A weaving apparatus for a composite form-fitting fabric

Abstract

This invention belongs to the field of composite material weaving equipment and discloses a weaving device for conformal composite fabrics. The weaving device includes a frame, a traction take-up section, a weft insertion section, a warp feed section, and a weft feed section. The traction take-up section includes a traction drive roller and a pressure roller arranged opposite each other, forming a pressing gap between them for the conformal fabric to pass through. The generatrices of the traction drive roller and the pressure roller are completely fitted and consistent with the contour line of the target conformal fabric. The weft insertion frame of the weft insertion section has a cross-section adapted to the bonding surface after the traction drive roller and the pressure roller are pressed together, and the cross-section is consistent with the cross-sectional contour of the target conformal fabric. This invention can adapt to the weaving of various conformal fabrics such as conical, arc-shaped, elliptical, spiral, wavy, and umbrella-shaped fabrics by changing the traction drive roller, pressure roller, and weft insertion frame, realizing fully automated continuous weaving, continuous fiber weaving without cutting, convenient equipment adjustment, and wide applicability.

Description

Technical Field

[0001] This invention belongs to the technical field of composite material weaving equipment, specifically relating to a weaving equipment for conformal composite fabrics, which is particularly suitable for the integrated continuous automated weaving of irregular conformal fabric preforms such as conical shells, arc shells, elliptical shells, and spiral plate shells in aerospace, weaponry, and transportation fields. Background Technology

[0002] Composite materials, due to their outstanding advantages such as lightweight, high strength, fatigue resistance, high design flexibility, and corrosion resistance, are gradually replacing traditional metallic materials such as aluminum alloys and titanium alloys, becoming the preferred material for key structural components in aerospace, weaponry, and transportation. For truncated conical components such as rocket engine casings, missile fairings, radomes, train head fairings, and propeller deflectors, increasingly higher requirements are placed on the mechanical properties and structural integrity of the reinforcement.

[0003] Currently, the preparation of conformal fabric reinforcements mainly employs the following two technical solutions:

[0004] The first approach uses a conical braided sleeve as a preform. This method uses specialized conical braiding equipment to directly weave fibers into a conical sleeve that approximates the shape of the target truncated cone. This sleeve is then fitted onto a mold and cured with adhesive to obtain the composite material product. However, this approach has the following significant drawbacks: the braiding process is extremely inefficient, making continuous, large-scale production difficult; the dimensional accuracy of the conical braided sleeve is difficult to control, especially with small cone angles or large sizes, easily leading to fiber buckling, wrinkling, or localized loosening; different braiding tooling is required for products with different cone angles and sizes, resulting in extremely poor adaptability; and the wall thickness of the braided sleeve is difficult to adjust, making it difficult to meet the mechanical design requirements of different products.

[0005] The second approach involves cutting, laminating, and attaching two-dimensional plain weave, twill, or unidirectional fabrics. This method involves cutting a standard rectangular fabric according to the fan-shaped outline of a frustum, obtaining multiple fan-shaped fabric pieces, which are then stacked and attached to a conical mold. While this approach can theoretically achieve arbitrary thickness and taper, its drawbacks are equally significant: cutting inevitably leads to the severing of fibers in the fabric, especially at the edges of the fan-shaped outline, where many fibers become discontinuous; in splicing or overlapping areas, the discontinuous fibers interrupt the load transfer path, easily causing stress concentration and severely weakening the overall mechanical properties of the composite material; the layup efficiency is extremely low, often requiring dozens or even hundreds of layers of fan-shaped fabric pieces to be manually laid for a large frustum component, resulting in cumbersome procedures, poor quality stability, and large batch-to-batch variations; material waste is extremely serious, with material utilization typically only 50%–70%, leading to huge cost losses for expensive high-performance reinforcing materials such as carbon fiber and ceramic fiber.

[0006] In recent years, major international and domestic manufacturers of 3D weaving machines have begun to innovate and optimize conventional looms to adapt to the production of irregularly shaped woven parts urgently needed by various industries. CN104195726A discloses an automated 2.5D 3D weaving device that automates the entire weaving process, including warp feeding, weft insertion, and finished product traction. However, this device can only weave regular sheet profiles and cannot weave conformal parts such as tapered tubular fabrics. CN103031652A discloses a weaving method for truncated cone fabrics, achieving a breakthrough in yarn addition technology as the diameter of the truncated cone cross-section increases in the 2.5D weaving structure. However, this method and equipment can only weave regular tapered profiles and cannot weave conformal parts such as tapered tubular fabrics or spherical shells.

[0007] In summary, current technologies lack a reinforcing fabric solution that can maintain fiber continuity, eliminate the need for cutting, achieve efficient and automated fabrication, and precisely conform to various irregular curved surfaces. Therefore, developing a conformal fabric weaving device capable of precisely conforming to various irregular shapes such as truncated conical surfaces, circular arc surfaces, elliptical surfaces, and helical plate surfaces, maintaining fiber continuity, and enabling continuous automated fabrication, has significant engineering value and scientific significance for improving the fabrication efficiency and mechanical property consistency of composite material components.

[0008] In view of this, the present invention is proposed. Summary of the Invention

[0009] The technical problem to be solved by the present invention is to overcome at least one of the shortcomings of the prior art and to provide a weaving device for conformal fabrics of composite materials.

[0010] The primary objective is to overcome the defects of traditional two-dimensional fabric cutting processes, such as fiber discontinuity, stress concentration, and low material utilization. The weaving equipment provided by this invention can directly weave a fabric with the same outline as the target conformal fabric without cutting or splicing, achieving fiber continuity along the conformal surface direction, eliminating stress concentration caused by cutting, and meeting the mechanical requirements of load-bearing / temperature-resistant components in high-reliability working conditions such as aerospace.

