Small and medium-sized composite molding multi-station molding equipment

Abstract

The present application relates to a kind of multi-station die pressing equipment, specifically to a kind of small and medium-sized composite forming multi-station die pressing equipment;Including support frame, support frame is equipped with multiple sets of module, module is arrayed arrangement, each set of module is equipped with drive device and pressure regulating element separately;It also includes the intelligent control module for controlling drive device;Module includes heating module and forming module;Forming module includes multiple groups of forming sub-mold, the number of forming sub-mold is same with the number of workpiece to be formed site, forming sub-mold only covers workpiece to be formed site in;Heating module includes multiple heating parts, heating part is interval arrangement;Heating part is equipped with the cavity that can be embedded forming sub-mold;Heating part includes heating base and heating cover;Heating module is also equipped with the positioning module for product in it.The small and medium-sized composite forming multi-station die pressing equipment of the present application has the advantages of flexible operation, strong process adaptability, multi-station parallel and strong adaptability to various products.

Description

Technical Field

[0001] This invention relates to a multi-station molding equipment, specifically a small-to-medium-sized multi-station molding equipment for composite material forming. Background Technology

[0002] Composite materials (such as carbon fiber reinforced resin matrix composites) have been widely used in aerospace, automotive, and sporting goods industries. To achieve optimal product performance, two key steps—heating and pressurization—are required to cure and densify the material, resulting in a predetermined geometry. Current molding processes typically include autoclave molding, compression molding, and vacuum infusion.

[0003] Among the existing mainstream molding processes: Autoclave process: (1) Low production efficiency and thermal efficiency: Due to the need to heat the huge tank space and circulating medium, the heat capacity is large, resulting in slow heating and cooling rates, low energy utilization, and molding time usually more than 2 hours. It is only suitable for complex curved surfaces or super-large parts, and is not suitable for mass production of low-priced small parts. (2) Pressure limitation and expensive equipment: Due to the safety design pressure of the tank, the static pressure of the fluid it provides is usually low (generally less than 1.0 MPa), which is difficult to meet the process requirements of some materials that require extremely high density or high-pressure compaction molding. (3) Cannot be adapted to some special products: For products containing parts that are not resistant to high temperature or foamed structures, due to the overall heating characteristics of the autoclave, the parts may be damaged or the foamed structure may expand secondary, resulting in product scrap.

[0004] Compression molding (hydraulic / mechanical): (1) Insufficient flexibility: It is usually designed as a single station. When it is necessary to process small batches of small-sized parts, there is a significant energy waste. Mold replacement and debugging are also cumbersome, and the process flexibility is poor. (2) A new mold must be designed for each new steering wheel, which prolongs the new product launch cycle and requires a large capital investment. (3) Poor adaptability to irregular parts: For irregular parts with embedded skeletons (such as steering wheels with skeletons), when the traditional flatbed hydraulic press presses down, it will contact the skeleton first rather than the mold surface. It is necessary to design a special transition tooling, which increases the complexity of the process. (4) The equipment is large and heavy and has high maintenance costs, and there is a risk of oil leakage and pollution.

[0005] In summary, existing composite material molding equipment generally suffers from drawbacks such as bulky equipment, high energy consumption, high maintenance costs, poor process flexibility, and difficulty in multi-station parallel operation. There is an urgent need for a new type of molding equipment that is compact in structure, low in energy consumption, easy to maintain, can operate in multiple parallel stations, and is highly adaptable to various products. Summary of the Invention

[0006] The present invention aims to provide a multi-station molding equipment for small and medium-sized composite materials, which has the advantages of flexible operation, strong process adaptability, multi-station parallel operation and strong adaptability to various products.

[0007] This solution includes a small-to-medium-sized composite material molding multi-station molding equipment, comprising a support frame on which multiple modules are mounted in an array. Multiple different molds can be installed simultaneously on the same frame, enabling independent single-station or multi-station operation, or array-style segmented pressing of long, strip-shaped workpieces, greatly improving equipment utilization. Each module is equipped with a separate drive device and pressure regulating element, allowing flexible adjustment of the molding pressure according to the process requirements of different composite material products. The solution also includes an intelligent control module for controlling the drive device. The module includes a heating module and a forming module. The forming module includes multiple forming sub-molds, the number of which is the same as the number of parts to be formed on the product. Specifically, if there are two parts to be formed, there are two sets of forming sub-molds. The forming sub-mold only covers the parts to be formed on the workpiece, with the rest of the workpiece extending from the port of the forming sub-mold. A limiting card is provided at the port of the forming sub-mold to ensure that a closed cavity is formed after the forming sub-mold is closed. Because the forming sub-mold only targets the parts of the workpiece that need to be processed, it has extremely high process adaptability for irregularly shaped workpieces with skeletons and workpieces requiring localized heating. The heating module includes multiple heating sections spaced apart. When processing irregularly shaped parts with embedded skeletons (such as a steering wheel with a skeleton), these intervals can avoid the product skeleton and areas with low heat resistance. Compared to traditional flatbed hydraulic presses that contact the skeleton first rather than the mold surface during pressing, requiring specially designed transition tooling, this application reduces process complexity. The heating unit has a cavity that can be embedded in the molding sub-mold, allowing heat to directly act on the core area of ​​the product through the molding sub-mold. This results in a rapid heating rate, significantly shortening the production cycle and saving energy. The heating unit includes a heating base and a heating cover. As a high-value, universal component, the heating module can be shared with multiple molding modules. Therefore, after pressure molding, the molding sub-mold can be removed and placed into the next molding sub-mold. The heating module does not require a molding cooling cycle, which not only reduces heat loss and significantly increases production capacity but also improves energy efficiency, aligning with the concept of green manufacturing. The heating module also includes a positioning module for fixing the product. This positioning module works in conjunction with the molding sub-mold to fix the relative position of the product and the molding sub-mold, ensuring a high product qualification rate.

