the impregnation worktable, and the impregnation liquid is applied to the surface of the fabric manually. The manual control of the walking module moves the roller pressing assembly above the fabric, and the manual control of the lifting module makes the roller pressing assembly press the fabric. When the semi-automatic roller pressing command is triggered, the walking module drives the roller pressing component to automatically reciprocate and press. After completion, the roller pressing component is manually lifted for cleaning.

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