[0011] The second objective is to overcome the shortcomings of low efficiency and poor precision in the conical braiding process, as well as the low material utilization and high reliance on manual labor in the two-dimensional cutting and pasting process. This invention provides a continuous automated weaving solution that can be achieved by replacing key components on a conventional loom, thereby achieving near-zero material loss and significantly reducing overall manufacturing costs.

[0012] The third objective is to address the problem that existing technologies cannot adapt to conformal fabrics with different tapers and cross-sectional shapes. This invention provides a widely applicable weaving device that can adapt to weaving various irregular shells such as conical, arc, elliptical, and spiral shells simply by changing the traction drive roller, pressure roller, and weft beater frame, thereby reducing equipment investment and product switching costs.

[0013] To solve the above-mentioned technical problems, the basic concept of the technical solution adopted by the present invention is as follows:

[0014] The present invention provides a weaving device for conformal fabric of composite material, comprising: a frame, a traction take-up section, a weft-beating section for beating the weft yarn toward the weft end, a warp-feeding section for feeding the warp yarn, and a weft-feeding section for feeding the weft yarn, all of which are disposed on the frame.

[0015] The traction take-up section includes a traction drive roller and a pressing roller arranged opposite to each other, and a pressing gap is formed between the traction drive roller and the pressing roller to allow the conformal fabric to pass through; the generatrices of the traction drive roller and the pressing roller are completely in contact and consistent with the outline of the target conformal fabric, and the conformal fabric is pressed and pulled out in the rotating state.

[0016] In a further embodiment, the conformal fabric is either a regular-shaped fabric or an irregular-shaped fabric;

[0017] Preferably, the conformal fabric is at least one of conical fabric, arc fabric, elliptical fabric, spiral fabric, wavy fabric or umbrella fabric;

[0018] Preferably, the conformal fabric is a conical fabric, and both the traction drive roller and the pressing roller are truncated conical rollers, with their generatrices being oblique straight lines;

[0019] Preferably, the conformal fabric is an arc-shaped fabric, and the generatrices of the traction drive roller and the pressing roller are both arc curves;

[0020] Preferably, the conformal fabric is an elliptical fabric, and the generatrices of the traction drive roller and the pressing roller are both elliptical curves;

[0021] Preferably, the conformal fabric is a spiral fabric, and the generatrices of the traction drive roller and the pressing roller are curves that are consistent with the unfolded contour of the spiral fabric.

[0022] Preferably, the conformal fabric is a wavy fabric, and the surfaces of the traction drive roller and the pressing roller are mutually complementary wavy shapes with alternating concave and convex shapes, and the generatrices of both are wavy curves.

[0023] Preferably, the conformal fabric is an umbrella-shaped fabric, and the generatrix of the traction drive roller and the generatrix of the pressing roller are geometrically coincident at the pressing position.

[0024] In a further embodiment, the traction drive roller is fixed on the traction drive shaft, the traction drive shaft is connected to the traction drive motor, and the traction drive motor is fixed on the frame via a traction drive bracket.

[0025] In a further embodiment, the pressing roller is connected to the pressing part drive, and the pressing part drive is fixed on the frame via the pressing part frame; the pressing part drive is used to drive the pressing roller to move towards the traction drive roller so that the two are fully in contact.

[0026] In a further embodiment, the pressing part is driven by a cylinder, an electric push rod, or a linear motor, and its extension and retraction direction is perpendicular to the contact surface between the traction drive roller and the pressing roller.

[0027] In a further embodiment, the pressing roller, driven by the pressing part, comes into contact with the traction drive roller and generates a pressing force, the pressing force being 1.5 to 10 times the sum of the resistance of the weft insertion part and the resistance of the warp feed part.

[0028] In a further embodiment, the clamping force is 2 to 4 times the sum of the resistance of the weft insertion section and the resistance of the warp insertion section.

[0029] In a further embodiment, the materials of the traction drive roller and the pressure roller are each independently selected from metal, ceramic, nylon, polyester, or rubber;

[0030] Preferably, the traction drive roller and the pressing roller are made of rubber.

[0031] In a further embodiment, the weft insertion section has a weft insertion frame, the weft insertion frame having a cross section adapted to the bonding surface after the traction drive roller and the pressing roller are pressed together, and the cross section is consistent with the cross-sectional profile of the target conformal fabric;

[0032] Preferably, the inner contour formed by the cross-section of the weft beater frame is consistent with the outer contour of the cross-section of the target conformal fabric, and the weft yarn is introduced into the weaving point through the inner hole of the weft beater frame.

[0033] In a further embodiment, the weft insertion frame is driven to connect with the weft insertion section and is fixed to the frame via the base plate of the weft insertion section; the installation position of the weft insertion frame on the base plate of the weft insertion section is adjustable.

[0034] In a further embodiment, the weft insertion frame is connected to the weft insertion base plate via an angle adjustment mechanism. The angle adjustment mechanism includes a rotation fulcrum on one side of the weft insertion frame and an arc-shaped guide groove on the other side. The weft insertion frame can rotate around the rotation fulcrum and be locked and fixed by the arc-shaped guide groove.

[0035] In a further embodiment, the warp feeding section includes multiple heald frames, a heald frame frame, a heald frame drive, and a heald frame drive base plate; the multiple heald frames are linked with the heald frame drive and are fixed to the frame through the heald frame frame and the heald frame drive base plate.

[0036] In a further embodiment, the weft feeding section includes a weft feeding section frame, a weft feeding drive, and a weft feeding rod; the weft feeding rod is connected to the weft feeding drive and is fixed to the frame via the weft feeding section frame.