[0008] Furthermore, it also includes a heat insulation panel that covers the exterior of the heating module. This further reduces heat loss and improves energy efficiency.

[0009] Furthermore, the cavity is located on the heating base, and the sidewalls of the cavity are angled, with the cavity gradually widening from the bottom to the opening. The outer wall of the molding sub-mold is angled to match the cavity, facilitating the replacement and placement of the molding sub-mold.

[0010] Furthermore, both the heating cover and the heating base are equipped with heating elements; the heating elements in the heating base are arranged in a three-dimensional surround cavity, which, together with the heating cover, achieves full-encirclement heating of the forming sub-mold, resulting in extremely high heating efficiency.

[0011] Furthermore, the heating cover is connected and fixed via a connecting plate; the heating module also includes a pressure boosting module, one end of which is fixedly connected to the connecting plate, and the other end can abut against the product. The design of the limiting module, combined with the downward pressure of the pressure boosting module, ensures that the position and quality of each batch of products produced are highly consistent, significantly improving the product qualification rate and quality stability.

[0012] Furthermore, a slot is provided at the port of the forming sub-mold, and the limiting card is engaged in the slot. Because some workpiece structures have narrow reserved gaps, the limiting card is relatively thin and easily damaged during installation and removal. Therefore, it is designed as a replaceable structure with a slot connection.

[0013] Furthermore, it also includes a handle, which is disposed on the heating module.

[0014] Furthermore, the heating cover is also provided with a relief groove corresponding to the spokes.

[0015] Furthermore, the intelligent control module is also equipped with temperature measurement and alarm functions.

[0016] The advantages of this invention are: 1) The overall structure of the equipment is lighter and more compact, resulting in lower manufacturing costs and easier handling and installation; 2) The use of replaceable molding sub-molds ensures that the heating module remains at its operating temperature for extended periods, eliminating the need for heating and cooling, thus achieving near-continuous production. Compared to traditional processes, energy consumption is reduced by 30-40%, significantly improving production efficiency and energy utilization; 3) Since the molding sub-mold only covers the area of ​​the steering wheel to be molded, the specific heating method can be selected based on the actual product, eliminating the need to heat the entire autoclave space. Heat can be directly applied to the core molding area, resulting in a rapid heating rate; 4) The molding pressure can be flexibly adjusted according to the process requirements of different composite material products, demonstrating strong process adaptability. The quantity and spacing can be configured according to the size and batch requirements of the workpiece being processed, enabling independent operation of single or multi-station workpieces or array-type segmented pressing of long strip workpieces; 5) The forming sub-mold is small in size and light in weight, and can be picked up and replaced manually or by ordinary robotic arms, avoiding the problems of traditional molds requiring large equipment such as forklifts for transportation and cumbersome operation due to their large weight; 6) The clearance between forming sub-molds and between heating parts allows the press pressure to act directly on the mold surface without the need for a transition tooling with a skeleton; it also avoids high-temperature heating of parts that are not resistant to high temperatures or foamed structures; it has high adaptability to the process of products with skeletons, irregular shapes, and local heating; 7) The heating base, as a high-value general-purpose component, can be shared by multiple low-cost forming modules. It can be shared with multiple forming modules (different models of the same product, such as different models of steering wheels, only the mold cavity of the forming sub-mold is different). When developing new products, only forming modules and positioning modules matching the new product need to be designed and manufactured, reducing mold development costs by more than 50%. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the multi-station molding equipment for small composite materials in this invention; Figure 2 This is a structural diagram of the module in the multi-station molding equipment for small composite materials of the present invention; Figure 3 This is a schematic diagram of the molding sub-mold and heating base in the multi-station molding equipment for small composite material forming of the present invention; Figure 4 This is a schematic diagram of the heating cover in the multi-station molding equipment for small composite materials of the present invention; Figure 5 This is a schematic diagram of the steering wheel and the molding sub-mold in the multi-station molding equipment for small composite material forming of the present invention.

[0018] Figure 6 This is a schematic diagram of the heating base in the multi-station molding equipment for small composite materials of the present invention; Figure 7 This is a structural diagram of the molding sub-mold in the multi-station molding equipment for small composite material forming in this invention.

