Carbon fiber dry preimpregnation yarn placement system and method

Abstract

The application provides a carbon fiber dry method pre-dipping yarn laying system and method, relates to the technical field of pre-dipping yarn laying, and the system comprises a unwinding unit, a yarn feeding unit, a laying unit and a control unit. The unwinding unit is used for mounting and fixing yarn of a winding material to a corresponding station. The yarn feeding unit is used for peeling a protective film of the yarn and conveying the yarn to a corresponding conveying path to complete yarn conveying. The laying unit is used for laying the yarn on the conveying path and solidifying the yarn on a workpiece surface to obtain a pressure signal of the workpiece surface. The cutting and re-feeding unit is used for cutting the yarn when the laying is completed and re-feeding a front end of the yarn to a laying starting point before a next cycle starts. The control unit is used for generating a first control instruction by using a preset PID algorithm to adjust an output torque and / or an output rotating speed, generating a second control instruction by using a curved surface reconstruction algorithm to dynamically change a transverse pitch between guide yarn nozzles in real time, and realizing high-precision and high-adaptability cooperative laying of multiple yarns on a complex curved surface with low artificial participation.

Description

Technical Field

[0001] This invention relates to the field of prepreg laying technology, specifically to a dry prepreg laying system and method for carbon fiber. Background Technology

[0002] Existing automatic yarn laying systems are mostly integrated structures designed for single strands of yarn or fixed yarn bundles. Their drive and control units are usually centralized or in parallel mode, which means that during the laying process, all yarns are forced to move at the same speed and the tension they bear is coupled to each other and difficult to stabilize independently.

[0003] To address this issue, some studies have attempted to introduce tension control mechanisms to dynamically compensate for the layup process. However, existing tension control technologies mostly employ passive or semi-active methods such as mechanical friction damping, simple brakes, or open-loop speed adjustment. These methods suffer from low tension control accuracy (fluctuation range often > ±2N) and slow response. During layup on complex curved surfaces, the yarn path length and stress state change in real time. This coarse tension control can lead to localized yarn slack or overstretching, resulting in layup wrinkles, gaps, or fiber damage, failing to meet the stringent requirements for layup tension stability in high-precision composite components.

[0004] In addition, the existing equipment is not fully equipped, the operation process requires manual intervention, and it is highly dependent on the operator's experience, resulting in poor consistency of process quality.

[0005] In summary, existing tile-laying systems cannot meet the requirements for laying complex curved surfaces. Summary of the Invention

[0006] This invention provides a carbon fiber dry prepreg yarn laying system and method to address the shortcomings of existing laying systems that cannot meet the requirements of laying complex curved surfaces, and to realize an automatic carbon fiber dry prepreg yarn laying system with less manual intervention, support for independent speed control of multiple strands, constant tension and actively adjustable transverse gap. This invention provides a carbon fiber dry prepreg yarn laying system, comprising: The unwinding unit is used to install and fix the yarn of the carbon fiber dry prepreg yarn roll to be processed to the corresponding station, forming an unwinding path for the yarn; The yarn feeding unit is used to peel off the protective film of the yarn on the unwinding path and transport the yarn with the protective film peeled off to the corresponding conveying path. It also acquires the real-time tension data and the current position of the yarn on the conveying path and sends them to the control unit. The unit then completes the yarn conveying on the conveying path according to the control instructions fed back by the control unit. The laying unit is used to lay the yarn on the conveying path and solidify it on the surface of the workpiece, and to obtain the pressure signal acting on the surface of the workpiece during the laying process. The cutting and refeeding unit is used to cut the yarn at the end of the laying process and refeed the yarn tip to the laying start point before the start of the next cycle. The control unit is used to generate a first control command based on the tension data and the pressure signal using a preset PID algorithm to adjust the output torque and / or output speed; and to generate a variable gap command as a second control command based on the current position of the yarn and preset trajectory data using a surface reconstruction algorithm to dynamically change the lateral pitch between each yarn guide in real time.

[0007] According to the present invention, a carbon fiber dry prepreg yarn laying system is provided, wherein the unwinding unit comprises: The unwinding spindle is used to install and fix the carbon fiber dry prepreg yarn roll. Spacer rings are used to separate and position the carbon fiber dry prepreg yarn rolls fitted on the corresponding work positions of the unwinding spindle in the axial direction, forming the unwinding path for each yarn. A yarn unwinding motor is used to apply a reverse torque to prevent the yarn on the unwinding path from slagging; The unwinding motor is rigidly connected to the unwinding spindle. A spring-loaded locking mechanism, disposed in the tension assembly of the unwinding path, is used to circumferentially lock the carbon fiber dry prepreg yarn roll.

[0008] According to the present invention, a carbon fiber dry prepreg yarn laying system is provided, wherein the yarn feeding unit includes: A film-peeling and winding mechanism is used to peel off and wind up the protective film of the yarn; Multiple sets of guide and drive rollers are used to transport the free end of the yarn after the protective film has been peeled off to the corresponding transport path; A tension sensor is installed at a preset position on the conveying path to acquire real-time tension data of the conveying path. A yarn feeding motor is used to output power to pull the yarn along the conveying path according to the first control command; A lateral spacing adjustment module is used to precisely position the yarns and adjust the lateral spacing between the yarns according to the second control command.

[0009] According to the present invention, a carbon fiber dry prepreg yarn laying system is provided, wherein the transverse variable spacing adjustment module includes: A multi-segment variable pitch screw is used to drive a floating yarn guide. The multi-segment variable pitch screw has threaded segments with an arithmetic progression of lead from the center to both ends. The floating yarn guides are respectively engaged with the threaded segments with corresponding leads. A stepper motor is used to provide power to drive a multi-segment variable pitch lead screw, which in turn drives the floating yarn guide mounted on the guide rail to perform coordinated lateral movement.

[0010] According to the present invention, a carbon fiber dry prepreg yarn laying system is provided, wherein the laying unit comprises: Fixed pressure rollers are used for preliminary positioning and pre-compacting of the yarn on the conveying path; Movable pressure rollers are used to further compact the yarn after initial positioning and pre-compaction treatment; An infrared heater is installed in the preset heating zones before and after the fixed pressure roller to heat the yarn passing through the heating zones; A pressure sensor is used to monitor the pressure signal acting on the surface of the workpiece during the laying process; A temperature sensor is used to monitor the surface temperature of the yarn in the heating zone.

[0011] According to the present invention, a carbon fiber dry prepreg yarn laying system includes a movable pressure roller comprising a telescopic mechanism adjustable by a pneumatic control valve, wherein the extension length and pressing angle of the telescopic mechanism are dynamically adjusted in real time according to the curved contour of the workpiece surface.

[0012] According to the carbon fiber dry prepreg yarn laying system provided by the present invention, the control unit is further configured to: Based on the workpiece surface curve and the real-time position of the current laying head in the workpiece coordinate system, a pneumatic control signal is generated using a preset kinematic model.

[0013] According to the present invention, a carbon fiber dry prepreg yarn laying system is provided, wherein the shearing and refeeding unit includes: The shearing module, located in the yarn feeding guide groove, is used to trigger a synchronous shearing program to shear the yarn when the laying length reaches a preset value or when a manual interruption command is received. The re-feeding module is used to activate the air flotation conveying mode according to the air pressure control signal, and re-feed the cut yarn front end to the laying starting point.

[0014] According to the carbon fiber dry prepreg yarn laying system provided by the present invention, the shearing and refeeding unit further includes: A low-temperature air-cooling unit is used to locally freeze the yarn before shearing.

[0015] The present invention also provides a method for laying carbon fiber dry prepreg yarn, comprising: Based on the unwinding unit, the yarn of the carbon fiber dry prepreg yarn roll to be processed is installed and fixed to the corresponding station to form an unwinding path for the yarn. Based on the yarn feeding unit, the protective film of the yarn on the unwinding path is peeled off, and the yarn with the protective film peeled off is transported to the corresponding conveying path. The real-time tension data and current position of the yarn on the conveying path are obtained and sent to the control unit. The yarn conveying on the conveying path is completed according to the control instructions fed back by the control unit. Based on the laying unit, the yarn on the conveying path is laid and solidified on the surface of the workpiece, and the pressure signal acting on the surface of the workpiece during the laying process is obtained. Based on the shearing and refeeding unit, the yarn is cut at the end of the laying and the yarn tip is refeeded to the laying start point before the start of the next cycle. Based on the control unit, a first control command is generated using a preset PID algorithm according to the tension data and the pressure signal to adjust the output torque and / or output speed; a variable gap command is generated using a surface reconstruction algorithm as a second control command according to the current position of the yarn and the preset trajectory data to dynamically change the lateral pitch between each yarn guide in real time.

[0016] The present invention also provides an electronic device, including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the program to implement the carbon fiber dry prepreg yarn laying method as described above.

[0017] The present invention also provides a non-transitory computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the carbon fiber dry prepreg yarn laying method as described above.

[0018] The present invention also provides a computer program product, including a computer program that, when executed by a processor, implements the carbon fiber dry prepreg yarn laying method as described above.