[0037] In a further embodiment, the angle between the traction direction of the traction winding section and the warp feeding direction of the warp feeding section is adjustable.

[0038] In a further embodiment, the frame is a frame structure, including columns and crossbeams connecting adjacent columns, with the top surface of the crossbeams forming a horizontal mounting surface.

[0039] In a further embodiment, the traction drive shaft and the traction drive machine are connected by a universal coupling to compensate for the eccentric motion generated when the generatrix of the traction drive roller rotates.

[0040] In a further embodiment, the conformal fabric is at least one of carbon fiber fabric, alumina fiber fabric, silicon carbide fiber fabric, glass fiber fabric, quartz fiber fabric, ceramic fiber fabric, or aramid fiber fabric.

[0041] By adopting the above technical solution, the present invention has the following beneficial effects compared with the prior art.

[0042] (1) Realize integrated continuous automatic weaving of conformal fabrics. The traction drive roller and the pressure roller are fully aligned and consistent with the fabric outline. The fabric cross-sectional shape is directly defined by the geometric outline of the roller surface. It can continuously and automatically weave conformal fabrics such as fan-shaped, conical, elliptical, and spiral without cutting or splicing, thus solving the problems of fiber discontinuity, stress concentration and material waste.

[0043] (2) The equipment is easy to adjust and has wide applicability. This invention only requires replacing the traction drive roller, the pressure roller, and the weft insertion frame on existing looms to achieve the weaving of different shaped conformal fabrics, resulting in low modification costs. The generatrices of the traction drive roller and the pressure roller can be customized according to the contour line of the target conformal fabric, and the cross-section of the weft insertion frame is adapted synchronously, thereby covering the weaving needs of various irregular shells such as cones, arcs, ellipses, and spiral plates. When it is necessary to switch product types, only the above three components need to be replaced and the corresponding process parameters need to be adjusted, without replacing the entire equipment, which greatly reduces equipment investment and product switching costs.

[0044] (3) The fibers are completely continuous and have excellent mechanical properties. Both the warp and weft yarns in the fabric remain continuous, with no cutting or splicing breaks, eliminating stress concentration and weak mechanical areas. The tensile and compressive strength of the components are significantly improved, meeting the requirements of high-end applications such as aerospace.

[0045] (4) The weaving process is stable and the fiber damage is small. The clamping force is precisely provided by the clamping part. The fabric is uniformly clamped and stably pulled out in the clamping gap. This is especially beneficial for weaving brittle high-performance fibers such as carbon fiber and alumina fiber, and effectively reduces fly filaments and fiber damage.

[0046] (5) Reduce human intervention and improve work safety. Fully automated knitting significantly reduces human intervention, lowers the risk of injury from flying yarn, and improves the working environment.

[0047] (6) Expand the range of weaving varieties and improve the mechanical properties of irregular cross sections. By replacing key components, a variety of conformal fabrics can be adapted, thus expanding the range of weaving varieties; the fibers are continuously distributed along the conformal surface, and the mechanical properties of the irregular cross section area are significantly improved.

[0048] The specific embodiments of the present invention will now be described in further detail with reference to the accompanying drawings. Attached Figure Description

[0049] The accompanying drawings, as part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments and descriptions of the invention are used to explain the invention, but do not constitute an undue limitation of the invention. Obviously, the drawings described below are merely some embodiments, and those skilled in the art can obtain other drawings based on these drawings without creative effort. In the drawings:

[0050] Figure 1 This is a schematic diagram of a weaving device for a conformal fabric of composite material according to the present invention;

[0051] Figure 2 This is a schematic diagram of a traction winding section of the present invention;

[0052] Figure 3 This is a schematic diagram of the traction drive roller and the pressure roller used in the truncated conical component of the present invention;

[0053] Figure 4 This is a schematic diagram of the traction drive roller and the pressure roller for the wave-shaped component of the present invention;

[0054] Figure 5 This is a side view of the traction drive roller and pressure roller used in the wave-shaped component of the present invention;

[0055] Figure 6 This is an angle diagram of the traction drive roller and the pressure roller for the umbrella-shaped component of the present invention;

[0056] Figure 7 This is another schematic diagram from a different angle of the traction drive roller and the pressing roller for the umbrella-shaped component of the present invention;

[0057] Figure 8 This is a schematic diagram of the weft insertion section for a truncated cone-shaped component;

[0058] Figure 9 This is a schematic diagram of the weft angle adjustment structure.

[0059] In the diagram: 1 - rack;

[0060] 2-Traction winding section; 2.1-Traction drive section, 2.1.1-Traction drive motor, 2.1.2-Traction drive bracket, 2.1.3-Traction drive shaft, 2.1.4-Traction drive roller; 2.2-Traction clamping section, 2.2.1-Clamping section frame, 2.2.2-Clamping section drive, 2.2.3-Clamping roller; 2.3-Busline;

[0061] 3-Weft insertion section; 3.1-Weft insertion section drive; 3.2-Weft insertion frame; 3.2.1-Vertical support plate; 3.2.2-Horizontal connecting plate; 3.2.3-Mounting component; 3.2.4-Rotation fulcrum; 3.2.5-Arc-shaped guide groove; 3.3-Weft insertion section base plate; 3.3.1-Bending section;

[0062] 4-Warp feeding section, 4.1-Shelf heald frame, 4.2-Heald frame frame, 4.3-Heald frame drive, 4.4-Heald frame drive base plate;

[0063] 5-Weft feed section, 5.1-Weft feed section frame, 5.2-Weft feed drive, 5.3-Weft feed rod.

