In-situ assembly method of composite sections and composite sections

Abstract

The application relates to the technical field of composite material assembly, and discloses an in-situ assembly method of a composite material section and the composite material section, which comprises the following steps: checking a main material version and a type number according to a list; checking a clean tooling mold; preparing auxiliary materials; confirming a personnel plan and checking the availability of parts and tooling tools. When pre-assembling, parts are placed back into a forming mold to be attached without being spaced, positioning is performed by using positioning tooling, and it is ensured that there is no interference, no stress and no excessive gap. Before gluing, the gluing surface is polished and roughened, and structural glue is applied, and gluing is completed on the mold. Then, standing or heating curing is performed, holes are made on the mold after curing, fittings are installed, or other components are continuously glued, until the section is completely assembled. The method uses a forming mold to replace a special assembly rack, reduces cost, saves storage, and adapts to structural changes; parts are assembled in situ without transfer deformation, the attachment precision is high, gluing is reliable, and the process integration is efficient.

Description

Technical Field

[0001] This application relates to the field of composite material assembly technology, and in particular to an in-situ assembly method for composite material segments and the composite material segments themselves. Background Technology

[0002] In aerospace, rail transportation, and shipbuilding industries, the assembly of composite material components is a crucial step in the product manufacturing process. Component assembly typically involves combining and connecting multiple pre-molded composite material parts according to their designed positions to ultimately form a complete component structure. Taking aerospace vehicle compartment assembly as an example, a single component often comprises dozens or even hundreds of composite material parts of different shapes and functions. These parts are individually cured and molded on different molds before being transferred to the assembly station for assembly.

[0003] Currently, the assembly industry commonly uses assembly jigs for part positioning and installation. An assembly jig is a specialized tooling designed specifically for a particular section, equipped with precision positioners, clamps, and supports to fix parts in their designed positions before gluing, riveting, or bolting. While assembly jigs ensure high assembly accuracy, they have several inherent drawbacks. First, assembly jigs are extremely expensive; the design and manufacturing cost of a complex jig can reach hundreds of thousands or even millions of yuan. This cost can be amortized for mass production, but it becomes unbearable for small-batch, multi-variety production. Second, during product development, as the technology is not yet finalized, design requirements change and structures iterate rapidly. Since assembly jigs are specialized tooling designed for specific structures, once the section structure changes, the original jig becomes unusable and needs to be redesigned and manufactured, resulting in significant resource waste and time costs. Third, assembly jigs themselves require substantial storage space and regular maintenance and calibration, further increasing manufacturing and management costs.

[0004] Furthermore, in traditional assembly methods, after parts are cured on the molding die, they need to be demolded and transferred to the assembly jig. During this process, the parts may undergo slight deformation or springback due to demolding stress, transport vibration, or temperature changes. When these deformed parts are positioned on the assembly jig, the parts may not achieve optimal fit, and the overall contour accuracy of the assembled section and the tightness of the connection parts may not be optimal. Summary of the Invention

[0005] The purpose of this application is to provide an in-situ assembly method for composite material components and the composite material components themselves, so as to solve the technical problems in the prior art, such as high cost of assembly jigs, inability to adapt to design changes, occupation of storage space, and decreased fit after parts are transferred.

[0006] To address the aforementioned technical problems, this application provides an in-situ assembly method for composite material components, comprising: a main material preparation step: retrieving main materials according to the main material list and verifying the version and grade of the main materials according to the assembly outline; a tooling and equipment preparation step: verifying all tools and fixtures, confirming that the molds and fixtures are in normal condition, and cleaning dust and adhesive residue from the surfaces of the molds and fixtures; an auxiliary material preparation step: preparing auxiliary materials; a pre-assembly inspection step: determining personnel allocation and production plan, checking the appearance of parts against the parts list, and verifying the availability of tooling, main materials, and auxiliary materials; and a pre-assembly step: assembling the component parts according to the positioning datum. Place the parts back into their respective molds, ensuring they fit snugly without gaps. Use positioning fixtures to position and pre-assemble each part, ensuring no interference, stress, or gaps exceeding design limits between parts. Adhesive bonding step: Roughen and clean the bonding surfaces of each part, apply structural adhesive, and then bond the parts together on the molds. Curing step: Allow the bonded sections to cure statically or by heating on the molds. Subsequent assembly steps: After curing, drill holes, install accessories, and / or bond / assemble other components on the molds until all assembly of the sections is complete.