[0019] This invention provides a carbon fiber dry prepreg yarn laying system and method. The system uses an unwinding unit to install and fix the yarn of the carbon fiber dry prepreg yarn roll to the corresponding station, forming an unwinding path for the yarn. A yarn feeding unit peels off the protective film from the yarn on the unwinding path and conveys the yarn to the corresponding conveying path. Real-time tension data and the current position of the yarn on the conveying path are acquired and sent to a control unit. The yarn is then conveyed according to control commands from the control unit. Finally, a laying unit lays the yarn on the conveying path and solidifies it onto the workpiece surface, obtaining… The invention utilizes pressure signals applied to the workpiece surface during the laying process; a shearing and refeeding unit cuts the yarn at the end of the laying process and refeeds the yarn tip to the laying start point before the next cycle begins; a control unit generates a first control command based on tension data obtained from the yarn feeding unit and pressure signals obtained from the laying unit, using a preset PID algorithm to adjust the output torque and / or output speed; and a surface reconstruction algorithm generates a variable gap command as a second control command based on the current yarn position obtained from the yarn feeding unit and preset trajectory data, to dynamically change the lateral pitch between each yarn guide nozzle in real time. This invention can calculate complex surface trajectories in real time, dynamically coordinate the feeding speed, tension, and lateral spacing of each yarn strand, ensuring flatness, wrinkle-free, and error-free gaps and overlaps during complex surface variable trajectory laying, achieving high-precision, highly adaptable collaborative laying of multiple yarn strands on complex surfaces with low human intervention. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0021] Figure 1 This is one of the structural schematic diagrams of the carbon fiber dry prepreg yarn laying system provided by the present invention; Figure 2 This is the second schematic diagram of the carbon fiber dry prepreg yarn laying system provided by the present invention; Figure 3 This is the third schematic diagram of the carbon fiber dry prepreg yarn laying system provided by the present invention; Figure 4 This is the fourth schematic diagram of the carbon fiber dry prepreg yarn laying system provided by the present invention; Figure 5 This is the fifth schematic diagram of the carbon fiber dry prepreg yarn laying system provided by the present invention; Figure 6 This is the sixth schematic diagram of the carbon fiber dry prepreg yarn laying system provided by the present invention; Figure 7 This is a schematic diagram of the PLC control principle of the carbon fiber dry prepreg yarn laying system provided by the present invention; Figure 8 This is a schematic diagram of the system circuit of the carbon fiber dry prepreg yarn laying system provided by the present invention; Figure 9 This is a schematic flowchart of the carbon fiber dry prepreg yarn laying method provided by the present invention; Figure 10 This is a schematic diagram of the structure of the electronic device provided by the present invention. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0023] More specifically, the existing deployment systems have the following drawbacks: 1) The system architecture is rigid and cannot support independent and collaborative operation of multiple yarns: Existing automated yarn laying systems are mostly monolithic structures designed for single strands or fixed yarn bundles, with their drive and control units typically in a centralized or parallel configuration. This architecture fundamentally limits the system's ability to independently and differentiate control multiple strands of yarn. Specifically, it cannot configure an independent drive source and tension sensing closed loop for each strand, resulting in all yarns being forced to travel at the same speed during laying, and the tension they bear being mutually coupled and difficult to stabilize independently. Therefore, existing technologies cannot achieve "independent speed control for multiple strands" and "constant tension control for each strand," severely restricting their application on complex components requiring differentiated laying parameters (such as varying angles and thicknesses), such as curved surfaces with varying curvature or concave-convex features.

[0024] 2) Open-loop or coarse tension control is difficult to adapt to dynamic laying processes: While existing technologies mention tension control, they mostly employ passive or semi-active methods such as mechanical friction damping, simple brakes, or open-loop speed regulation. These methods cannot quickly and accurately compensate for tension disturbances caused by changes in roll diameter, conveyor speed fluctuations, mechanical vibrations, and surface curvature. Tension control accuracy is low (fluctuation range often > ±2N), and response is slow, classifying it as static or quasi-static control. When laying yarns on complex curved surfaces, the yarn path length and stress state change in real time. This coarse tension control can lead to localized yarn slack or overstretching, resulting in layup wrinkles, gaps, or fiber damage, failing to meet the stringent requirements for layup tension stability in high-precision composite components.

[0025] 3) The yarn gap cannot be dynamically adjusted, which easily leads to overlapping or resin-rich defects: Existing multi-strand laying heads typically employ fixed-groove width or fixed-spaced comb teeth, locking the lateral relative positions of the yarns. However, when laying yarns on surfaces with varying curvature or cross-section, the ideal spacing of each yarn on the projected surface changes in real time to accommodate the geometric variations of the laying path. A fixed spacing can lead to uncontrollable "gap" or "overlap" between yarns. Excessive gaps result in resin-rich areas, reducing mechanical properties; overlap leads to localized thickness deviations and increased porosity. Current technology lacks an active mechanism capable of online, continuous adjustment of the lateral output spacing of multi-strand yarns.

[0026] 4) The functional modules are discrete, lacking integrated adaptive capabilities for complex curved surfaces: Existing equipment treats unwinding, feeding, tension control, shearing, and compaction as separate processes or modules, resulting in low mechanical and electrical integration. The modules lack coordination and a unified control center capable of sensing surface geometry and dynamically coordinating the various execution units. Therefore, when facing complex surfaces, the system struggles to achieve real-time dynamic matching of the laying trajectory, yarn feeding speed, compaction pressure, and surface curvature. The compaction mechanism is often rigid or a simple floating design, unable to adaptively conform to the surface, easily leading to uneven pressure, incomplete laying, or material slippage. The entire laying process is highly dependent on operator experience, resulting in poor consistency in process quality.

[0027] 5) Insufficient adaptability to fluctuations in the industrial environment: Most existing layup equipment operates in relatively ideal laboratory environments. However, actual industrial sites face significant fluctuations in temperature and humidity, as well as vibration interference from surrounding equipment. The physical properties of carbon fiber prepreg (such as adhesion and layup properties) are extremely sensitive to temperature and humidity, and external vibrations can easily cause deviations in high-precision layup trajectories. Current technologies lack proactive sensing and real-time compensation mechanisms for these environmental factors, making it difficult to guarantee consistent layup quality in complex industrial environments. 6) Frequent business process interruptions and insufficient automation and continuity: The existing technology for cutting and refeeding (or yarn changing) processes has a low degree of automation, often requiring manual intervention or equipment downtime. After cutting, the system often cannot automatically and accurately refeed the yarn tip to the laying start point, requiring manual yarn feeding and alignment, which severely disrupts the continuity of laying, increases non-productive time, and introduces human error. This interruption in the process makes it impossible to achieve efficient and continuous automated cyclic operations, especially in multi-strand and multi-layer operations, which significantly affects overall production efficiency and layup accuracy.

[0028] In view of the prominent problems in the existing technology, such as the difficulty in independently adjusting the laying speed of multi-strand yarns, insufficient tension control precision, easy generation of uncontrollable gaps or overlapping defects in variable curvature paths, and inability to adapt to complex curved surface trajectories, this invention proposes a carbon fiber dry prepreg yarn laying system and method.

[0029] The following is combined Figures 1-8 The present invention describes a carbon fiber dry prepreg yarn laying system. Figure 1 This is one of the structural schematic diagrams of the carbon fiber dry prepreg yarn laying system provided by the present invention. Figure 1 As shown, the system includes: The unwinding unit 110 is used to install and fix the yarn of the carbon fiber dry prepreg yarn roll to be processed to the corresponding station, forming an unwinding path for the yarn.

[0030] The carbon fiber dry prepreg yarn rolls to be processed can be selected according to the requirements of the laying process.

[0031] According to the example embodiment, 1-5 strands of carbon fiber dry prepreg yarn rolls (width 3-10mm) with suitable specifications are selected as the carbon fiber dry prepreg yarn rolls to be processed.

[0032] During installation, the mandrels of each yarn roll are sequentially inserted into their corresponding workstations.

[0033] The yarn feeding unit 120 is used to peel off the protective film of the yarn on the unwinding path, and transport the yarn with the protective film peeled off to the corresponding conveying path. It acquires the real-time tension data and the current position of the yarn on the conveying path and sends them to the control unit. It also completes the yarn conveying on the conveying path according to the control instructions fed back by the control unit.

[0034] After the roll material is installed and secured, the prepreg yarn needs to be unwound and threaded. Specifically, the protective film at the end of each yarn on the unwinding path is smoothly peeled off from the yarn body, and the free ends of each unwound yarn are sequentially threaded into their respective independent conveying paths.

[0035] During the conveying process, tension data is detected in real time and fed back to the control unit for tension regulation. The control unit generates the first control command to dynamically adjust the output of the corresponding yarn feed, forming a fast closed-loop compensation (e.g., response time ≤ 0.1 seconds). This strictly controls the tension fluctuation of each channel within a preset range (e.g., ±0.3N), thereby maintaining a constant tension per yarn under complex curved surfaces and variable speed laying conditions, providing a reliable guarantee for high-quality layering.

[0036] In addition, to overcome the problems of "dead gaps" and "overlaps" caused by changes in path geometry during complex curved surface laying, real-time position feedback is monitored during the conveying process and fed back to the control unit. The control unit generates a second control command to drive the module to dynamically change the lateral pitch between each yarn guide in real time, ensuring seamless bonding of the yarn layup on the variable curvature surface.

[0037] The laying unit 130 is used to lay the yarn on the conveying path and solidify it on the surface of the workpiece, and to obtain the pressure signal acting on the surface of the workpiece during the laying process.

[0038] After precise tension control, the multi-strand prepreg yarn is simultaneously conveyed to the laying unit 130 at the front end of the modular frame for laying and curing.