[0064] It should be noted that these accompanying drawings and textual descriptions are not intended to limit the scope of the invention in any way, but rather to illustrate the concept of the invention to those skilled in the art by referring to specific embodiments. Detailed Implementation

[0065] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments will be clearly and completely described below with reference to the accompanying drawings. The following embodiments are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0066] In the description of this invention, it should be noted that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0067] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0068] like Figure 1 As shown, the present invention provides a weaving device for conformal composite fabrics. The weaving device includes a frame 1, a traction take-up section 2, a weft beat-up section 3, a warp feed section 4, and a weft feed section 5. The weft beat-up section 3 beats the weft yarn towards the weft end, the warp feed section 4 supplies the warp yarn, and the weft feed section 5 supplies the weft yarn; all components are mounted on the frame 1.

[0069] The frame 1 serves as the supporting foundation for the entire weaving equipment. It is a frame structure welded from structural steel, comprising vertically positioned columns at the four corners and upper and lower crossbeams connecting adjacent columns. All four sides of the frame 1 are composed of crossbeams. The top surface of each crossbeam is precision-machined to form a horizontal mounting surface, serving as the mounting reference for each functional component. Along the warp direction, the frame 1 is sequentially divided into a warp feed mounting area, a weft insertion mounting area, and a traction mounting area: the warp feed mounting area is used to install the warp feed unit 4; the weft insertion mounting area is used to install the weft insertion unit 3; and the traction mounting area is used to install the traction take-up unit 2. The weft feed unit 5 is mounted on the side of the frame 1. Anchor bolt mounting holes are provided at the bottom of the frame 1 for fixing it to the foundation.

[0070] The traction winding unit 2 includes a traction drive unit 2.1 and a traction clamping unit 2.2. For example... Figure 2 As shown, the traction drive unit 2.1 includes a traction drive motor 2.1.1, a traction drive bracket 2.1.2, a traction drive shaft 2.1.3, and a traction drive roller 2.1.4. The traction drive motor 2.1.1 is a servo motor and is fixed to the frame 1 via the traction drive bracket 2.1.2. The output end of the traction drive motor 2.1.1 is connected to the traction drive shaft 2.1.3 via a transmission mechanism, driving the traction drive shaft 2.1.3 to rotate. The traction drive roller 2.1.4 is fixed to the traction drive shaft 2.1.3 and rotates together with it. The generatrix 2.3 of the traction drive roller 2.1.4 is consistent with the outline of the target conformal fabric.

[0071] The traction pressing unit 2.2 includes a pressing unit frame 2.2.1, a pressing unit drive 2.2.2, and a pressing roller 2.2.3. The pressing unit frame 2.2.1 is fixed on the frame 1, and the pressing unit drive 2.2.2 is mounted on the pressing unit frame 2.2.1. The pressing roller 2.2.3 is connected to the output end of the pressing unit drive 2.2.2 and can move relative to the traction drive roller 2.1.4 under the drive of the pressing unit drive 2.2.2. The generatrix of the pressing roller 2.2.3 is also consistent with the outline of the target conformal fabric and is completely in contact with the generatrix 2.3 of the traction drive roller 2.1.4.

[0072] The traction drive roller 2.1.4 and the pressure roller 2.2.3 are arranged opposite each other. For example, the pressure roller 2.2.3 is located above the traction drive roller 2.1.4, and a pressing gap is formed between the traction drive roller 2.1.4 and the pressure roller 2.2.3 to allow the conformal fabric to pass through. The pressing part drive 2.2.2 drives the pressure roller 2.2.3 to move towards the traction drive roller 2.1.4, so that the generatrices 2.3 of the two rollers are fully in contact, and a predetermined pressing force is applied to the conformal fabric passing through the pressing gap. The traction drive 2.1.1 drives the traction drive roller 2.1.4 to rotate, and the pressure roller 2.2.3 rotates synchronously with the traction drive roller 2.1.4 at the same angular velocity under the action of friction, continuously and slowly pulling out the conformal fabric in the pressing gap.

[0073] The clamping drive 2.2.2 can be a cylinder, an electric actuator, or a linear motor, with its extension and retraction direction perpendicular to the contact surfaces of the traction drive roller 2.1.4 and the clamping roller 2.2.3. In this embodiment, the clamping drive 2.2.2 uses a cylinder with a compressed air pressure of 0.6 MPa. The cylinder provides stable output and rapid response, making it suitable as a clamping force source. By adjusting the compressed air pressure, the clamping force between the clamping roller 2.2.3 and the traction drive roller 2.1.4 can be easily adjusted.

[0074] The clamping force needs to take into account both the weft insertion resistance and the warp feed resistance. Insufficient clamping force will cause the fabric to slip during traction, affecting traction stability and fabric dimensional accuracy; excessive clamping force will increase equipment load and may even damage the fibers. In this embodiment, the clamping force is set to 2 to 4 times the sum of the weft insertion resistance and the warp feed resistance. This clamping force range ensures sufficient traction friction without causing excessive compression damage to the fibers.

[0075] The traction drive roller 2.1.4 and the pressure roller 2.2.3 can be made of metal, ceramic, nylon, polyester, or rubber. In this embodiment, the traction drive roller 2.1.4 and the pressure roller 2.2.3 are made of rubber. Rubber has moderate hardness and good elasticity, which can increase the coefficient of friction between the roller surface and the fabric, prevent slippage, and provide a cushioning effect to reduce damage to the fibers.