[0007] Optionally, after the part is placed back into the forming mold, the position of the positioning fixture is checked by calibrating the fixture or using a laser tracker to ensure that the positioning accuracy meets the assembly requirements.

[0008] Alternatively, use #120 to #240 sandpaper to roughen each adhesive surface, and then clean the sanded adhesive surface with anhydrous ethanol and degreased cotton cloth.

[0009] Optionally, in the bonding step, the mixing time and amount of structural adhesive are recorded when preparing the adhesive, and the weight ratio of the structural adhesive is 100:17.

[0010] Optionally, in the bonding step, while applying the structural adhesive, a sample block of the structural adhesive is simultaneously prepared and labeled. The sample block is cured together with the section for subsequent testing and verification of the bonding quality.

[0011] Optionally, in the bonding step, after applying the structural adhesive, each part is placed in a predetermined position, positioned using the positioning fixture, excess adhesive is removed using a scraper, and excess adhesive residue is wiped off using a degreased cotton cloth soaked in anhydrous ethanol.

[0012] Optionally, in the curing step, the curing method is static curing for 24 hours, or heating curing at 50℃±5℃ for 1 hour.

[0013] Optionally, the subsequent assembly steps include a cap fitting step: after curing, holes are drilled and tray nuts are installed according to the assembly drawing using the positioning fixture, the cap is fitted to the section, and the cap is temporarily fixed with paper tape and holes are fitted.

[0014] Optionally, the subsequent assembly steps include the steps of installing the tray nut and the water-cooling bracket: installing the tray nut onto the structural beam and using pop rivets to fasten the water-cooling bracket onto the structural beam.

[0015] Optionally, the subsequent assembly steps include a charging port installation step: connecting the charging port and charging port cover to the section via a charging port hinge, tightening with screws and nuts, applying thread-locking adhesive before bolt installation, and marking the bolt head with anti-loosening paste after tightening.

[0016] Optionally, the subsequent assembly steps include a hole-making step: using a hand drill to hold a twist drill and drill the mounting hole positioning point according to the drilling position of the template tool, then using a pneumatic drill to hold a dagger drill and a vertical drill to drill the initial mounting hole according to the positioning point, and then enlarging the hole in sequence.

[0017] Optionally, the process may also include a weighing step and a non-destructive testing step after the subsequent assembly step: weighing the assembled section, performing non-destructive testing on the section, and then conducting a quality inspection according to the inspection outline.

[0018] Optionally, the auxiliary materials include one or more of the following: paper tape, anhydrous ethanol, degreased cotton cloth, glue mixing bowl, sandpaper, sandpaper sheets for pneumatic grinders, and scrapers.

[0019] This application also provides a composite material segment assembled using any of the above-mentioned in-situ assembly methods, wherein each component of the segment is positioned and bonded on its respective molding die, the molding die also serving as an assembly frame during the assembly process, and the segment has bonding surfaces for each component bonded by structural adhesive.

[0020] Optionally, the segment is a battery compartment segment, which includes one or more components such as a battery compartment structural beam, a battery compartment outer curved surface, a cover, a charging port, a water-cooling bracket, and a hole-guided carbon tube. Each component is positioned and glued together on its respective molding die.

[0021] Compared with the prior art, this application has the following beneficial effects: First, this method eliminates the need for separate design and manufacturing of dedicated assembly jigs. Each component uses its own forming mold as a positioning reference, and the forming mold also serves as an assembly jig during the assembly process. This significantly reduces the design and manufacturing costs of tooling, while saving storage space and maintenance costs for assembly jigs. It is particularly suitable for scenarios where the product development stage involves frequent structural changes and general-purpose jigs cannot be used.