[0039] Simultaneously, the pressure signal acting on the workpiece surface during the laying process is acquired. This pressure data is synchronously converted into an auxiliary feedback quantity for tension control, and fused with the signal collected by the independent tension sensor at the front end to form a multi-dimensional perception of the laying state.

[0040] The shearing and refeeding unit 140 is used to cut the yarn at the end of the laying and refeed the yarn front end to the laying start point before the start of the next cycle.

[0041] When the laying is complete, the yarn is cut. After cutting, the system automatically enters the refeeding and reset phase.

[0042] The control unit 150 is used to generate a first control command based on the tension data and the pressure signal using a preset PID algorithm to adjust the output torque and / or output speed; and to generate a variable gap command as a second control command based on the current position of the yarn and preset trajectory data using a surface reconstruction algorithm to dynamically change the lateral pitch between each yarn guide in real time.

[0043] The system employs a negative feedback mechanism based on the PID algorithm to perform reverse adjustment in response to the deviation direction of tension and pressure.

[0044] When the system detects that the pressure or tension deviates from the preset threshold, the control unit 150 generates the first control command and starts the electro-pneumatic coordinated adjustment mechanism: on the one hand, by adjusting the reverse torque output of the corresponding channel servo motor, the damping and yarn feeding balance at the yarn feeding end are dynamically controlled; on the other hand, the proportional pressure valve or cylinder connected to the pressure roller is synchronously controlled to realize real-time compensation of the bonding pressure.

[0045] Adjusting the servo motor: The control unit 150 compares the real-time tension with the set value through an adaptive PID algorithm, generates the first control command, and dynamically adjusts the torque or speed of the corresponding yarn feeding motor to form a fast closed-loop compensation (e.g., response time ≤ 0.1 seconds), ensuring that the tension fluctuation of each channel is controlled within the preset range (e.g., ±0.3N), adapting to the constant tension maintenance under complex curved surfaces and variable speed conditions.

[0046] In some embodiments, the specific adjustment strategy is as follows: the control unit 150 employs a negative feedback adjustment mechanism. When the monitored real-time tension is greater than a set threshold (i.e., the yarn is too tight), the system determines that the yarn supply is insufficient, and the control unit 150 outputs a first control command to increase the speed or output torque of the corresponding yarn feeding motor to accelerate the yarn feeding speed, thereby releasing the tension. When the monitored real-time tension is less than a set threshold (i.e., the yarn is slack), the system determines that the yarn supply is excessive, and the control unit 150 outputs a first control command to reduce the speed or output torque of the corresponding yarn feeding motor (or even apply reverse braking torque) to slow down the yarn feeding, thereby tightening the yarn and eliminating slack. Through the above dynamic adjustment, the tension fluctuation is maintained within a preset range (e.g., ±0.3N).

[0047] Adjusting the proportional pressure valve / cylinder: When the monitored real-time bonding pressure exceeds a preset threshold (i.e., excessive pressure): Control unit 150 outputs a first control command, reducing the analog voltage / current signal supplied to the electric proportional pressure valve. The proportional valve then reduces its output air pressure, causing the cylinder thrust connected to the pressure roller to decrease, thereby reducing the bonding pressure. When the monitored real-time bonding pressure is less than a preset threshold (i.e., insufficient compaction): Control unit 150 outputs a first control command, increasing the analog signal supplied to the electric proportional pressure valve. The proportional valve then increases its output air pressure, driving the cylinder to increase its thrust, thereby compensating for and increasing the bonding pressure.

[0048] This dual-path coordinated adjustment can complete the closed-loop response in a short time (e.g., ≤0.2 seconds), ensuring that the tension and pressure during the laying process remain within the set fluctuation range (e.g., tension ≤±0.3N, pressure ≤±2N).

[0049] This application integrates three major components: controlled passive unwinding, independent servo yarn feeding, and real-time closed-loop control, constructing a collaborative control mechanism of "damping supply - precise traction - dynamic stability".

[0050] During the laying process, the control unit 150 also drives the module to dynamically change the lateral pitch between each yarn guide nozzle in real time based on the variable gap command issued by the surface reconstruction algorithm. Specifically, the control unit 150 calculates the ideal yarn layout width under the current curvature based on the preset trajectory data and the real-time position feedback (of the yarn) through the built-in surface reconstruction and path width prediction algorithm; then it generates a variable gap command to drive the stepper motor in the module to rotate a specific angle, so as to dynamically change the lateral pitch between each yarn guide nozzle in real time.

[0051] This invention provides a carbon fiber dry prepreg yarn laying system. The system uses an unwinding unit to install and fix the yarn of the carbon fiber dry prepreg roll to the corresponding station, forming an unwinding path for the yarn. A yarn feeding unit peels off the protective film from the yarn along the unwinding path and conveys the yarn to the corresponding conveying path. Real-time tension data and the current yarn position are acquired and sent to a control unit. The system then completes the yarn conveying along the conveying path based on control commands from the control unit. Finally, a laying unit lays the yarn along the conveying path and solidifies it onto the workpiece surface, obtaining the laid yarn. The invention utilizes pressure signals applied to the workpiece surface during the laying process; a shearing and refeeding unit cuts the yarn at the end of the laying process and refeeds the yarn tip to the laying start point before the next cycle begins; a control unit generates a first control command based on tension data obtained from the yarn feeding unit and pressure signals obtained from the laying unit, using a preset PID algorithm to adjust the output torque and / or output speed; and a surface reconstruction algorithm generates a variable gap command as a second control command based on the current yarn position obtained from the yarn feeding unit and preset trajectory data, to dynamically change the lateral pitch between each yarn guide nozzle in real time. This invention can calculate complex surface trajectories in real time, dynamically coordinate the feeding speed, tension, and lateral spacing of each yarn strand, ensuring flatness, wrinkle-free, and error-free gaps and overlaps during complex surface variable trajectory laying, achieving high-precision, highly adaptable collaborative laying of multiple yarn strands on complex surfaces with low human intervention.

[0052] The unwinding unit 110 is further described below. In some embodiments, the unwinding unit 110 includes: The unwinding spindle 1101 is used to install and fix the carbon fiber dry prepreg yarn roll; Spacer ring 1102 is used to separate and position the carbon fiber dry prepreg yarn roll sleeved on the corresponding station of the unwinding spindle in the axial direction, so as to form the unwinding path for each yarn. The unwinding motor 1103 is used to apply a reverse torque to prevent the yarn on the unwinding path from slagging; The unwinding motor is rigidly connected to the unwinding spindle. A spring-loaded locking mechanism, disposed in the tension assembly of the unwinding path, is used to circumferentially lock the carbon fiber dry prepreg yarn roll.

[0053] Specifically, the unwinding unit is as follows: Figure 2 As shown, Figure 2 (a) is a front view of the unwinding unit. Figure 2 (b) is a top view of the unwinding unit. Figure 2 (c) is an oblique side view of the unwinding unit. Figure 2 It includes an unwinding spindle 1101, a spacer ring 1102, an unwinding motor 1103, a bearing housing 210, a fiber yarn core 220, a bushing 230, a tension assembly 240, and a knob 250.

[0054] Each yarn roll is subjected to a controllable reverse torque by an independent unwinding motor 1103, which provides moderate damping to prevent the yarn from slack.

[0055] During installation, the mandrels of each yarn roll are sequentially inserted into the corresponding positions of the unwinding spindle 1101, and are separated and positioned axially by the "long-short" combination spacers 1102 to ensure that the set intervals are maintained between each roll, thereby forming an independent and non-interfering unwinding path and tension control range for each yarn.

[0056] According to the example embodiment, a magnetorheological damper (MR damper) can be used as the resistance source for the unwinding shaft, replacing the reverse torque control of the unwinding motor 1103 in the original solution. By adjusting the magnetic field strength, the damping torque can be changed in real time, achieving stepless and silent adjustment of the unwinding resistance. This solution offers precise torque control, a wide dynamic range, and no mechanical wear, making it suitable for environments sensitive to noise and maintenance.

[0057] The roll material is circumferentially locked by the spring-loaded block mechanism independently configured in the tension assembly of each channel (i.e., the unwinding path), and the end knob of the bushing is tightened to press the spacer ring and the roll material together.

[0058] According to the example embodiment, the axial movement is limited to ≤0.2mm.

[0059] Furthermore, in some embodiments, after installation is completed, each roll needs to be manually rotated for resistance verification. The rotational resistance of a single roll is required to be uniform, and the resistance deviation between multiple strands is ≤0.5 N·m, in order to ensure the initial stability and consistency of tension during unwinding.

[0060] The yarn feeding unit 120 is further described below. In some embodiments, the yarn feeding unit 120 includes: The film peeling and winding mechanism 1201 is used to peel off and wind up the protective film of the yarn. Multiple sets of guide and drive rollers 1202 are used to transport the free end of the yarn after the protective film has been peeled off to the corresponding transport path; Tension sensor 1203 is set at a preset position on the conveying path to acquire real-time tension data of the conveying path; The yarn feeding motor 1204 is used to output power to pull the yarn on the conveying path according to the first control command; The transverse spacing adjustment module 1205 is used to precisely position the yarn and adjust the transverse spacing between the yarns according to the second control command.

[0061] Specifically, the protective film at the end of each yarn on the unwinding path is smoothly peeled off from the yarn body and introduced into the corresponding channel by the film peeling and winding mechanism 1201. This mechanism is linked with the main conveying mechanism through the transmission system to realize the synchronous and passive winding of the release film, ensuring that it is collected smoothly and neatly, and avoiding interference with the yarn path.

