A servo motor control system and method for a carbon fiber automatic fiber placement device

Abstract

The application provides a kind of servo motor control system and method of carbon fiber automatic fiber placement equipment, belong to motor control technical field, the system includes electrical cabinet, PLC control panel and tension test and winding unit;Tension test and winding unit contains discharge / collects reel assembly, discharge / collects tension sensor, discharge / collects diameter ultrasonic sensor, tension source and traction assembly.PLC control panel is configured to execute semi-closed loop or full closed loop tension control mode: semi-closed loop mode utilizes diameter ultrasonic sensor to detect diameter and calculates tension, and the tension source is adjusted by controller;Full closed loop mode utilizes tension sensor to determine actual tension, and the tension source is adjusted by controller.The application provides two kinds of switchable tension control mode, can verify and correct semi-closed loop mode with full closed loop mode, compatible thermosetting and thermoplastic tow, improve safety and aesthetic, while having automatic winding function.

Description

Technical Field

[0001] This invention relates to the field of motor control technology, and in particular to a servo motor control system and method for an automatic carbon fiber fiber placement device. Background Technology

[0002] With the rapid development of the aerospace industry, the importance of carbon fiber composites in this sector has become increasingly apparent, driving the development of automated fiber placement technology. Automated fiber placement machines are one of the main pieces of equipment in the production of aerospace components. When placing carbon fiber bundles in a fiber placement machine, the carbon fiber bundles need to maintain stable tension, which is fundamental to ensuring placement quality and precision.

[0003] Defects and shortcomings of existing technology: 1. Currently, the tension control of automatic fiber placement machines when laying carbon fiber bundles is mainly based on semi-closed loop, that is, the tension is calculated by changing the displacement or angle. This may lead to a deviation between the calculated result and the actual value. 2. Some existing tension control and testing devices are only used for testing thermosetting filaments, or only for testing thermoplastic filaments, or only for testing filaments with a width of no more than 6.35 mm; 3. Open-type carbon fiber tow tension detection devices can easily cause injury to fingers and other objects when operating at high speeds, posing a certain safety hazard. In addition, they are not aesthetically pleasing.

[0004] Therefore, there is an urgent need in this field for a servo motor control method for an automated carbon fiber layup device that can achieve precise tension control, is compatible with various carbon fiber tow types and widths, and has higher safety.

[0005] The information disclosed in this background section is intended only to enhance the understanding of the overall background of the invention and should not be construed as an admission or in any way implying that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0006] The purpose of this invention is to provide a servo motor control method for an automatic carbon fiber layup device that can achieve precise tension control, is compatible with various carbon fiber tow types and widths, and has higher safety.

[0007] To achieve the above objectives, the present invention provides the following solution: A servo motor control system for an automated carbon fiber layup device includes: Electrical cabinet; The PLC control panel is located inside the electrical cabinet; Tension testing and winding unit, wherein the tension testing and winding unit further includes: The unloading reel assembly is used to carry carbon fiber bundles; Take-up reel assembly for collecting filament bundles; The feeding tension sensor is used to detect the tension of the filament bundle during the feeding process; The take-up tension sensor is used to detect the tension of the filament bundle during the take-up process; An ultrasonic sensor for feeding roll diameter is used to detect the diameter of the material on the feeding roll. Ultrasonic sensor for take-up roll diameter, used to detect the diameter of the take-up roll; Tension generator, used to provide tension to the filament bundle; and Traction assembly, used to pull the filament bundle; The PLC control panel is configured to execute either a semi-closed-loop tension control mode or a fully closed-loop tension control mode. The semi-closed-loop tension control mode is as follows: the diameter of the carbon fiber bundle is automatically detected by the ultrasonic sensor of the unwinding roll diameter and / or the ultrasonic sensor of the winding roll diameter, and tension calculation is automatically performed. Then, the controller automatically adjusts the tension generation source to control the tension. The fully closed-loop tension control mode is as follows: the tension of the carbon fiber bundle is measured by the feeding tension sensor and / or the receiving tension sensor, and then the controller automatically adjusts the tension generation source to control the tension of the bundle.

[0008] Optionally, the tension source is a brake or a motor.

[0009] Optionally, a guide wheel is also included, the groove width of which is configured to meet the tension test of carbon fiber tows with a maximum width of 12.7 mm.

[0010] Optionally, a protective cabinet is also included, with the tension testing and winding unit located inside the protective cabinet; the shell of the protective cabinet is a transparent PVC board.