[0022] Secondly, this method enables in-situ assembly of each component. Each part remains in its position on the mold from the time it is cured until the end of the assembly. There is no shape springback or stress release caused by demolding, transfer and repositioning. This avoids deformation and accumulation of positioning errors during the transfer of parts, making the relative position between each part highly consistent with the design state. The product fit is higher, and the overall contour accuracy and the tightness of the connection parts are significantly improved.

[0023] Third, this method verifies the positioning fixture using calibration fixtures or laser trackers, and combines this with process control such as grinding and roughening, solvent cleaning, and precise adhesive mixing to ensure the quality of the bonded surface and the bonding strength of the structural adhesive. The simultaneous fabrication of the furnace-produced sample provides a reliable basis for testing the bonding quality, ensuring the structural integrity and mechanical properties of the section. Fourth, this method has high process integration and flexibility. Multiple operations such as pre-assembly, bonding, curing, hole drilling, and accessory installation can be completed sequentially on the mold, reducing the number of times parts are transferred between different workstations, shortening the assembly cycle, and allowing for the selection of appropriate subsequent assembly sub-steps for sections with different structures, demonstrating good adaptability and customizability. Attached Figure Description

[0024] Figure 1 This is a flowchart illustrating the in-situ assembly method of composite material segments in an embodiment of the present invention. Figure 2 This is a schematic diagram of the battery compartment section in an embodiment of the present invention. Detailed Implementation

[0025] The following embodiments further illustrate the technical solutions of this application. It should be understood that the specific embodiments described herein are merely for explaining this application. Furthermore, it should be noted that, for ease of description, only the parts relevant to this application are shown in the accompanying drawings, not all of them.

[0026] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections or detachable connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal connections between two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0027] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0028] The present application will be further described in detail below with reference to specific embodiments. It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of the present application. All technical solutions implemented based on the above content of the present application fall within the scope of protection claimed in this application.

[0029] This invention provides an in-situ assembly method for composite material components and the composite material component itself. The core inventive concept of this method is that after each component is cured on its respective molding die, the components are not removed from the die. Instead, these molding dies are used directly as positioning references and support bases. Positioning fixtures are used to position and pre-assemble each component. Then, all subsequent assembly processes, such as gluing, drilling, and accessory installation, are performed directly on the die until the entire assembly of the component is completed. In other words, the molding die also serves as an assembly frame throughout the assembly process. The components remain in a positioned state on the die from the completion of curing to the end of assembly, eliminating the need for demolding, transfer, and repositioning.

[0030] This embodiment provides an in-situ assembly method for composite material segments, such as... Figure 1 As shown, the specific steps include: S1: Main material preparation: Collect the main materials according to the main material list, and check the version and grade of the main materials according to the assembly outline.

[0031] Specifically, in the main material preparation stage, operators first retrieve the main materials required for this assembly from the warehouse or transfer station according to the main material list. After retrieving the main materials, operators need to check the version and grade of each main material against the assembly outline to confirm that the material version used is correct and the grade is consistent with the design requirements. The purpose of this step is to prevent assembly quality accidents caused by material confusion. In actual operation, operators need to record the main material information used on the assembly process record card, including the material name, batch number, version, and quantity used, to achieve traceability throughout the entire process.

[0032] S2: Tooling and Equipment Preparation: Check all tools and fixtures, confirm that the molds and fixtures are in normal condition, and clean the dust and adhesive residue from the surfaces of the molds and fixtures.