[0062] Subsequently, the free ends of each stripped yarn are sequentially fed into their respective independent conveying paths. The yarn first passes through multiple sets of guide and drive rollers 1202. These multiple sets of guide and drive rollers 1202 provide stable and reliable transmission friction, effectively preventing slippage during yarn feeding, thus laying the foundation for subsequent precise tension control.

[0063] According to an example embodiment, the multiple sets of guide and drive rollers 1202 include four sets of guide and drive rollers arranged in a specific layout. Further, in some embodiments, the four sets of guide and drive rollers adopt an S-shaped multi-point enveloping layout; specifically, the four sets of rollers are arranged in a staggered manner, so that when the yarn passes through each roller sequentially, an enveloping angle greater than 90° is formed on the surface of each roller. By increasing the effective contact arc length between the yarn and the roller surface to fully extend the yarn, and in conjunction with a special coating with a high coefficient of friction on the roller surface, static friction anchor points sufficient to overcome yarn tension fluctuations are established.

[0064] Furthermore, in some embodiments, the surfaces of multiple sets of guide and transmission rollers 1202 are all coated with a special coating with a high coefficient of friction.

[0065] Guided and driven by the rollers, the yarn is smoothly conveyed to the precisely designed yarn feeding guide groove for positioning, and finally drawn out from the end of the pressure roller with curved surface self-adaptation function, ready to contact the workpiece surface and begin to be laid.

[0066] To achieve precise and stable control of the tension of multiple yarns, high-precision tension sensors 1203 are installed at key locations in each independent conveying path. During the conveying process, the high-precision tension sensors integrated into each yarn track detect tension data in real time and feed it back to the control unit 150.

[0067] According to the example embodiment, the tension sensor 1203 adopts the strain gauge or micro-torque detection principle, with a range of 0–10N and an accuracy of ±0.1N. It acquires tension signals in real time at a frequency of not less than 100Hz, and transmits them to the control unit 150 after processing.

[0068] According to the example embodiment, a machine vision unit (such as a Basler camera) can be introduced to replace the tension sensor 1203 to monitor the yarn shape and laying status in real time, and to detect mechanical disturbances of the system in conjunction with a vibration sensor. The control unit 150 adopts a model predictive control algorithm to integrate multi-source information for feedforward-feedback composite control, further improving the system's ability to suppress sudden disturbances and the predictive maintenance level of laying quality.

[0069] This application employs a collaborative design combining passive drag-type unwinding with independent servo active yarn feeding. Each yarn package is subjected to a controllable reverse torque by an independent unwinding motor 1103, providing appropriate damping to prevent yarn slack. Simultaneously, high-response servo yarn feeding motors 1204 in downstream channels actively pull the yarn, achieving dynamic torque balance between the two. This constitutes the front-end execution stage of tension control, supporting independent speed regulation of multiple yarns. The torque or speed of the yarn feeding motor 1204 is controlled by a first control command.

[0070] Furthermore, to overcome the challenges of "dead gaps" and "overlaps" caused by path geometry changes in complex curved surface laying, the system innovatively integrates a transverse variable pitch adjustment module 1205 at the end of the yarn feeding mechanism, adjacent to the entrance of the dual pressure roller assembly. This module replaces the traditional fixed yarn feeding guide groove, dynamically changing the transverse pitch between each yarn guide nozzle in real time according to the second control command, ensuring seamless bonding of the yarn layup on the variable curvature surface.

[0071] The following provides a further description of the lateral variable spacing adjustment module 1205. In one embodiment, the lateral variable spacing adjustment module 1205 includes: A multi-segment variable pitch screw is used to drive a floating yarn guide. The multi-segment variable pitch screw has threaded segments with an arithmetic progression of lead from the center to both ends. The floating yarn guides are respectively engaged with the threaded segments with corresponding leads. A stepper motor is used to provide power to drive a multi-segment variable pitch lead screw, which in turn drives the floating yarn guide mounted on the guide rail to perform coordinated lateral movement.

[0072] The lateral variable pitch adjustment module 1205 uses a micro precision stepper motor as its power core. By driving a specially designed multi-segment variable pitch lead screw, it drives a set of floating yarn guides mounted on a precision linear guide rail to perform coordinated lateral movement.

[0073] The lead screw has threaded segments with an arithmetic progression of lead from the center to both ends (such as P, 2P, 3P...). Each yarn guide is engaged with the threaded segment corresponding to its lead, thus ensuring that the lateral pitch change between all adjacent yarn guides remains strictly consistent when the lead screw rotates.

[0074] During the yarn laying process, the control unit 150 also drives the module to dynamically change the lateral pitch between each yarn guide nozzle in real time based on the variable gap command issued by the surface reconstruction algorithm. Specifically, the control unit 150 calculates the ideal yarn layout width under the current curvature based on the preset trajectory data and the real-time position feedback (of the yarn) through the built-in surface reconstruction and path width prediction algorithm; then it generates a variable gap command to drive the stepper motor in the module to rotate a specific angle, so as to dynamically change the lateral pitch between each yarn guide nozzle in real time. On this basis, the stepper motor drives the variable lead screw to rotate according to the variable gap command (second control command), so that each yarn guide nozzle meshing on different lead segments of the screw produces differentiated displacement, thereby dynamically changing the lateral pitch between each yarn guide nozzle in real time, ensuring seamless bonding of the yarn layup on the variable curvature surface.

[0075] This mechanism supports stepless continuous adjustment of the center distance of multi-strand yarns within a fixed range (e.g., 3.5mm to 8mm), with a short adjustment response time (e.g., ≤0.2 seconds) and a positioning accuracy of up to ±0.05mm.

[0076] Through this active adjustment process, the system ensures that the transverse alignment width of the multi-strand yarns has been precisely pre-corrected based on the current curvature characteristics before they contact the pressure rollers and finally adhere to the mold surface, thereby guaranteeing the uniformity and density of the layup gaps from a physical perspective.

[0077] In some embodiments, each yarn can be equipped with an independent micro transverse movement module to achieve asynchronous, asymmetric spacing adjustment of the yarn guide nozzles. Each yarn guide nozzle is mounted on an independent linear module consisting of a precision ball screw driven by a micro servo motor. It can move independently along the transverse guide rail and receive independent commands from the control system, thereby achieving independent control of the lateral position of each yarn output.

[0078] The following provides a further description of the laying unit 130. In one embodiment, the laying unit 130 includes: Fixed pressure roller 1301 is used for preliminary positioning and pre-compacting of the yarn on the conveying path; The movable pressure roller 1302 is used to further compact the yarn after the initial positioning and pre-compaction treatment; An infrared heater 1303 is disposed in the preset heating zones before and after the fixed pressure roller, and is used to heat the yarn passing through the heating zones; Pressure sensor 1304 is used to monitor the pressure signal acting on the surface of the workpiece during the laying process; Temperature sensor 1305 is used to monitor the surface temperature of the yarn in the heating zone.

[0079] Specifically, the laying process is completed in collaboration between the fixed pressure rollers 1301 and the movable pressure rollers 1302 arranged in sequence. Under constant tension control, the prepreg yarn is first initially positioned and pre-compacted by the fixed pressure rollers 1301; then it enters the area of ​​the movable pressure rollers 1302.

[0080] In some embodiments, the movable pressure roller 1302 includes a telescopic mechanism adjustable by a pneumatic valve, wherein the extension length and pressing angle of the telescopic mechanism are dynamically adjusted in real time according to the curved contour of the workpiece surface.

[0081] The pressure roller, through a telescopic mechanism regulated by a pneumatic valve, can dynamically adjust its extension length and bonding pressure according to the curved contour of the workpiece, thereby achieving adaptive distribution and stable maintenance of the laying pressure.

[0082] In some embodiments, the fixed pressure roller 1301 and the movable pressure roller 1302 are made of special elastic material, which effectively protects the yarn surface while providing uniform adhesion.

[0083] According to the example embodiment, a servo electric cylinder (such as an IAI or HIWIN product) can be used to replace the pneumatic cylinder connected to the pressure roller. The electric cylinder drives the ball screw through a servo motor, achieving precise and programmable pressure control without the need for an external air source.

[0084] Furthermore, to overcome the laying difficulties caused by the low viscosity and high stiffness of dry prepreg yarn at room temperature, this embodiment of the invention integrates a synergistic mechanism of stepped heating and real-time closed-loop curing based on infrared radiation. This mechanism uses two sets of infrared heaters 1303 with preset heating zones before and after the fixed pressure roller 1301 to implement stepped precise temperature control of the yarn in a "preheating-pressing-enhanced curing" process: the first stage of preheating initially activates the resin; after being compacted by the pressure roller, the resin is instantly heated to the optimal viscosity window to achieve firm adhesion; the second stage of enhanced heating promotes its full curing.

[0085] According to the example embodiment, in the resin curing stage, a high-frequency induction heater can be used instead of the infrared heater 1303 to heat the pressure roller or specific yarn guiding components, achieving faster and more energy-efficient internal heating. Alternatively, a high-power ultraviolet LED array combined with photocurable prepreg yarn can be used to achieve instant curing. This alternative solution can significantly shorten the curing waiting time and increase the layup speed, making it suitable for mass production scenarios with extremely high production efficiency requirements.