[0011] Optionally, the tension testing and winding unit further includes: A backsheet winding reel is used to peel off and collect the backsheet from the carbon fiber bundles while simultaneously pulling the bundles for transport. Lead screw traction assembly: used to axially pull the wire bundle back and forth during material collection; Tension roller assembly: used to tension the filament bundle, so that the filament bundle always maintains a certain tension; Traction motor: Used to drive the traction assembly and convey the filament bundle to the receiving area; Lead screw traction motor: used to drive the movement of the lead screw; Take-up reel motor: Used to drive the take-up reel to rotate, thereby collecting the filament bundle.

[0012] Optional features also include: ventilation openings: since the electronic components inside the electrical cabinet generate heat when they are working, ventilation openings are used for the circulation of hot and cold air to reduce the temperature inside the cabinet; Long handle: Used for easy movement of electrical cabinets; Power interface: Used to connect to a power source and provide electrical power to the electrical cabinet; Emergency stop button: Used to stop the test cabinet from working immediately in case of an emergency; Lighting: Used to illuminate the interior of the protective cabinet so that the test status can be observed; Switch buttons: used to start, stop, jog, and stop the machine; Main switch: Used to connect the power supply and provide electrical energy to the electrical cabinet; Fan: Used to dissipate heat from the electrical cabinet and lower the internal temperature. Base: Used to support and move the device.

[0013] A servo motor control method for an automated carbon fiber layup device includes the following steps: Select either semi-closed-loop tension control mode or full closed-loop tension control mode via the PLC control panel. If the semi-closed-loop tension control mode is selected, the diameter of the carbon fiber bundle is automatically detected by the ultrasonic sensor for unwinding and / or the ultrasonic sensor for rewinding, and tension calculation is automatically performed. Then, the controller automatically adjusts the tension generation source to control the tension. If the full closed-loop tension control mode is selected, the tension of the carbon fiber bundle is measured by the feeding tension sensor and / or the receiving tension sensor, and then the controller automatically adjusts the tension generation source to control the tension of the bundle.

[0014] Optionally, the semi-closed-loop tension control mode generates tension by controlling the resistance torque, while the fully closed-loop tension control mode generates tension by controlling the speed.

[0015] Optionally, it also includes: verifying the accuracy of the semi-closed-loop tension control mode through the full closed-loop tension control mode, and correcting the semi-closed-loop tension control mode based on the verification results.

[0016] Optionally, it also includes: peeling and collecting the back film on the carbon fiber tow via a back film winding reel, while simultaneously traction tow delivery.

[0017] Optionally, it also includes: using a lead screw traction assembly to axially pull the filament bundle back and forth during take-up, so that the filament bundle is evenly wound on the take-up reel.

[0018] Compared with the prior art, the present invention has the following beneficial effects: This invention offers dual-mode tension control, balancing accuracy and adaptability: It supports both semi-closed-loop and full-closed-loop tension control modes, allowing users to choose flexibly according to their needs. The semi-closed-loop mode uses an ultrasonic sensor to detect the roll diameter and calculate the tension, suitable for conventional working conditions; the full-closed-loop mode uses a tension sensor to provide real-time feedback and adjust the tension, significantly improving tension control accuracy.

[0019] It can verify and correct the semi-closed-loop mode: The precise tension value obtained through the full closed-loop tension control method can verify the calculation results of the semi-closed-loop tension control mode and correct it according to the deviation, thereby further improving the control reliability of the semi-closed-loop mode.

[0020] Compatible with multiple tow types and wider tow widths: This device is designed with a back film winding reel, which can be used for tension testing of thermosetting prepreg tows and thermoplastic prepreg tows; at the same time, the guide wheel has been improved, and its groove width can meet the needs of carbon fiber tows with a maximum width of 12.7mm, which significantly improves the versatility of the equipment.

[0021] Enhanced operational safety and aesthetic appeal: The tension testing and winding unit is housed inside a protective cabinet made of transparent PVC panels. This facilitates observation of the testing process, effectively prevents high-speed rotating parts from injuring operators, and also makes the overall machine look cleaner and more aesthetically pleasing.

[0022] Integrated automatic winding function improves work efficiency: The device, through the cooperation of the lead screw traction component and the take-up reel component, can automatically achieve axial back-and-forth traction of the filament bundle during the take-up process, so that the filament bundle is evenly wound on the take-up reel, reducing manual intervention and improving the winding quality and automation level. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a schematic diagram of the servo motor control system of the automatic carbon fiber placement equipment provided in an embodiment of the present invention.