[0033] Specifically, during the tooling and equipment preparation phase, operators check all tools and fixtures against the technical documents to confirm that the molds and fixtures are in normal usable condition. Mold usability checks include verifying the integrity of the mold's working surface, the clarity of the positioning datum, and whether the mold's airtightness meets requirements. Fixture usability checks include confirming that the positioning fixtures are free from deformation and wear, and that the calibration fixtures and measuring equipment such as laser trackers are within their calibration validity period. Subsequently, operators use a white cotton cloth dampened with cleaning agent, along with a plastic scraper and vacuum cleaner, to thoroughly clean the mold and fixture surfaces, removing dust, adhesive residue, and other contaminants. During cleaning, residual adhesive on the mold surface can be gently scraped off with a plastic scraper, avoiding the use of metal tools to prevent damage to the mold surface. After cleaning, the mold's working surface should be visually clean, free of oil stains, and free of particulate matter residue.

[0034] S3: Preparation of auxiliary materials: Prepare auxiliary materials.

[0035] Specifically, during the auxiliary material preparation phase, operators prepare all auxiliary materials required for the assembly. These materials include one or more of the following: masking tape, anhydrous ethanol, degreased cotton cloth, adhesive mixing bowl, sandpaper, pneumatic sander scrapers, and scrapers. Masking tape is used to temporarily secure parts and mask non-bonded areas; anhydrous ethanol serves as a cleaning solvent for wiping bonded surfaces; degreased cotton cloth is used to apply anhydrous ethanol for cleaning; the adhesive mixing bowl is used to weigh and mix structural adhesive; sandpaper is used for manual sanding of bonded surfaces; pneumatic sander scrapers are mounted on the pneumatic sander for rapid sanding of large areas; and scrapers are used to apply structural adhesive and remove excess adhesive. Operators check and prepare each auxiliary material item against the list in the assembly outline, ensuring that all materials are complete and in sufficient quantity. They also check the expiration dates and quality of the auxiliary materials; expired or deteriorated auxiliary materials must not be used.

[0036] S4: Pre-assembly inspection: Determine personnel allocation and production plan, check the appearance of parts against the parts list, and verify the availability of tooling, equipment, main materials and auxiliary materials.

[0037] Specifically, in the pre-assembly inspection phase, operators first determine the personnel allocation plan, clarify the operators and their responsibilities for each position, and confirm the production plan. Then, operators check the condition of each part against the parts list, including whether the part's appearance is damaged, whether the surface is clean, and whether the shape and dimensions meet design requirements. For composite material parts, special attention must be paid to whether there are internal defects such as delamination, pores, and fiber wrinkles, and whether the edges are neat and free of burrs. Only parts that pass inspection can proceed to the assembly process. Based on this, operators further verify the tooling, tools, main materials, and auxiliary materials list in the standard operating procedure, confirming that each tooling, workpiece, main material, and auxiliary material is ready. Simultaneously, the certificates of conformity for molds and tooling need to be verified to ensure they are valid, and the availability of all tools, main materials, and auxiliary materials is confirmed again. Only after all the above checks and confirmations are passed can the pre-assembly process begin.

[0038] S5: Pre-assembly: Place each component of the section back into its corresponding forming mold according to the positioning reference, so that the parts fit the mold without gaps. Use positioning fixtures to position and pre-assemble each part to ensure that there is no interference, no stress, and no gaps exceeding the design allowable range between parts.

[0039] Specifically, in the pre-assembly step, operators place each component of the section back into its corresponding forming mold according to the positioning reference. Taking the battery compartment section as an example, firstly, the battery compartment structural beam is placed back into the structural beam mold according to the positioning reference, ensuring that the structural beam and mold surface are completely fitted, and visually inspected to ensure there is no gap. Then, according to the tooling drawing, the positioning fixture is installed on the structural beam mold, and the position of the positioning fixture is verified using a calibration fixture or laser tracker to ensure that the positioning accuracy meets the assembly requirements. After the positioning fixture is installed, operators pre-assemble parts such as beam ribs according to the assembly drawing using the positioning fixture, that is, placing each part on the mold according to the design position and temporarily fixing it with the positioning fixture to verify the relative positional relationship between the parts. During the pre-assembly process, operators need to carefully confirm whether there is interference between parts, whether they are in a stress-free state, and whether the gaps between parts are within a reasonable range. Specifically, it should be ensured that adjacent parts do not squeeze or collide with each other, that each part does not produce significant elastic deformation or forced assembly stress under the constraint of the positioning fixture, and that the fit clearance meets the design requirements. If interference or gaps are found to be out of tolerance, the cause should be identified and resolved before proceeding to the bonding process. If the pre-assembly inspection is satisfactory, proceed to the next step of bonding surface treatment.