[0086] The arrangement of the fixed pressure roller 1301, the movable pressure roller 1302, and the infrared heater 1303 is as follows: Figure 4 As shown, Figure 4 (a) is a front view of the laying unit roller assembly. Figure 4 (b) is a top view of the laying unit roller assembly. Figure 4 (c) is an oblique side view of the laying unit roller assembly. Figure 4 It includes a fixed pressure roller 1301, a movable pressure roller 1302, an infrared heater 1303, a pneumatic control valve 410, and a feeding guide trough 420.

[0087] A high-precision pressure sensor 1304 installed on the outside of the movable pressure roller is used to monitor the pressure signal acting on the surface of the workpiece during the laying process in real time and to feed it back to the control unit 150 at a preset frequency (e.g., above 20Hz).

[0088] According to the example embodiment, a machine vision unit (such as a Basler camera) can be introduced to replace the pressure sensor 1304 to monitor the yarn morphology and laying status in real time, and to detect mechanical disturbances in the system in conjunction with a vibration sensor. The control unit 150 adopts a model predictive control algorithm, integrates multi-source information for feedforward-feedback composite control, and further improves the system's ability to suppress sudden disturbances and the predictive maintenance level of laying quality.

[0089] The laying unit 130 also includes a temperature sensor 1305, which is used to monitor the surface temperature of the yarn in the heating zone. According to the example embodiment, for the stepped heating and real-time closed-loop curing co-processing machine, the system supports independent setting of temperature and duration for each stage, and performs dynamic closed-loop adjustment based on feedback from the real-time temperature sensor 1305. Simultaneously, it achieves real-time linkage between heating power and laying speed, thereby ensuring uniform and controlled heat input per unit area. Through this orderly and coordinated online process, the system significantly improves the flatness, wetting quality, and curing reliability when laying on complex curved surfaces.

[0090] The control unit 150 is further described below. In some embodiments, the control unit 150 is further configured to: Based on the workpiece surface curve and the real-time position of the current laying head in the workpiece coordinate system, a pneumatic control signal is generated using a preset kinematic model.

[0091] The control unit 150 not only achieves independent decoupled control of each channel to avoid tension coupling interference, but also uniformly schedules each execution unit according to the laying trajectory, curvature changes, and multi-strand coordination requirements, ensuring consistent tension and reliable laying during continuous operation. This integrated control system is the core technical support for achieving high-precision, multi-strand coordinated laying in this embodiment of the invention.

[0092] The specific implementation process of unified scheduling of various execution units is as follows: 1) Real-time analysis and feature extraction of trajectory data: The control unit 150 first reads the CNC code of the laying path and fits the discrete path points into a continuous spatial curve. In each calculation cycle, the system uses a differential algorithm to calculate the geometric characteristic parameters of the current contact point based on the real-time position of the laying head in the workpiece coordinate system, including the tangential velocity vector, normal vector, and local radius of curvature.

[0093] 2) Co-parameter solution based on kinematic model: The system utilizes a built-in kinematic model to solve the target instructions of each execution unit in parallel based on the above characteristics: First, it calculates the independent theoretical linear velocity (differential feeding) required for each yarn to eliminate the turning stroke difference based on the radius of curvature; second, it predicts the projected width based on the change of the surface normal and solves the lateral correction pitch (variable gap) required for the variable pitch module; at the same time, it calculates the theoretical contact depth of the pressure roller by combining the path normal angle and converts it into a pneumatic control signal (pressure adaptive).

[0094] 3) Timing synchronization and multi-channel instruction distribution: To ensure strict alignment of the above commands in physical execution, the system employs a synchronous refresh mechanism. The control unit 150 temporarily stores the calculated speed, position, and pressure commands for all channels in a buffer register and simultaneously sends them to each servo driver and actuator when the next synchronization pulse is triggered. This mechanism ensures synchronized response in four dimensions: head movement, differential yarn feed, variable gap lateral movement, and pressure adjustment.

[0095] The shearing and retransmission unit 140 is further described below. In some embodiments, the shearing and retransmission unit 140 includes: The shearing module 1401 is disposed in the yarn feeding guide groove and is used to trigger a synchronous shearing program to shear the yarn when the laying length reaches a preset value or when a manual interruption command is received. The re-feeding module 1402 is used to activate the air flotation conveying mode according to the air pressure control signal, and re-feed the cut yarn front end to the laying starting point.

[0096] Specifically, such as Figure 5 As shown, Figure 5 (a) is a front view of the shearing and refeeding unit. Figure 5 (b) is a top view of the shearing and reloading unit. Figure 5 (c) is an oblique side view of the shearing and refeeding unit. Figure 5 It includes a telescopic cylinder 510, a shearing blade 520, a guide groove 530, a feeding main wheel 540, an upper roller 550, and a pressure application component 560.

[0097] The signal indicating the end of yarn laying includes reaching a preset laying length or receiving a manual interruption command. When the triggering conditions for the end-of-laying signal are met, the system triggers a synchronous shearing program to cut the yarn. The shearing module 1401, located in the yarn feeding guide groove, is independently controlled by a high-speed solenoid valve. This solenoid valve drives a double-acting cylinder, which in turn drives a tungsten carbide alloy cutter to complete an instantaneous cutting action along a precision guide rail.

[0098] According to the example embodiment, the shearing action can be completed within 0.1 seconds, ensuring that the cross-sectional tilt angle is ≤1° and the roughness Ra is ≤3.2μm, which meets the requirements for high-precision docking.

[0099] Furthermore, for multi-strand collaborative operations, the system supports two modes: fully synchronous shearing and sequential partial shearing. Users can flexibly select the mode on the interface according to the process to avoid sudden changes in yarn tension caused by asynchronous shearing.

[0100] In some embodiments, a high-power normally closed electromagnet can be used as the shearing power source to replace the pneumatic cylinder. When energized, the electromagnet attracts, driving the cutter to complete the shearing; when de-energized, it resets under the action of a spring. This solution eliminates the need for the entire air source system, resulting in a more compact structure, but the impact force and speed consistency of a single shearing action are slightly lower than those of the pneumatic solution.

[0101] After shearing is completed, the system automatically enters the refeeding and reset stage. Receiving a pneumatic control signal from the control unit 150, the system adjusts the pressure roller cylinder via a proportional pressure valve, causing the movable pressure roller to briefly lift. Simultaneously, the upper pressure roller, originally used to clamp the yarn, is lifted by the cylinder, disengaging from contact with the yarn. The main feeding wheel then switches to an air-floating conveying mode—forming an air film under the yarn using compressed air, allowing the yarn to be smoothly pushed to the unified laying starting point under low friction.

[0102] The re-feed length can be set by parameters, and in some embodiments, the positioning accuracy reaches ±0.5mm.

[0103] According to the example embodiment, a servo electric cylinder (such as an IAI or HIWIN product) can be used instead of a pneumatic cylinder. The electric cylinder drives a ball screw via a servo motor, achieving precise, programmable pressure control without requiring an external air source. For shearing actions, a high-speed linear motor can be used to perform instantaneous cutting. This solution eliminates dependence on compressed air, improves energy efficiency, and is particularly suitable for working environments with high cleanliness requirements or where air sources are inconvenient.

[0104] Furthermore, during the reset process, the system monitors the position of the front end of each channel yarn in real time and confirms whether it has reached the reference plane through photoelectric sensors, ensuring that the multiple yarns are in the same position at the beginning of the next laying cycle.

[0105] Furthermore, in some embodiments, after repositioning is completed, the system automatically performs a self-test process: verifying the zero point of each channel tension sensor, confirming the reset status of the shearing mechanism, and detecting the temperature stability of the heating system. Once all tests are passed, the human-machine interface displays a "system ready" status, and the pressure and tension control system returns to standby mode.

[0106] The embodiments of the present invention realize the fully automated closed loop of "layout-cutting-reset" process, with a single cycle time of ≤3 seconds, which greatly reduces manual intervention and is particularly suitable for multi-strand and multi-layer continuous laying operation scenarios, ensuring the consistency of production rhythm and process.

[0107] In some embodiments, the shearing and retransmission unit 140 further includes: A low-temperature air-cooling unit is used to locally freeze the yarn before shearing.

[0108] To improve cutting quality, the system is equipped with a low-temperature air-cooling unit in the yarn feeding guide groove. Before cutting, the pre-impregnated yarn is locally frozen to temporarily increase its rigidity, thereby ensuring a neat cut surface without fuzz.

[0109] In one specific embodiment, the structural diagram of the carbon fiber dry prepreg yarn laying system provided by the present invention is as follows: Figure 6 As shown, Figure 6 (a) is a front view of the carbon fiber dry prepreg yarn layup system. Figure 6 (b) is a rear view of the carbon fiber dry prepreg yarn laying system, including a main board 610, an unwinding unit 110, a film peeling and winding mechanism 1201, a cylinder 620, a yarn feeding mechanism 630, a pressure roller mechanism 640, an unwinding motor 1103, a yarn feeding motor 1204, a shearing cylinder 650, a proportional pressure valve 660, and a solenoid directional valve 670.

[0110] Yarn feeding mechanism 630 Figure 3 As shown, it includes multiple sets of guide and transmission rollers 1202, a film peeling and winding mechanism 1201, a yarn feeding motor 1204, a feeding assembly 310, and a transverse variable spacing adjustment module 1205.

[0111] The pressure roller mechanism 640 includes a fixed pressure roller 1301, a movable pressure roller 1302, and an infrared heater 1303.

[0112] This invention uses a programmable logic controller (PLC) as the central control core and adopts a hierarchical distributed architecture to achieve unified management and real-time coordination of multi-axis motion, pneumatic actuation, sensor acquisition and human-machine interaction.