[0076] The weaving equipment of this invention can be adapted to weaving different shapes of conformal fabrics by replacing the traction drive roller 2.1.4, the pressure roller 2.2.3, and the beat-up frame 3.2. The shapes of various conformal fabrics and their corresponding traction drive rollers and pressure rollers include, but are not limited to, the following:

[0077] like Figure 3 As shown, when the target conformal fabric is a truncated cone tubular fabric (conical fabric), the generatrices of the traction drive roller 2.1.4 and the pressing roller 2.2.3 are both oblique straight lines consistent with the outline of the truncated cone tubular fabric. Both rollers are truncated cone rollers, and their small end diameter is adapted to the small end inner diameter of the target truncated cone component, and their large end diameter is adapted to the large end inner diameter of the target truncated cone component.

[0078] When the target conformal fabric is an arc-shaped component, the generatrices of the traction drive roller 2.1.4 and the pressing roller 2.2.3 are both arc curves that are consistent with the cross-sectional contour of the arc-shaped target body. The generatrices of the traction drive roller and the pressing roller are both arc curves, and their generatrices have the same radius of curvature as the cross-sectional radius of curvature of the target arc component.

[0079] When the target conformal fabric is an elliptical component, the generatrices of the traction drive roller 2.1.4 and the pressing roller 2.2.3 are both elliptical curves that are consistent with the cross-sectional profile of the elliptical shell. The generatrices of the traction drive roller and the pressing roller are both elliptical curves, and the ratio of their major and minor axes is consistent with the ratio of the major and minor axes of the cross-section of the target elliptical component.

[0080] When the target conformal fabric is a spiral component, the generatrices of the traction drive roller 2.1.4 and the pressing roller 2.2.3 are both curves that are consistent with the unfolded contour of the spiral plate shell. Both rollers are spiral generatrices rotating bodies, and their generatrices are consistent with the unfolded contour of the target spiral component.

[0081] like Figure 4 and Figure 5 As shown, when the target conformal fabric is a wavy component, the generatrices of the traction drive roller 2.1.4 and the pressing roller 2.2.3 are both wavy curves that are consistent with the cross-sectional profile of the wavy fabric. The surfaces of the two rollers are wavy shapes with alternating concave and convex shapes that cooperate with each other. The wavelength and amplitude of the wavy curves are consistent with the cross-sectional profile of the target wavy component.

[0082] like Figure 6 and Figure 7 As shown, when the target conformal fabric is an umbrella-shaped component, the generatrix of the traction drive roller 2.1.4 is a curve corresponding to the cross-sectional profile of the umbrella-shaped fabric, and the generatrix of the pressing roller 2.2.3 is geometrically coincident with the generatrix of the traction drive roller 2.1.4 at the pressing position, and the pressing gap between the two is consistent with the cross-sectional profile of the umbrella-shaped component.

[0083] When the target conformal fabric is other irregular shell fabric, the generatrices of the traction drive roller 2.1.4 and the pressure roller 2.2.3 are customized according to the cross-sectional profile of the target fabric, so that the generatrices of the two rollers are completely fitted and consistent with the cross-sectional profile of the target fabric, and the cross-sectional shape of the fabric is directly defined by the generatrices.

[0084] It should be noted that the "busline" refers to the contact line between the two rollers when they are pressed together.

[0085] like Figure 1 As shown, the weft insertion section 3 is located on the side preceding the traction and take-up section 2. For example... Figure 8 and Figure 9 As shown, the beat-up section 3 includes a beat-up drive 3.1, a beat-up frame 3.2, and a beat-up base plate 3.3. The beat-up drive 3.1 adopts a crank-connecting rod mechanism or a cam mechanism and is fixed to the frame 1 via the beat-up base plate 3.3. The beat-up frame 3.2 is connected to the beat-up drive 3.1 and reciprocates along the warp direction under the drive of the beat-up drive 3.1.

[0086] The beat-up frame 3.2 can be planar or have an irregular cross-section. The beat-up frame 3.2 is an annular frame whose sides are in contact with the side surfaces after being pressed by the traction drive roller 2.1.4 and the pressure roller 2.2.3. When the target conformal fabric is a truncated cone-shaped component, the beat-up frame 3.2 is an irregularly shaped frame consistent with the profile of the truncated cone cross-section. The inner contour enclosed by the irregular cross-section of the beat-up frame 3.2 is consistent with the outer contour of the target conformal fabric cross-section, and the weft yarn is introduced into the weaving point through the inner hole of the beat-up frame 3.2. This ensures that the weft yarn is distributed according to the cross-sectional profile of the target conformal fabric when pushed towards the weaving point by the beat-up frame, guaranteeing the conformal accuracy of the fabric.

[0087] The mounting position of the weft insertion frame 3.2 on the weft insertion base plate 3.3 is adjustable. This allows the position of the weft insertion frame 3.2 to be precisely aligned with the contact surfaces of the traction drive roller 2.1.4 and the pressure roller 2.2.3, ensuring that the weft yarn is accurately inserted into the weave. The adjustment can be achieved by using a bolt with a slotted hole for locking, or by using a screw and nut mechanism for precise adjustment.

[0088] In one embodiment, the weft insertion frame is connected to the weft insertion base plate via an angle adjustment mechanism. The angle adjustment mechanism includes a rotation fulcrum 3.2.4 on one side of the weft insertion frame and an arc-shaped guide groove 3.2.5 on the other side. The weft insertion frame can rotate around the rotation fulcrum 3.2.4 and be locked and fixed by the arc-shaped guide groove 3.2.5.