[0040] S6: Adhesive bonding: The adhesive bonding surfaces of each part are roughened and cleaned by grinding. After applying structural adhesive, the parts are bonded and assembled on the molding die.

[0041] Specifically, in the bonding process, the bonding surfaces of each part are first treated. Operators use 120-240 grit sandpaper to roughen each bonding surface. The purpose of sanding is to remove the smooth layer from the bonding surface, increasing the roughness and effective bonding area, thereby improving the bonding strength. During sanding, care should be taken to apply even pressure to avoid over-sanding in certain areas, which could damage the parts. After sanding, use a pneumatic tool or vacuum cleaner to remove the dust generated during sanding. Then, use a degreased cotton cloth dampened with anhydrous ethanol to wipe and clean the sanded bonding surfaces, removing surface grease, dust, and other contaminants. Avoid touching the cleaned bonding surfaces directly with your hands to prevent sweat contamination. After the bonding surfaces are treated, operators prepare the structural adhesive according to the prescribed ratio. In this embodiment, the structural adhesive used is EA9394, with a weight ratio of 100:17. Operators must use a precision electronic scale to weigh the resin and hardener separately, mix them thoroughly until the color is uniform, and record the mixing time and amount to trace the bonding quality. Simultaneously, structural adhesive sample blocks are prepared and labeled. These sample blocks are small test blocks made using the same structural adhesive and under the same conditions as the product; they are cured together with the component and used for subsequent bonding quality testing and verification. Labels are affixed to the sample blocks indicating the production date, adhesive batch number, product number, etc. Then, the operator evenly applies the prepared structural adhesive to the bonding surfaces of each component, places each component in the designated assembly position, and uses positioning fixtures for positioning and clamping to ensure accurate relative positioning between the components. After applying the structural adhesive, excess adhesive will squeeze out from the joints. The operator uses a scraper to remove the excess adhesive along the joint direction, and then uses a cotton cloth soaked in anhydrous ethanol to wipe away any remaining adhesive residue. When wiping, care should be taken to be gentle to avoid bringing adhesive into non-bonded areas, and to avoid leaving any fibers of the cotton cloth near the bonded surface.

[0042] S7: Curing: After the bonding is completed, the segment is left to cure statically or by heating on the molding die.

[0043] Specifically, in the curing step, the bonded section, along with the molding die, is cured together. The curing method is determined based on the type of structural adhesive and process requirements. For room temperature curing structural adhesives, they can be left to cure under ambient conditions for 24 hours. For structural adhesives requiring heat curing, the section and mold are placed in a heating device and cured at 50 degrees Celsius ± 5 degrees Celsius for one hour. During the curing process, the positioning fixture remains in its installed position to ensure that the parts do not shift during curing. After curing, the sample block accompanying the curing furnace should be removed along with the section for subsequent bonding quality inspection.

[0044] S8: Subsequent assembly: After curing, holes are drilled, accessories are installed and / or other components are glued together on the molding die until all assembly work of the section is completed.

[0045] In subsequent assembly steps, the cured section is not demolded and continues to undergo various subsequent assembly operations on the molding die. Depending on the specific structure of the section, the subsequent assembly steps include one or more sub-steps such as cap fitting, installation of tray nuts and water-cooling brackets, charging port installation, and hole drilling, until all assembly work of the section is completed.