[0025] Figure 2 This is a schematic diagram of the main components of the tension testing and winding unit provided in an embodiment of the present invention.

[0026] Figure 3 A schematic diagram illustrating the tension generation principle provided in an embodiment of the present invention.

[0027] Figure 4 This is a schematic diagram of the fully closed-loop tension control principle provided in an embodiment of the present invention.

[0028] Figure 5 A schematic diagram of the semi-closed-loop tension control principle provided in an embodiment of the present invention. Detailed Implementation

[0029] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0030] The purpose of this invention is to provide a servo motor control system and method for an automatic carbon fiber layup device that can achieve precise tension control, is compatible with various carbon fiber tow types and widths, and has higher safety.

[0031] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0032] Example 1:

[0033] This embodiment provides a servo motor control system for an automatic carbon fiber layup device, such as... Figure 1 As shown, it includes: Electrical cabinet: Used to protect the normal operation of components and provide power distribution and circuit protection functions; Ventilation openings: Since the electronic components inside the electrical cabinet generate heat when they are working, ventilation openings are used for the circulation of hot and cold air to reduce the temperature inside the cabinet; Long handle: Used for easy movement of electrical cabinets; Power interface: Used to connect to a power source and provide electrical power to the electrical cabinet; Emergency stop button: Used to stop the test cabinet from working immediately in case of an emergency; Protective cabinet: Used to prevent injury to the human body during testing. The outer shell of the protective cabinet is made of transparent PVC board, which allows clear observation of the internal testing conditions. Lighting: Used to illuminate the interior of the protective cabinet so that the test status can be observed; PLC control panel: Used to control the conveying speed and display parameters such as material radius, tension and speed; Switch buttons: used to start, stop, jog, and stop the machine; Main switch: Used to connect the power supply and provide electrical energy to the electrical cabinet; Fan: Used to dissipate heat from the electrical cabinet and lower the internal temperature. Base: Used to support and move the device; Tension testing and winding unit: used for tension testing and winding of carbon fiber filaments.

[0034] like Figure 2 As shown, the tension testing and winding unit includes: Back film winding reel: used to peel and collect the back film on the carbon fiber bundle while simultaneously pulling the bundle for transport; Feed tension sensor: used to detect the tension of the filament bundle during the feeding process; Take-up tension sensor: used to detect the tension of the filament bundle during the take-up process; Ultrasonic sensor for take-up roll diameter: used to detect the diameter of the take-up roll. Lead screw traction assembly: used to axially pull the wire bundle back and forth during material collection; Take-up reel assembly: used to collect filament bundles, which can be wound onto the take-up reel; Ultrasonic sensor for unloading roll diameter: used to detect the diameter of the material on the unloading roll; Traction assembly: used to pull the filament bundle, drawing the material on the feed reel to the take-up area; Feed reel assembly: used to carry carbon fiber bundles; Tension roller assembly: used to tension the filament bundle, so that the filament bundle always maintains a certain tension; Tension source: can be a brake or a motor, providing tension to the filament bundle; Traction motor: Used to drive the traction assembly and convey the filament bundle to the receiving area; Lead screw traction motor: used to drive the movement of the lead screw; Take-up reel motor: Used to drive the take-up reel to rotate, thereby collecting the filament bundle.

[0035] Example 2:

[0036] This embodiment provides a servo motor control method for an automatic carbon fiber layup equipment, including the following steps: selecting a semi-closed-loop tension control mode or a full-closed-loop tension control mode through a PLC control panel; If the semi-closed-loop tension control mode is selected, the diameter of the carbon fiber bundle is automatically detected by the ultrasonic sensor for unwinding and / or the ultrasonic sensor for rewinding, and tension calculation is automatically performed. Then, the controller automatically adjusts the tension generation source to control the tension. If the full closed-loop tension control mode is selected, the tension of the carbon fiber bundle is measured by the feeding tension sensor and / or the receiving tension sensor, and then the controller automatically adjusts the tension generation source to control the tension of the bundle.

[0037] like Figure 3As shown, there are three ways to generate tension: tension generated by friction, tension generated by controlling the resistance torque, and tension generated by controlling the speed.

[0038] This device uses both resistance torque and speed control to generate tension. The semi-closed-loop tension control mode uses resistance torque to generate tension, while the fully closed-loop tension control mode uses speed control to generate tension.

[0039] like Figure 4 As shown, the closed-loop tension control principle is as follows: a specific tension value is set for the carbon fiber bundle, and the rotation speed of the unwinding reel is adjusted in real time through feedback from the tension sensor, thereby ensuring tension stability.