[0113] In this embodiment, the main controller of the control unit 150 is selected from the Siemens S7-1200 series (CPU 1215C). Its integrated high-speed counter, pulse output channel and powerful logic operation capability provide a hardware foundation for the synchronous control of multi-channel servo motors, the precise logic action of pneumatic components and the safety interlock of the whole system.

[0114] After system startup, the control unit first drives the independent servo motors and pneumatic components of each channel to complete initialization, providing power for yarn feeding, tension adjustment, and actuators. Operators set parameters such as the target tension and laying length of each yarn through the human-machine interface (HMI) and then initiate the pre-test process. At this time, the system controls the servo motors to run at low speed, sequentially drawing out small amounts of pre-impregnated yarn to observe whether the output is smooth along the tangential direction without twisting or wrinkling. Simultaneously, the tension sensors integrated in each channel monitor the yarn tension in real time, and the data is fed back to the control system for analysis and display, ensuring that the tension in each channel remains stable within the set range. During the test, the system automatically executes a self-test program, monitoring and diagnosing the status of each sensor, servo driver, pneumatic valve, and actuator, and displaying the test results and system status in real time on the HMI. If any component malfunctions, the system will issue an alarm and pause the process; if all tests are normal, it signifies that the system has completed its startup verification and is ready for multi-strand independent speed control and coordinated laying operations.

[0115] To meet the demands of multi-axis collaboration and complex input / output, the system has been expanded with dedicated functional modules: the analog input module (AI) is responsible for real-time acquisition of continuous signals from tension sensors, pressure roller sensors, and thermocouples in the heating zone; the analog output module (AO) is used to send speed / torque commands to the servo driver and output high-precision pressure control signals to the electro-proportional pressure valve; and the digital input / output module (DI / DO) is used to process status signals from limit switches, photoelectric sensors, etc., and directly drive switching actuators such as solenoid valves and relays.

[0116] All expansion modules exchange data at high speed with the central processing unit via the PLC backplane bus, ensuring real-time control response. Furthermore, the system utilizes motion control modules such as TM Counters & Positions to achieve precise position and speed synchronization management of multiple servo drives (e.g., Mitsubishi MR-JE series), forming a visual interactive layer for parameter setting, process monitoring, and data management. This completes the end-to-end hardware integration from signal perception and central decision-making to instruction execution.

[0117] The core control mechanism of this invention is a pneumatic-electric integrated coordination system centrally scheduled by a PLC. At the execution level, the pneumatic subsystem handles key actions such as pressure regulation, high-speed shearing, and auxiliary conveying: the movable pressure roller achieves stepless pressure regulation (control accuracy ±0.5N) through a double-acting cylinder precisely controlled by an electro-proportional pressure valve; high-speed shearing is triggered by the PLC at a specific DO point, driving a two-position five-way high-speed solenoid valve to reverse, causing compressed air to push the double-acting cylinder to complete instantaneous cutting; during the re-feeding stage, an independent solenoid valve controls the upper pressure roller lifting cylinder to disengage, and an air-floating nozzle controlled by a precision pressure regulating valve is activated to create a low-friction conveying environment. All key pneumatic actions are equipped with magnetic switches for position feedback, forming an execution confirmation closed loop.

[0118] At the control layer, the PLC acts as the "central nervous system" to achieve a collaborative closed loop of multiple physical quantities: by integrating a non-contact infrared temperature sensor to monitor the surface temperature of the yarn in the heating zone in real time, and feeding the signal back to the AI ​​module to participate in decision-making; at the same time, it drives the heating controller (such as a solid-state relay or thyristor power regulator) in the execution layer to accurately adjust the power of the infrared heater according to the analog quantity or PWM signal output by the AO / DO module, thus constructing a complete temperature closed-loop control.

[0119] Building upon this foundation, the system operates an independent tension-pressure composite closed loop for each yarn. A PID algorithm adjusts the torque of the yarn-feeding servo motor, feeding the result forward to the pneumatic pressure regulating unit. During complex curved surface placement, commands for each motion axis are calculated and synchronized in real-time based on CAD trajectory data. Finally, an internal sequential control program (SFC) coordinates the actions of the servo motor, solenoid valve, proportional valve, and temperature control unit with millisecond-level precision. This "sensing-decision-pneumatic / electrical / thermal coordinated execution" architecture, integrating temperature sensing and power regulation, ensures the system's real-time response, synchronization, and process consistency during multi-strand, variable-trajectory placement.

[0120] The schematic diagram of the PLC control principle in this embodiment is as follows: Figure 7 As shown, the system circuit diagram is as follows: Figure 8 As shown in the figure: 1. AC POWER DISTRIBUTION (380V / 220V): AC power distribution (380V / 220V), serving as the power input and distribution point for the equipment; QF0, QF-H, QF-P: Circuit breakers (air switches), used for circuit protection; KM0: AC contactor main contacts; FIL: Filter (for interference suppression); ACL: Reactor (limiting harmonic current); TO SERVO DRIVES (L1 / L2 / L3): Connect to the servo drive main power supply (three-phase live wire); PE: Protective ground; SSR: Solid state relay; IR HEATER: Electromagnetic induction heater; PSU (AC220V-DC24V): Switching power supply (converts AC 220V to DC 24V); +24V DC: Positive terminal of DC 24V power supply; 0V DC (M): DC 0V (negative terminal / common terminal).

[0121] 2. PLC CONTROL SYSTEM & SENSORS: The PLC control system and sensors form the brain and sensing layer of the equipment; PLC CPU S7-1200 (CPU 1215C): PLC central processing unit; AI MODULE (SM 1231): Analog input module; AO MODULE (SM 1222): Analog output module; PROFINET (RJ4S): Industrial real-time Ethernet communication bus interface; HMI SCREEN: Touch screen (human-machine interface); Tension Sensor 1 (0-10V): Tension sensor 1 (input voltage signal); Pressure Sensor (4-20mA, 2-wire): Pressure sensor (input current signal); IR Temp Sensor (4-20mA): Infrared temperature sensor (input current signal).

[0122] 3. ACTUATORS & ANALOG I / O: Actuators and analog I / O for controlling pneumatic components and regulating analog signals; AO Ch0: Analog output channel 0 (connected to a proportional valve); AO Ch1: Analog output channel 1; 0-10V / 4-20mA: Voltage and current signal standards; Proportional Pressure Valve: Proportional valve (for precise air pressure control); Digital Inputs: Digital input signals; CPU Digital I / O: CPU's built-in digital input / output points; YV1 Cut Valve: YV1 cut-off valve; YV2 LiR Valve: YV2 pressure control valve; YV3 Air Float Valve: YV3 airflow valve; E-stop Button (NC): Emergency stop button (normally closed); Safety Door Switch (NO): Safety door switch (normally open); NPN Position Photoelectric Sensor: NPN type position photoelectric sensor.

[0123] 4. MOTION CONTROL SYSTEM is a motion control system used to control the movement of motors; SERVO DRIVEAxis 1, Axis 2…N: servo drives (corresponding to axes 1, 2…N); PULSE / Dir (Pulse Direction): pulse / direction control mode (common in stepper motors or simple servos); SERVO MOTOR M1: servo motor M1; SERVOMOTOR MN: servo motor MN; STEPPER MOTOR M-Gap (Variable Pitch): stepper motor M-gap (variable pitch).

[0124] Furthermore, in some embodiments, a core environmental adaptation mechanism is provided. The core environmental adaptation mechanism of this invention is embodied in a multi-sensor fusion and dynamic compensation strategy centrally scheduled by the control unit. At the execution layer, temperature and humidity sensors are arranged in the unwinding area, yarn feeding path, and near the pressure rollers to monitor the influence of the environment on resin viscosity and yarn softness in real time; vibration sensors are installed in key parts of the frame and the pressure roller mechanism to detect mechanical vibrations transmitted from the outside during equipment operation.

[0125] The collected data is uploaded to the controller in real time. Through a built-in environment-process mapping algorithm, the following parameters are dynamically adjusted: based on temperature and humidity changes, the tension setpoints of each channel (±0.1N level) and the infrared heating temperature (±2℃) are fine-tuned to compensate for changes in resin flowability; based on vibration spectrum characteristics, the servo motor torque output and the opening of the air pressure valve are adjusted in real time to suppress layup path deviations and pressure fluctuations caused by vibration. This system enables the layup process to be environmentally adaptive, maintaining process consistency and stable layup quality even in industrial environments that are not constantly temperature and humidity controlled or where vibration is present.

[0126] Furthermore, the modular architecture of this invention aims to support flexible production and rapid maintenance response, with standardized interfaces and a parameter self-identification mechanism at its core. At the execution layer, key functional units—including the unwinding unit, pressure roller mechanism, and shearing module—are designed as independent modules that can be quickly plugged in and replaced. Each module is connected to the main frame via mechanical positioning pins and electrical quick connectors, allowing for replacement by hand or with simple tools within minutes. Each module is embedded with an RFID tag or storage chip to record its specifications and historical process data. The system control unit automatically reads the information after a module is connected and loads the corresponding preset process parameters, achieving "plug and play, parameter self-loading." This design significantly reduces downtime for product changeovers, specification adjustments, or maintenance, supports flexible switching between various yarn specifications and laying processes, and improves production adaptability and equipment availability.