[0046] Specifically, the cap fitting process is performed after curing. Operators use positioning fixtures to drill holes and install tray nuts on the section according to the assembly drawing. When drilling holes, a pneumatic drill with a suitable drill bit is used, drilling according to the positions and diameters marked on the assembly drawing. During drilling, the drill bit feed speed should be carefully controlled to avoid delamination of the composite material. After the tray nuts are installed, the cap is fitted to the section, and the fit and gap between the cap and section are checked. If the fit is good, the cap is temporarily fixed with masking tape, and the holes are fitted according to the positions on the assembly drawing. This involves drilling or enlarging holes simultaneously with the cap and section in place to ensure the positional accuracy of the connecting holes.

[0047] In the installation of the tray nuts and water-cooling brackets, the operator first installs the tray nuts into their designated positions on the structural beam, and then uses blind rivets to fasten the water-cooling brackets to the structural beam. When installing the blind rivets, ensure that the rivet gun is perpendicular to the rivet axis, and that the rivet head is flat and secure after riveting. For sections requiring water-cooling plates, the positioning and fastening of the water-cooling plates are completed in this step.

[0048] During the charging port installation process, the operator connects the charging port and charging port cover to the section using the charging port hinges. Specifically, two charging port hinge guides are used to connect the first and second charging port hinges to the third charging port hinge, respectively. Then, screws and nuts are used to connect the first and second charging port hinges to the charging port body, and the third charging port hinge to the charging port cover. For bolted connections, threadlocker is applied to the threaded portion of the bolts before installation to prevent loosening in a vibrating environment. After tightening the bolts, anti-loosening compound is applied to the bolt heads for visual inspection to check for looseness later. Additionally, hex socket head cap screws are used to install the charging port latch onto the charging port cover. During installation, ensure the U-hole opening direction of the latch matches the assembly diagram. Threadlocker is also applied to the bolts before installation and anti-loosening compound is applied after tightening. Finally, hex socket head cap screws and anti-loosening nuts are used to install the charging port locker in the predetermined position of the battery compartment charging port. After tightening, anti-loosening compound is applied to the bolt heads.

[0049] After completing the above sub-steps, the operator still needs to cut and assemble the carbon nanotubes. First, determine the cutting dimensions of the purchased carbon nanotubes according to the design requirements. Use a pneumatic grinder or cutter to cut the carbon nanotubes into segments according to the predetermined dimensions, and then fit the cut carbon nanotubes to the battery compartment. During the fitting process, use a pneumatic grinder to trim the exposed part of the carbon nanotube according to the contour of the outer curved surface of the battery compartment, so that the end face of the carbon nanotube is flush with the outer curved surface of the battery compartment. Subsequently, use 120-grit and 240-grit sandpaper to roughen the outer end face of the carbon nanotube and the bonding surface between the outer curved surface of the battery compartment and the carbon nanotube, in preparation for bonding.

[0050] The hole-making process is carried out in the middle and late stages of section assembly. Operators use a hand drill to hold a twist drill and mark the positioning points for the battery compartment mounting holes according to the drilling positions on the template fixture. These positioning points mark the center position of the holes and serve as the reference for subsequent drilling. After the positioning points are made, a pneumatic drill is used to hold a dagger drill, and a vertical drill is used to create the initial holes for the mounting holes based on the positioning points. The diameter of the initial hole is smaller than the final hole diameter, requiring a series of reaming operations to gradually enlarge it to the final hole diameter required by the design. During reaming, care should be taken to keep the drill bit aligned with the hole axis to avoid deviation.

[0051] After all assembly processes are completed, weighing and non-destructive testing are performed. Operators use electronic scales to weigh the assembled sections, record the actual weight, and compare it with the design weight; the deviation should be within the allowable range. Then, non-destructive testing is performed on the sections, using methods such as ultrasonic testing, infrared thermography, or X-ray inspection to confirm the absence of defects such as delamination, porosity, and debonding. Finally, quality inspections are conducted item by item according to the inspection outline, including visual inspection, dimensional inspection, and adhesive quality inspection. After all inspections are passed, the qualified components are packaged and stored.