[0089] like Figure 8 and Figure 9As shown, in this embodiment, the weft insertion base plate 3.3 is a plate-shaped component, horizontally mounted on the crossbeam of the frame 1. The weft insertion base plate 3.3 has bends 3.3.1 on both sides, and they are symmetrical. Mounting holes are pre-drilled on the bends 3.3.1, which are then fixedly connected to the frame 1 by bolts. The weft insertion frame is a ring-shaped frame, vertically mounted on the weft insertion base plate 3.3, and its bottom sides are adjustablely fixedly connected to the bends 3.3.1 on both sides of the weft insertion base plate 3.3. A mounting component 3.2.3 is located in the middle of the bottom of the weft insertion frame. The mounting component 3.2.3 is L-shaped, with the short side of the L-shape horizontally positioned and integrally formed or fixedly connected to the weft insertion frame. The long side of the L-shape extends vertically and has a connecting hole. The output end of the weft insertion drive 3.1 is fixedly connected to the connecting hole of the mounting component 3.2.3. The weft insertion frame reciprocates back and forth under the drive of the weft insertion drive 3.1.

[0090] The bottom of each of the vertical sides of the weft insertion frame is equipped with a horizontal connecting plate 3.2.2. One of the horizontal connecting plates 3.2.2 has a circular through hole, which is fixedly connected to the weft insertion base plate 3.3 by bolts. When the bolts are loosened, the weft insertion frame 3.2 can rotate around the bolt at the circular through hole (which serves as a pivot point 3.2.4). The other horizontal connecting plate 3.2.2 has an arc-shaped elongated hole (serving as an arc-shaped guide groove 3.2.5), which is fixedly connected to the weft insertion base plate 3.3 at different positions by bolts passing through the arc-shaped elongated hole. By adjusting the relative position of the arc-shaped elongated hole and the weft insertion base plate 3.3, the weft insertion frame 3.2 can be rotated around the bolt at the circular through hole to the desired angle and locked in place. The center of the arc-shaped elongated hole is located on the central axis of the circular through hole to ensure that the bolt can slide smoothly along the arc-shaped elongated hole during adjustment.

[0091] The lower part of both vertical sides of the weft-forming frame 3.2 is also provided with vertical support plates 3.2.1. The cross-section of each vertical support plate 3.2.1 gradually decreases from bottom to top to reduce the weight of the component while ensuring support strength and providing clearance. A horizontal connecting plate 3.2.2 is set inside the vertical support plates 3.2.1. The horizontal connecting plate 3.2.2 and the vertical support plates 3.2.1 are respectively fixedly connected to the weft-forming frame with bolts.

[0092] With the above structure, the angle of the beat-up frame 3.2 relative to the beat-up base plate 3.3 can be flexibly adjusted according to the shape requirements of the target conformal fabric, ensuring that the irregular cross-section of the beat-up frame 3.2 is precisely aligned with the surface of the conformal fabric after being pressed together by the traction drive roller and the pressure roller, thus ensuring that the weft yarn can be accurately beaten into the weave. After the angle adjustment is completed, tightening the bolts on both sides will reliably fix the beat-up frame 3.2, ensuring the stability of the beat-up frame position during weaving. This adjustment structure is simple, easy to operate, and reliable in positioning, and can adapt to the weaving needs of conformal fabrics with different tapers and cross-sectional shapes without replacing any parts.

[0093] like Figure 1 As shown, the warp feed unit 4 is located on the front process side of the weft insertion unit 3. The warp feed unit 4 includes multiple shed heald frames 4.1, a heald frame frame 4.2, a heald frame drive 4.3, and a heald frame drive base plate 4.4. The multiple shed heald frames 4.1 are arranged sequentially along the warp direction, and each shed heald frame 4.1 has heald threads, through which the warp yarns pass. The shed heald frames 4.1 are linked with the heald frame drive 4.3, moving up and down under the drive of the heald frame drive 4.3 to separate the warp yarns into upper and lower layers, forming an opening. The heald frame drive 4.3 can employ a cam-type opening mechanism, a multi-arm opening mechanism, or an electronic jacquard opening mechanism. The heald frame frame 4.2 supports the shed heald frames 4.1, and the heald frame drive base plate 4.4 fixes the heald frame drive 4.3. Both the heald frame frame 4.2 and the heald frame drive base plate 4.4 are fixed to the frame 1. The tension and speed of each warp yarn supplied by the warp feed unit are controllable. The control of yarn tension and speed can be achieved using existing methods or improved methods.

[0094] The weft feeding section 5 includes a weft feeding frame 5.1, a weft feeding drive 5.2, and a weft feeding rod 5.3. The weft feeding frame 5.1 is fixed to the frame 1, the weft feeding drive 5.2 is mounted on the weft feeding frame 5.1, and the weft feeding rod 5.3 is connected to the weft feeding drive 5.2. The weft feeding rod 5.3 is used to clamp the weft yarn and guide it into the shed. The weft feeding drive 5.2 can be a rapier weft insertion mechanism, an air-jet weft insertion mechanism, or a water-jet weft insertion mechanism. In this embodiment, a rapier weft insertion mechanism is preferred.

[0095] The traction drive shaft 2.1.3 is connected to the traction drive motor 2.1.1 via a universal coupling to compensate for the eccentric motion generated when the generatrix of the traction drive roller 2.1.4 rotates. Since the generatrix of the traction drive roller 2.1.4 is a curve consistent with the contour of the conformal fabric, its center of rotation may deviate from its center of mass, resulting in eccentric vibration during rotation. The universal coupling absorbs this eccentricity, ensuring smooth transmission and reducing equipment vibration and fiber damage.

[0096] The angle between the traction direction of the traction take-up unit 2 and the warp feed direction of the warp feed unit 4 is adjustable. For tapered fabrics and other conformal fabrics, a certain angle needs to be maintained between the traction direction and the warp feed direction to accommodate the shrinkage or expansion of the fabric in the width direction. This angle adjustment can be achieved by rotating the overall mounting angle of the traction take-up unit 2, or by adjusting the mounting angles of the traction drive roller 2.1.4 and the pressure roller 2.2.3.