[0040] like Figure 5 As shown, the semi-closed-loop tension control principle is as follows: the ultrasonic sensor automatically detects the roll diameter of the carbon fiber bundle and automatically calculates the tension, and then the controller automatically adjusts the brake to control the tension.

[0041] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the systems disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the descriptions are relatively simple; relevant parts can be referred to the method section.

[0042] This document uses specific examples to illustrate the principles and implementation methods of the present invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of the present invention. Furthermore, those skilled in the art will recognize that, based on the ideas of the present invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. A servo motor control system for an automatic carbon fiber layup device, characterized in that, include: Electrical cabinet; The PLC control panel is located inside the electrical cabinet; Tension testing and winding unit, wherein the tension testing and winding unit further includes: The unloading reel assembly is used to carry carbon fiber bundles; Take-up reel assembly for collecting filament bundles; The feeding tension sensor is used to detect the tension of the filament bundle during the feeding process; The take-up tension sensor is used to detect the tension of the filament bundle during the take-up process; An ultrasonic sensor for feeding roll diameter is used to detect the diameter of the material on the feeding roll. Ultrasonic sensor for take-up roll diameter, used to detect the diameter of the take-up roll; Tension generator, used to provide tension to the filament bundle; and Traction assembly, used to pull the filament bundle; The PLC control panel is configured to execute either a semi-closed-loop tension control mode or a fully closed-loop tension control mode. The semi-closed-loop tension control mode is as follows: the diameter of the carbon fiber bundle is automatically detected by the ultrasonic sensor of the unwinding roll diameter and / or the ultrasonic sensor of the winding roll diameter, and tension calculation is automatically performed. Then, the controller automatically adjusts the tension generation source to control the tension. The fully closed-loop tension control mode is as follows: the tension of the carbon fiber bundle is measured by the feeding tension sensor and / or the receiving tension sensor, and then the controller automatically adjusts the tension generation source to control the tension of the bundle.

2. The servo motor control system of the automatic carbon fiber layup equipment according to claim 1, characterized in that, The tension source is a brake or a motor.

3. The servo motor control system of the automatic carbon fiber layup equipment according to claim 1, characterized in that, It also includes a guide wheel, the groove width of which is configured to meet the tension test of carbon fiber tows with a maximum width of 12.7 mm.

4. The servo motor control system of the automatic carbon fiber layup equipment according to claim 1, characterized in that, It also includes a protective cabinet, and the tension testing and winding unit is located inside the protective cabinet; the shell of the protective cabinet is a transparent PVC board.

5. The servo motor control system of the automatic carbon fiber layup equipment according to claim 1, characterized in that, The tension testing and winding unit also includes a back film winding reel for peeling off and collecting the back film on the carbon fiber bundle, while simultaneously pulling the bundle for transport.

6. A servo motor control method for an automatic carbon fiber layup device, characterized in that, The system applied to any one of claims 1 to 5 includes the following steps: Select either semi-closed-loop tension control mode or full closed-loop tension control mode via the PLC control panel. If the semi-closed-loop tension control mode is selected, the diameter of the carbon fiber bundle is automatically detected by the ultrasonic sensor for unwinding and / or the ultrasonic sensor for rewinding, and tension calculation is automatically performed. Then, the controller automatically adjusts the tension generation source to control the tension. If the full closed-loop tension control mode is selected, the tension of the carbon fiber bundle is measured by the feeding tension sensor and / or the receiving tension sensor, and then the controller automatically adjusts the tension generation source to control the tension of the bundle.

7. The servo motor control method for the automatic carbon fiber layup equipment according to claim 6, characterized in that, The semi-closed-loop tension control mode generates tension by controlling the resistance torque, while the fully closed-loop tension control mode generates tension by controlling the speed.

8. The servo motor control method for the automatic carbon fiber layup equipment according to claim 6, characterized in that, Also includes: The accuracy of the semi-closed-loop tension control mode is verified by the full closed-loop tension control mode, and the semi-closed-loop tension control mode is corrected based on the verification results.

9. The servo motor control method for the automatic carbon fiber layup equipment according to claim 6, characterized in that, Also includes: The back film is peeled off and collected from the carbon fiber bundle by wrapping the back film around a spool, while the bundle is simultaneously pulled and transported.

10. The servo motor control method for the automatic carbon fiber layup equipment according to claim 6, characterized in that, Also includes: The lead screw traction assembly pulls the filament bundle axially back and forth during the take-up process, so that the filament bundle is evenly wound on the take-up reel.

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