[0052] In another embodiment, the curing method can be adjusted according to the type of structural adhesive. For two-component epoxy structural adhesives, either room temperature static curing or accelerated curing with heat can be used, both of which can achieve the required bond strength. The difference is that heat curing can shorten the curing time. Operators can flexibly choose according to the production schedule and workshop ambient temperature, making the process highly adaptable.

[0053] In another embodiment, for simplified sections that do not require the installation of water-cooling brackets or charging ports, the corresponding installation sub-steps can be omitted, but the core steps such as pre-assembly, gluing, and curing remain unchanged, reflecting the modularity and adaptability of the method of the present invention.

[0054] In a specific product embodiment of the present invention, a composite material segment assembled using the above-described in-situ assembly method is provided. This segment is specifically a battery compartment, such as... Figure 2 As shown, it includes one or more of the following components: a battery compartment structural beam 11, a battery compartment outer curved surface 12, a cover 13, a charging port 14, a water-cooling bracket 15, and a carbon fiber guide tube 16. These components are each molded and cured on their respective molding molds, and then positioned and bonded directly on these molds. The molding molds also serve as assembly frames during the assembly process. The section has adhesive surfaces for each component, bonded together with structural adhesive. A continuous and uniform structural adhesive layer is formed between the adhesive surfaces of the components, ensuring the overall structural strength and sealing of the section.

[0055] In the above method, all assembly processes are completed on the molding die. From the completion of curing to the end of assembly, each component of the section remains in its original position on the die. This avoids the deformation and springback that may occur during the transfer of parts to the assembly frame after demolding in traditional processes, and also avoids the accumulation of positioning errors caused by repositioning on the assembly frame. Since the molding die itself is designed based on the final shape of the part, its surface accuracy directly determines the part's external shape accuracy. In-situ assembly on the die ensures that the relative positional relationships between the parts are completely consistent with the design state, thereby improving the overall assembly accuracy and fit quality of the section.

[0056] Meanwhile, since there is no need to design and manufacture dedicated assembly jigs, tooling and warehousing costs are significantly reduced, making it particularly suitable for scenarios where the structure undergoes frequent iterations during product development. When the structure of a section changes, only the forming mold needs to be adjusted accordingly. The forming mold itself is necessary for part manufacturing, and there is no issue of additional tooling costs due to assembly requirements. This advantage is particularly prominent in the development of aerospace products, significantly shortening the development cycle and reducing development costs.

[0057] The above embodiments are merely illustrative of the principles and effects of this application. Any person skilled in the art can modify or alter the above embodiments without departing from the purpose of this application. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the purpose disclosed in this application should still be covered by the claims of this application.

Claims

1. A method for in-situ assembly of a composite material segment, characterized in that, include: Main material preparation steps: Collect the main materials according to the main material list, and check the version and grade of the main materials according to the assembly outline; Tooling and equipment preparation steps: Check all tools and fixtures, confirm that the molds and fixtures are in normal condition, and clean the dust and adhesive residue from the surfaces of the molds and fixtures; Auxiliary material preparation steps: Prepare auxiliary materials; Pre-assembly inspection steps: Determine personnel allocation and production plan, check the appearance of parts against the parts list, and verify the availability of tooling, main materials, and auxiliary materials; Pre-assembly steps: Place each component of the section back into its corresponding molding mold according to the positioning reference, ensuring that the parts fit the mold without gaps, and use positioning tooling to position and pre-assemble each part, ensuring that there is no interference, stress, or gaps exceeding the design allowable range between parts; Bonding steps: Grind and roughen and clean the bonding surfaces of each part, apply structural adhesive, and then bond and assemble each part on the molding mold; Curing steps: Allow the bonded section to cure statically or by heat on the molding mold; Subsequent assembly steps: After curing, perform hole drilling, accessory installation, and / or bonding and assembly of other components on the molding mold until the entire assembly of the section is completed.