[0097] In one specific implementation, the overall installation angle of the traction take-up unit 2 is adjustable relative to the frame 1, thereby making the angle between the traction direction of the traction take-up unit 2 and the warp feed direction of the warp feed unit 4 adjustable. This angle adjustment mechanism can be achieved using an arc-shaped adjustment groove on the frame 1 in conjunction with a locking bolt. Loosening the locking bolt and rotating the traction take-up unit 2 to the desired angle fixes the traction take-up unit 2 in place. By adjusting the aforementioned angle, different traction path lengths are obtained in different areas of the fabric's width direction, thus matching the geometric differences of the conformal fabric in the width direction. This avoids fabric wrinkles or uneven stretching caused by inconsistencies between the warp feed and traction directions, further ensuring the weaving quality of the conformal fabric.

[0098] Example 1 (Conical Tube Fabric)

[0099] This embodiment provides a specific implementation method for weaving carbon fiber conical tube fabric using the above-described weaving equipment.

[0100] Weave a carbon fiber conical tube according to the processing requirements. The inner diameter of the small end of the woven part is 65 mm, the inner diameter of the large end is 130 mm, the height is 165 mm, and the thickness is 3 mm.

[0101] like Figure 3 As shown, the dimensions of the traction drive roller and the pressure roller are selected according to the size of the fabric: 60 mm diameter at the small end, 164 mm diameter at the large end, and a height of 263.72 mm. Measurements show that the outer diameter of the roller is 65 mm at 12.68 mm from the small end and 130 mm at 230 mm from the small end. Marks are made on both rollers, and then the traction drive roller is installed on the traction drive shaft, and the pressure roller is installed on the traction and pressure section.

[0102] Pressurizing drive cylinder is supplied with 0.3 MPa compressed air. The bonding line of the two rollers is adjusted to be parallel to the eyelet of the heald frame. Then, the traction drive motor is jogged to check that the traction drive roller and the pressing roller can rotate tightly at the same angular velocity.

[0103] After debugging, within the range marked on the traction drive roller of the yarn feeding section, the warp yarns are inserted into the corresponding eyelets of the heald frame and the beating frame, and the yarns are threaded onto the weft feeding rod of the weft feeding section to begin pre-knitting.

[0104] During the weaving process, it was found that after introducing 0.3 MPa compressed air into the pressing drive cylinder, the pressure between the traction drive roller and the pressing roller was too low, resulting in irregular pre-woven knots. The compressed air pressure in the pressing drive cylinder was adjusted to 0.4 MPa, and then a second pre-weaving was performed. At this point, the woven knots were neat and tight. Continuous automatic weaving was then performed. The rotation speed of the traction drive motor was calculated based on the diameter of the corresponding part of the drive traction roller. Weaving stopped after reaching the set rotation speed, and the final weaving was completed into a cylinder.

[0105] The carbon fiber conical tube fabric was taken out for testing. The knots were tight and neat, and the fabric passed the inspection completely.

[0106] In this embodiment, both the warp and weft yarns are made of T700-12K carbon fiber. The warp density is 4 yarns per centimeter, and the weft density is approximately 2 yarns per centimeter at the large end and approximately 6 yarns per centimeter at the small end. The weft density gradually changes from the small end to the large end, matching the geometry of the conical cylinder.

[0107] Example 2 (Wave-shaped fabric)

[0108] This embodiment provides a specific implementation method for weaving a wavy, conformal fabric using the aforementioned weaving equipment.

[0109] The target conformal fabric is a wavy fabric, exhibiting periodic wave-like undulations along its width. For example... Figure 4 and 5 As shown, the surfaces of the traction drive roller and the pressure roller are alternating wavy shapes that complement each other. The wavy generatrices of the two rollers are completely in contact, and their concave and convex parts correspond and complement each other. That is, the raised part of the traction drive roller is positioned opposite the corresponding concave part of the pressure roller, forming a pressing gap between them for the conformal fabric to pass through. The contour of this pressing gap is consistent with the cross-sectional contour of the target wavy fabric. The generatrices of both the traction drive roller and the pressure roller are wavy curves, and the wavelength and amplitude of these wavy curves are consistent with the cross-sectional contour of the target wavy fabric. When the two rollers rotate synchronously, the fabric is pressed and pulled out within the wavy pressing gap, and the wavy cross-sectional contour of the fabric is directly defined by the wavy curve generatrices.

[0110] The irregular cross-section of the beat-up frame is a wave shape that matches the cross-sectional contour of the wave-shaped fabric. Its inner contour matches the outer contour of the cross-section of the target wave-shaped fabric. The weft yarn is introduced into the weaving point through the inner hole of the beat-up frame.

[0111] Both warp and weft yarns are made of carbon fiber. During the weaving process, the compressed air pressure of the pressing drive cylinder is set to 0.5 MPa. The traction drive roller and the pressing roller rotate at the same angular velocity, pressing and pulling the wavy fabric for output. The wavy cross-sectional profile of the fabric is directly defined by the wavy curve generatrix.

[0112] The resulting wavy conformal fabric, after weaving, has continuous fibers without cutting, and its outline is consistent with the target wavy fabric.

[0113] Example 3 (Umbrella Fabric)

[0114] This embodiment provides a specific implementation method for weaving umbrella-shaped conformal fabrics using the aforementioned weaving equipment.