[0127] Based on a modular frame, this system employs an integrated electric and pneumatic drive system, incorporating multiple independently driven adaptive unwinding units and a high-precision lateral spacing adjustment mechanism. A closed-loop system, formed by a high-response servo motor and tension sensor, enables independent and precise tension control and independent speed adjustment. The spacing mechanism dynamically adjusts the lateral pitch of adjacent yarns according to path requirements. A shearing and refeeding mechanism ensures continuous operation, and the pressure roller assembly adaptively adjusts the pressing angle and pressure based on the curvature of the surface. Furthermore, by integrating a multi-dimensional sensor network and a central controller, the system can calculate complex curved surface trajectories in real time, dynamically coordinating the feed speed, tension, and lateral spacing of each yarn strand. This ensures flat, wrinkle-free, and error-free laying of multiple yarn strands on complex curved surfaces, maintaining a smooth, wrinkle-free, and error-free layout.

[0128] Compared with traditional processes, the carbon fiber dry prepreg yarn laying system provided by this invention has the following significant technical advantages: 1) The accuracy of multi-strand independent and coordinated deployment is significantly improved: To address the inherent limitation of existing automated yarn laying systems, which rely on centralized drive and control and thus cannot achieve independent operation of multiple yarn strands, this invention innovatively constructs a physical isolation channel based on a "long-short" precision spacer ring and multiple independent sensor-control units. Each yarn strand has a strictly independent transport path and a dedicated high-precision tension sensor and control loop, achieving decoupling of multiple channels from the mechanical layout and detection perspective. The direct technical effect is that the control unit can independently calculate and allocate appropriate laying speeds and target tensions for each yarn strand based on the three-dimensional trajectory data of complex curved surfaces through a collaborative algorithm. With the help of a unified drive system and closed-loop adjustment, multiple yarn strands achieve synchronous and precise bonding on variable curvature surfaces (minimum curvature radius ≥ 50mm), with an angle deviation of ≤ 2° between the laying trajectory and the theoretical path. This effectively prevents yarn accumulation, wrinkles, or gaps caused by forced speed synchronization, fundamentally improving the laying accuracy and internal quality of complex components.

[0129] 2) Tension and pressure dual closed-loop control and stability optimization: To address the problems of crude open-loop tension control and large process fluctuations caused by manual pressure adjustment in traditional technologies, this invention employs a collaborative closed-loop mechanism of electrical control (servo motor) and pneumatic control (proportional pressure valve / cylinder) centrally scheduled by a PLC. At the conveying end, a high-precision tension sensor (±0.1N) and the servo motor form a fast-response (≤0.1 seconds) tension closed loop; at the compaction end, an external pressure sensor and a proportional valve achieve stepless precise pressure adjustment (accuracy ±0.5N). This system, through multi-source signal fusion and real-time calculation, provides millisecond-level compensation for disturbances caused by changes in roll diameter, speed fluctuations, and surface curvature, stabilizing tension fluctuations within ±0.3N and pressure fluctuations within ±2N throughout the entire laying process. This high-stability control fundamentally ensures the fiber orientation consistency, resin distribution uniformity, and interlayer bond strength of the composite material layup, and is expected to reduce the dispersion of the component's mechanical properties by more than 20%.

[0130] 3) Achieve suppression and elimination of gaps / overlaps on complex curved surfaces: To address the problem of uncontrollable layup quality caused by fixed spacing in existing technologies, this invention achieves "controllable gap" by introducing a transverse variable spacing adjustment module and a trajectory following algorithm. The system can actively adjust the output spacing of multi-strand yarns in real time according to changes in surface curvature. When laying complex components such as conical shells and S-shaped air inlets, the yarn gap error is controlled within ±0.1mm, effectively eliminating the resin-rich bands and fiber bulges common in traditional processes. This improves the surface smoothness of the layup by more than 40%, significantly enhancing the density and aerodynamic shape quality of the produced components.

[0131] 4) Full-process automation and a leapfrog improvement in operational efficiency: To address the inefficiencies and quality fluctuations caused by the discrete processes, low automation, and excessive manual intervention in existing technologies, this invention achieves a fully automated closed-loop operation from yarn loading, constant tension conveying, adaptive laying and compaction to automatic shearing and reloading through mechatronics integration. Key innovations include the integration of low-temperature air-cooled instantaneous shearing (action time ≤0.1 seconds, cross-sectional mass Ra≤3.2μm) and low-friction reloading based on air flotation principle (positioning accuracy ±0.5mm), reducing the single "layout-cutting-resetting" cycle time to ≤3 seconds. Combined with a visual human-machine interface and parameterized process management, the system simplifies operation to parameter setting and process monitoring, increasing the efficiency of multi-strand laying operations by over 50% compared to traditional manual methods, and ensuring high repeatability of process parameters and final product quality in mass production.

[0132] 5) Overall improvement in system performance and adaptability: Addressing the combined pain points of traditional equipment—poor flexibility, slow changeover, and inconvenient reliability maintenance—this invention employs synergistic optimization at the mechanical, control, and system architecture levels. Regarding process adaptability and flexible production, the system utilizes a pneumatically adaptive floating pressure roller structure to achieve real-time fitting of complex curved surfaces. Combined with a software system supporting multi-yarn synchronous planning, multi-mode shearing, and adjustable process formulations, the same platform can adapt to the laying requirements of prepreg yarns of different widths (3-10mm) and different ply counts (1-5 plies) without major hardware adjustments, achieving an upgrade from a "dedicated machine" to a "flexible manufacturing unit." In terms of system reliability, an integrated main control PLC and standardized bus architecture are adopted to reduce electrical complexity and failure rate; key actuators are equipped with status feedback sensors for real-time monitoring and early warning; modular mechanical design allows for rapid disassembly and replacement of core components such as the shearing unit and pressure roller mechanism, significantly shortening maintenance time and costs. This synergistic design enables the system to meet the needs of multi-variety, batch production while ensuring long-term operational stability and production continuity, achieving a balance of high adaptability, high reliability, and ease of maintenance.

[0133] 6) Significantly enhanced environmental adaptability: To address the challenges of composite material layup processes being sensitive to temperature and humidity and susceptible to vibration interference, this system integrates a network of temperature, humidity, and vibration sensors, combined with a real-time compensation algorithm, to proactively adapt to environmental changes. The system automatically adjusts tension and heating parameters to suppress layup deviations caused by vibration, reducing layup quality fluctuations by more than 30% in fluctuating environments (temperature variation ±5℃, humidity variation ±20%RH), significantly improving the system's industrial adaptability and processability.

[0134] 7) Achieve breakthroughs in flexible production and rapid changeover capabilities. Through modular design and RFID parameter self-identification technology, this system has upgraded from "dedicated equipment" to "flexible manufacturing cell". Changeover time has been reduced from several hours to less than 10 minutes, supporting efficient response to multi-variety, small-batch orders. Simultaneously, the modular design reduces maintenance complexity and spare parts inventory costs, improving overall equipment availability and lifespan.

[0135] The carbon fiber dry prepreg yarn laying method provided by the present invention is described below. The carbon fiber dry prepreg yarn laying method described below can be referred to in correspondence with the carbon fiber dry prepreg yarn laying system described above. Figure 9 This is a schematic diagram of the carbon fiber dry prepreg yarn laying method provided by the present invention, as shown below. Figure 9 As shown, the method includes: Step 910: Based on the unwinding unit, install and fix the yarn of the carbon fiber dry prepreg yarn roll to be processed to the corresponding station to form an unwinding path for the yarn; Step 920: Based on the yarn feeding unit, peel off the protective film of the yarn on the unwinding path, and transport the yarn with the protective film peeled off to the corresponding conveying path. Obtain the real-time tension data and current position of the yarn on the conveying path and send them to the control unit. Complete the yarn conveying on the conveying path according to the control instructions fed back by the control unit. Step 930: Based on the laying unit, the yarn on the conveying path is laid and solidified on the surface of the workpiece, and the pressure signal acting on the surface of the workpiece during the laying process is obtained. Step 940: Based on the shearing and refeeding unit, cut the yarn at the end of the laying and refeed the yarn front end to the laying start point before the start of the next cycle; Step 950: Based on the control unit, according to the tension data and the pressure signal, a first control command is generated using a preset PID algorithm to adjust the output torque and / or output speed; according to the current position of the yarn and the preset trajectory data, a variable gap command is generated using a surface reconstruction algorithm as a second control command to dynamically change the lateral pitch between each yarn guide in real time.

[0136] The method performs similar functions to the system provided earlier. Other functions can be found in the previous descriptions and will not be repeated here.

[0137] Figure 10 An example is a schematic diagram of the physical structure of an electronic device, such as... Figure 10As shown, the electronic device may include: a processor 1010, a communication interface 1020, a memory 1030, and a communication bus 1040, wherein the processor 1010, the communication interface 1020, and the memory 1030 communicate with each other through the communication bus 1040. The processor 1010 can call logical instructions in the memory 1030 to execute a carbon fiber dry prepreg yarn laying method, which includes: based on the unwinding unit, installing and fixing the yarn of the carbon fiber dry prepreg yarn roll to be processed to the corresponding work station to form an unwinding path for the yarn; based on the yarn feeding unit, peeling off the protective film of the yarn on the unwinding path, and conveying the yarn with the protective film peeled off to the corresponding conveying path, acquiring real-time tension data and the current position of the yarn on the conveying path and sending them to the control unit, and completing the yarn conveying on the conveying path according to the control instructions fed back by the control unit; based on the laying unit, placing the... The yarn on the conveying path is laid out and solidified on the workpiece surface, and the pressure signal acting on the workpiece surface during the laying process is acquired; based on the shearing and refeeding unit, the yarn is cut at the end of the laying and the yarn front end is refeeded to the laying start point before the start of the next cycle; based on the control unit, a first control command is generated using a preset PID algorithm according to the tension data and the pressure signal to adjust the output torque and / or output speed; based on the current position of the yarn and the preset trajectory data, a variable gap command is generated using a surface reconstruction algorithm as a second control command to dynamically change the lateral pitch between each yarn guide nozzle in real time.