2. The in-situ assembly method for composite material segments according to claim 1, characterized in that, After the parts are placed back into the forming mold, the position of the positioning fixture is checked by calibrating the fixture or using a laser tracker to ensure that the positioning accuracy meets the assembly requirements.

3. The in-situ assembly method for composite material segments according to claim 1, characterized in that, Use #120 to #240 sandpaper to roughen each adhesive surface, then clean the sanded adhesive surface with anhydrous ethanol and degreased cotton cloth.

4. The in-situ assembly method for composite material segments according to claim 1, characterized in that, In the bonding step, the mixing time and amount of structural adhesive are recorded when preparing the adhesive, and the weight ratio of the structural adhesive is 100:

17.

5. The in-situ assembly method for composite material segments according to claim 1, characterized in that, In the bonding step, while applying the structural adhesive, a sample block of the structural adhesive is simultaneously prepared and labeled. The sample block is cured together with the section and used for subsequent testing and verification of the bonding quality.

6. The in-situ assembly method for composite material segments according to claim 1, characterized in that, In the bonding step, after applying structural adhesive, each part is placed in a predetermined position, positioned using the positioning fixture, excess adhesive is removed using a scraper, and excess adhesive residue is wiped off using a degreased cotton cloth soaked in anhydrous ethanol.

7. The in-situ assembly method for composite material segments according to claim 1, characterized in that, In the curing step, the curing method is static curing for 24 hours, or heating curing at 50℃±5℃ for 1 hour.

8. The in-situ assembly method for composite material segments according to claim 1, characterized in that, The subsequent assembly steps include a cap fitting step: after curing, holes are drilled and tray nuts are installed according to the assembly drawing using the positioning fixture to fit the cap to the section, and the cap is temporarily fixed with paper tape and holes are fitted.

9. The in-situ assembly method for composite material segments according to claim 1, characterized in that, The subsequent assembly steps include the installation of the tray nut and the water-cooling bracket: the tray nut is installed on the structural beam, and the water-cooling bracket is fastened to the structural beam using pop rivets.

10. The in-situ assembly method for composite material segments according to claim 1, characterized in that, The subsequent assembly steps include the charging port installation step: connecting the charging port and charging port cover to the section through the charging port hinge, and tightening with screws and nuts. Apply thread-locking adhesive before bolt installation, and mark the bolt head with anti-loosening paste after tightening.

11. The in-situ assembly method for composite material segments according to claim 1, characterized in that, The subsequent assembly steps include a hole-making step: using a hand drill to hold a twist drill and drill the mounting hole positioning point according to the drilling position of the template tool, then using a pneumatic drill to hold a dagger drill and a vertical drill to drill the initial mounting hole according to the positioning point, and then enlarging the hole in sequence.

12. The in-situ assembly method for composite material segments according to claim 1, characterized in that, It also includes a weighing step and a non-destructive testing step after the subsequent assembly step: the assembled section is weighed and non-destructive testing is performed on the section, and then quality inspection is carried out according to the inspection outline.

13. The in-situ assembly method for composite material segments according to claim 1, characterized in that, The auxiliary materials include one or more of the following: paper tape, anhydrous ethanol, degreased cotton cloth, glue mixing bowl, sandpaper, sandpaper sheets for pneumatic grinders, and scrapers.

14. A composite material segment, characterized in that, The component is assembled using the in-situ assembly method according to any one of claims 1-13. Each component of the segment is positioned and bonded on its respective molding die. The molding die also serves as an assembly frame during the assembly process. The segment has bonding surfaces for each component bonded by structural adhesive.

15. The composite material segment according to claim 14, characterized in that, The section is the battery compartment section, which includes one or more components such as the battery compartment structural beam, the outer curved surface of the battery compartment, the cover, the charging port, the water-cooling bracket, and the hole guide carbon tube. Each component is positioned and glued together on its respective molding mold.

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