[0115] The target conformal fabric is an umbrella-shaped fabric, with its cross-section along the width direction exhibiting an umbrella-shaped unfolded profile. For example... Figure 6 and Figure 7As shown, the traction drive roller, a conical roller, is positioned below, with its body uniformly expanding in diameter from one end to the other along the axial direction to form a truncated cone profile. The pressure roller, a cylindrical roller, is positioned above. The generatrix of the traction drive roller and the pressure roller are geometrically coincident at the pressing position, and the pressing gap between them matches the cross-sectional profile of the umbrella-shaped fabric. When the two rollers rotate at the same angular velocity, their linear velocities are the same at the contact line, achieving uniform pressing and traction output of the umbrella-shaped fabric. This contact line directly defines the cross-sectional profile shape of the umbrella-shaped fabric.

[0116] The irregular cross-section of the beat-up frame is the same shape as the cross-section of the umbrella fabric, and its inner contour is the same as the outer contour of the cross-section of the target umbrella fabric. The weft yarn is introduced into the weaving point through the inner hole of the beat-up frame.

[0117] Both the warp and weft yarns are made of glass fiber. During the weaving process, the compressed air pressure of the pressing drive cylinder is set to 0.4 MPa.

[0118] The resulting umbrella-shaped conformal fabric, after weaving, has continuous, uncut fibers and an outline consistent with the target umbrella-shaped fabric, and can be directly used in the manufacture of composite material components such as umbrella-shaped radomes.

[0119] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-described technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A weaving device for conformal fabrics of composite materials, characterized in that, include: The frame (1), the traction take-up section (2), the weft beater section (3) for beating the weft yarn toward the weft end, the warp feeder section (4) for supplying the warp yarn, and the weft feeder section (5) for supplying the weft yarn are all mounted on the frame (1). The traction take-up section (2) includes a traction drive roller (2.1.4) and a pressing roller (2.2.3) arranged opposite to each other. A pressing gap is formed between the traction drive roller (2.1.4) and the pressing roller (2.2.3) to allow the conformal fabric to pass through. The generatrices of the traction drive roller (2.1.4) and the pressing roller (2.2.3) are fully fitted and consistent with the outline of the target conformal fabric.

2. The weaving equipment according to claim 1, characterized in that, The conformal fabric can be a regular or irregular shaped fabric; Preferably, the conformal fabric is at least one of conical fabric, arc fabric, elliptical fabric, spiral fabric, wavy fabric or umbrella fabric.

3. The weaving equipment according to claim 1 or 2, characterized in that, The traction drive roller (2.1.4) is fixed on the traction drive shaft (2.1.3), the traction drive shaft (2.1.3) is connected to the traction drive machine (2.1.1), and the traction drive machine (2.1.1) is fixed on the frame (1) through the traction drive bracket (2.1.2).

4. The weaving equipment according to any one of claims 1-3, characterized in that, The pressing roller (2.2.3) is connected to the pressing drive (2.2.2), which is fixed on the frame (1) via the pressing frame (2.2.1). The pressing drive (2.2.2) is used to drive the pressing roller (2.2.3) to move toward the traction drive roller (2.1.4) so ​​that the two are fully in contact. Preferably, the pressing part drive (2.2.2) is a cylinder, an electric push rod or a linear motor, and its extension and retraction direction is perpendicular to the contact surface of the traction drive roller (2.1.4) and the pressing roller (2.2.3); Preferably, the pressing roller (2.2.3) is driven by the pressing part drive (2.2.2) and comes into contact with the traction drive roller (2.1.4) to generate a pressing force, which is 1.5 to 10 times the sum of the resistance of the weft insertion part (3) and the resistance of the warp feed part (4).

5. The weaving equipment according to any one of claims 1-4, characterized in that, The weft insertion section (3) has a weft insertion frame (3.2), which has a cross section that is adapted to the bonding surface after the traction drive roller (2.1.4) and the pressing roller (2.2.3) are pressed together, and the cross section is consistent with the cross section profile of the target conformal fabric; Preferably, the inner contour of the cross section of the weft beater frame (3.2) is consistent with the outer contour of the cross section of the target conformal fabric, and the weft yarn is introduced into the weaving point through the inner hole of the weft beater frame (3.2).

6. The weaving equipment according to claim 5, characterized in that, The weft insertion frame (3.2) is connected to the weft insertion drive (3.1) and fixed to the frame (1) via the weft insertion base plate (3.3); the installation position of the weft insertion frame (3.2) on the weft insertion base plate (3.3) is adjustable.

7. The weaving equipment according to claim 6, characterized in that, The weft insertion frame (3.2) is connected to the weft insertion base plate (3.3) via an angle adjustment mechanism. The angle adjustment mechanism includes a rotation fulcrum (3.2.4) on one side of the weft insertion frame (3.2) and an arc-shaped guide groove (3.2.5) on the other side. The weft insertion frame (3.2) can rotate around the rotation fulcrum (3.2.4) and be locked and fixed by the arc-shaped guide groove (3.2.5).

8. The weaving equipment according to any one of claims 1-7, characterized in that, The warp feeding section (4) includes multiple heald frames (4.1), heald frame frame (4.2), heald frame drive (4.3), and heald frame drive base plate (4.4); the multiple heald frames (4.1) are linked with the heald frame drive (4.3) and are fixed to the frame (1) through the heald frame frame (4.2) and the heald frame drive base plate (4.4).

9. The weaving equipment according to any one of claims 1-8, characterized in that, The weft feeding section (5) includes a weft feeding frame (5.1), a weft feeding drive (5.2), and a weft feeding rod (5.3); the weft feeding rod (5.3) is connected to the weft feeding drive (5.2) and is fixed to the frame (1) through the weft feeding frame (5.1).

10. The weaving apparatus according to any one of claims 1-9, characterized in that, The materials of the traction drive roller (2.1.4) and the pressure roller (2.2.3) are each independently selected from metal, ceramic, nylon, polyester or rubber; Preferably, the traction drive roller (2.1.4) and the pressing roller (2.2.3) are made of rubber.

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