[0138] Furthermore, the logical instructions in the aforementioned memory 1030 can be implemented as software functional units and, when sold or used as independent products, can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0139] On the other hand, the present invention also provides a computer program product, which includes a computer program that can be stored on a non-transitory computer-readable storage medium. When the computer program is executed by a processor, the computer can execute the carbon fiber dry prepreg yarn laying method provided by the above methods. The method includes: based on an unwinding unit, installing and fixing the yarn of the carbon fiber dry prepreg yarn roll to be processed to a corresponding workstation to form an unwinding path for the yarn; based on a yarn feeding unit, peeling off the protective film of the yarn on the unwinding path and conveying the yarn with the protective film peeled off to a corresponding conveying path; acquiring real-time tension data and the current position of the yarn on the conveying path and sending them to a control unit; and according to the control... The control commands fed back by the unit complete the yarn conveying along the conveying path; based on the laying unit, the yarn on the conveying path is laid and solidified on the workpiece surface, and the pressure signal acting on the workpiece surface during the laying process is obtained; based on the shearing and refeeding unit, the yarn is cut at the end of the laying and the yarn front end is refeeded to the laying start point before the start of the next cycle; based on the control unit, a first control command is generated using a preset PID algorithm according to the tension data and the pressure signal to adjust the output torque and / or output speed; based on the current position of the yarn and the preset trajectory data, a variable gap command is generated using a surface reconstruction algorithm as a second control command to dynamically change the lateral pitch between each yarn guide nozzle in real time.

[0140] In another aspect, the present invention also provides a non-transitory computer-readable storage medium storing a computer program thereon. When executed by a processor, the computer program implements the carbon fiber dry prepreg yarn laying method provided by the above methods. The method includes: based on an unwinding unit, installing and fixing the yarn of the carbon fiber dry prepreg yarn roll to be processed to a corresponding workstation to form an unwinding path for the yarn; based on a yarn feeding unit, peeling off the protective film of the yarn on the unwinding path and conveying the yarn with the protective film peeled off to a corresponding conveying path; acquiring real-time tension data and the current position of the yarn on the conveying path and sending them to a control unit; and completing the conveying according to the control instructions fed back by the control unit. The system includes: yarn delivery along a path; a laying unit that lays the yarn along the delivery path and fixes it to the workpiece surface, acquiring pressure signals acting on the workpiece surface during the laying process; a shearing and refeeding unit that cuts the yarn at the end of the laying process and refeeds the yarn head to the laying start point before the next cycle begins; a control unit that generates a first control command based on the tension data and the pressure signal using a preset PID algorithm to adjust the output torque and / or output speed; and a surface reconstruction algorithm that generates a variable gap command as a second control command based on the current yarn position and preset trajectory data to dynamically change the lateral pitch between each yarn guide nozzle in real time.

[0141] The system embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs. Those skilled in the art can understand and implement this without any creative effort.

[0142] Through the above description of the embodiments, those skilled in the art can clearly understand that each embodiment can be implemented by means of software plus necessary general-purpose hardware platforms, and of course, it can also be implemented by hardware. Based on this understanding, the above technical solutions, in essence or the part that contributes to the prior art, can be embodied in the form of a software product. This computer software product can be stored in a computer-readable storage medium, such as ROM / RAM, magnetic disk, optical disk, etc., and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute the methods described in the various embodiments or some parts of the embodiments.

[0143] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A carbon fiber dry prepreg yarn laying system, characterized in that, include: The unwinding unit is used to install and fix the yarn of the carbon fiber dry prepreg yarn roll to be processed to the corresponding station, forming an unwinding path for the yarn; The yarn feeding unit is used to peel off the protective film of the yarn on the unwinding path and transport the yarn with the protective film peeled off to the corresponding conveying path. It also acquires the real-time tension data and the current position of the yarn on the conveying path and sends them to the control unit. The unit then completes the yarn conveying on the conveying path according to the control instructions fed back by the control unit. The laying unit is used to lay the yarn on the conveying path and solidify it on the surface of the workpiece, and to obtain the pressure signal acting on the surface of the workpiece during the laying process. The cutting and refeeding unit is used to cut the yarn at the end of the laying process and refeed the yarn tip to the laying start point before the start of the next cycle. The control unit is used to generate a first control command based on the tension data and the pressure signal using a preset PID algorithm to adjust the output torque and / or output speed; and to generate a variable gap command as a second control command based on the current position of the yarn and preset trajectory data using a surface reconstruction algorithm to dynamically change the lateral pitch between each yarn guide in real time.

2. The system according to claim 1, characterized in that, The unwinding unit includes: The unwinding spindle is used to install and fix the carbon fiber dry prepreg yarn roll. Spacer rings are used to separate and position the carbon fiber dry prepreg yarn rolls fitted on the corresponding work positions of the unwinding spindle in the axial direction, forming the unwinding path for each yarn. A yarn unwinding motor is used to apply a reverse torque to prevent the yarn on the unwinding path from slagging; The unwinding motor is rigidly connected to the unwinding spindle. A spring-loaded locking mechanism, disposed in the tension assembly of the unwinding path, is used to circumferentially lock the carbon fiber dry prepreg yarn roll.

3. The system according to claim 1, characterized in that, The yarn feeding unit includes: A film-peeling and winding mechanism is used to peel off and wind up the protective film of the yarn; Multiple sets of guide and drive rollers are used to transport the free end of the yarn after the protective film has been peeled off to the corresponding transport path; A tension sensor is installed at a preset position on the conveying path to acquire real-time tension data of the conveying path. A yarn feeding motor is used to output power to pull the yarn along the conveying path according to the first control command; A lateral spacing adjustment module is used to precisely position the yarns and adjust the lateral spacing between the yarns according to the second control command.

4. The system according to claim 3, characterized in that, The lateral variable spacing adjustment module includes: A multi-segment variable pitch screw is used to drive a floating yarn guide. The multi-segment variable pitch screw has threaded segments with an arithmetic progression of lead from the center to both ends. The floating yarn guides are respectively engaged with the threaded segments with corresponding leads. A stepper motor is used to provide power to drive a multi-segment variable pitch lead screw, which in turn drives the floating yarn guide mounted on the guide rail to perform coordinated lateral movement.

5. The system according to claim 3, characterized in that, The laying unit includes: Fixed pressure rollers are used for preliminary positioning and pre-compacting of the yarn on the conveying path; Movable pressure rollers are used to further compact the yarn after initial positioning and pre-compaction treatment; An infrared heater is installed in the preset heating zones before and after the fixed pressure roller to heat the yarn passing through the heating zones; A pressure sensor is used to monitor the pressure signal acting on the surface of the workpiece during the laying process; A temperature sensor is used to monitor the surface temperature of the yarn in the heating zone.

6. The system according to claim 5, characterized in that, The movable pressure roller includes a telescopic mechanism that is adjustable via a pneumatic control valve. The extension length and pressing angle of the telescopic mechanism are dynamically adjusted in real time according to the curved contour of the workpiece surface.

7. The system according to claim 1, characterized in that, The control unit is also used for: Based on the workpiece surface curve and the real-time position of the current laying head in the workpiece coordinate system, a pneumatic control signal is generated using a preset kinematic model.

8. The system according to claim 7, characterized in that, The shearing and retransmission unit includes: The shearing module, located in the yarn feeding guide groove, is used to trigger a synchronous shearing program to shear the yarn when the laying length reaches a preset value or when a manual interruption command is received. The re-feeding module is used to activate the air flotation conveying mode according to the air pressure control signal, and re-feed the cut yarn front end to the laying starting point.

9. The system according to claim 1, characterized in that, The shearing and re-feeding unit further includes: A low-temperature air-cooling unit is used to locally freeze the yarn before shearing.

10. A method for laying carbon fiber dry prepreg yarn, characterized in that, include: Based on the unwinding unit, the yarn of the carbon fiber dry prepreg yarn roll to be processed is installed and fixed to the corresponding station to form an unwinding path for the yarn. Based on the yarn feeding unit, the protective film of the yarn on the unwinding path is peeled off, and the yarn with the protective film peeled off is transported to the corresponding conveying path. The real-time tension data and current position of the yarn on the conveying path are obtained and sent to the control unit. The yarn conveying on the conveying path is completed according to the control instructions fed back by the control unit. Based on the laying unit, the yarn on the conveying path is laid and solidified on the surface of the workpiece, and the pressure signal acting on the surface of the workpiece during the laying process is obtained. Based on the shearing and refeeding unit, the yarn is cut at the end of the laying and the yarn tip is refeeded to the laying start point before the start of the next cycle. Based on the control unit, a first control command is generated using a preset PID algorithm according to the tension data and the pressure signal to adjust the output torque and / or output speed; a variable gap command is generated using a surface reconstruction algorithm as a second control command according to the current position of the yarn and the preset trajectory data to dynamically change the lateral pitch between each yarn guide in real time.

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