[0019] In the diagram, 1 is the module, 1-1 is the molding sub-mold, 1-11 is the upper mold, 1-12 is the lower mold, 1-2 is the slot, 1-3 is the limiting card, 1-4 is the locking block, 1-5 is the groove, 2 is the heating part, 2-1 is the heating base, 2-2 is the heating cover, 2-3 is the cavity, 2-4 is the connecting plate, 2-5 is the heating oil circuit, 3 is the positioning block, 4 is the elastic rubber, 5 is the heat insulation plate, 6 is the handle, 7 is the support frame, 8 is the cylinder, 9 is the adjustable valve with pressure gauge, and 10 is the steering wheel. Detailed Implementation

[0020] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments: according to Figures 1 to 7 As shown, this solution provides a multi-station molding equipment for small and medium-sized composite materials. Multiple modules are mounted on the support frame 7, arranged in an array. Each module is equipped with its own drive device and pressure regulating element. In this embodiment, the drive device is preferably a cylinder 8, which is controlled independently or in groups via a valve control circuit. The pressure regulating element is preferably an adjustable valve 9 with a pressure gauge. Specifically, the number and spacing of the modules can be configured according to the product size and batch requirements. Because each module is equipped with its own cylinder 8, the pressure of each module can be controlled independently or in groups, thereby enabling single-station or multi-station independent operation or array-type segmented pressing of long strip-shaped workpieces. Multiple molds can also be installed simultaneously for parallel operation, significantly increasing the output per unit time, making it particularly suitable for the mass production of small and medium-sized parts. Preferably, the working air pressure of the cylinder 8 is precisely controlled by the adjustable valve 9 with a pressure gauge, allowing for flexible adjustment of the molding pressure according to the process requirements of different composite material products, resulting in strong process adaptability. An adjustable valve 9 with a pressure gauge is installed on the main air supply line. Operators can precisely set the working air pressure of the input cylinder 8 by adjusting a knob. The pressure gauge displays the current air pressure value in real time, ensuring stable and controllable air pressure during the molding process. The adjustable range of the valve 9 with a pressure gauge can cover the differentiated molding pressure requirements of different composite material products. The support frame 7 is preferably constructed of steel profiles connected by welding or bolts, possessing sufficient overall rigidity and stability to withstand the mold-closing reaction force generated when multiple cylinders 8 operate simultaneously. A horizontal beam is provided above the support frame 7 for mounting the cylinders 8; the support frame 7 also includes a worktable.

[0021] The module includes a heating module and a forming module. The forming module includes multiple forming sub-molds 1-1, the number of which is the same as the number of parts of the workpiece to be formed. In this embodiment, as... Figure 3 , Figure 5As shown, taking a typical passenger car carbon fiber steering wheel 10 as an example, such steering wheels usually use genuine leather / suede at the 3 and 9 o'clock positions (grip area), and carbon fiber at the 6 o'clock position (lower rim) and 12 o'clock position (upper rim). This means the steering wheel 10 (workpiece) has two areas to be molded; therefore, in this embodiment, there are two sets of molding sub-molds 1-1. The molding sub-mold 1-1 only covers the 6 o'clock (lower rim) and 12 o'clock (upper rim) positions of the steering wheel; the rest of the steering wheel 10 extends from the port of the molding sub-mold 1-1. Therefore, for steering wheels with a frame (including irregularly shaped products with an embedded frame), the pressure from mold closing acts directly on the molding sub-mold 1-1, eliminating the need for transitional tooling for the frame. For example... Figure 7 As shown, a limiting card 1-3 is provided at the port of the molding sub-mold 1-1. The limiting card 1-3 is provided with a slot that is compatible with the steering wheel frame. After the molding sub-mold 1-1 is closed, its mold cavity forms a closed cavity.

[0022] The number of heating sections 2 is the same as the number of molding sub-molds 1-1. The heating module includes two heating sections 2, which are spaced apart to avoid the foamed layers at the 3 o'clock and 9 o'clock positions (hand grip area) of the steering wheel. Each heating section 2 has a cavity 2-3 that can be embedded in the molding sub-mold 1-1, providing high process adaptability for products with irregular shapes containing skeletons and products requiring localized heating. Specifically, each heating section 2 includes a heating base 2-1 and a heating cover 2-2. The heating base 2-1 is fixed to the worktable, and the heating cover 2-2 is rigidly connected to the end of the telescopic rod of the cylinder 8, thereby driving the heating cover 2-2 to rapidly rise and fall vertically under pneumatic pressure, realizing the mold opening and closing actions. The cavity 2-3 is located on the heating base 2-1, and the side walls of the cavity 2-3 have an inclination angle, gradually expanding from the bottom upwards. The outer wall of the molding sub-mold 1-1 has an inclination angle adapted to the cavity 2-3, facilitating the pulling out and insertion of the molding sub-mold 1-1.

[0023] Both the heating cover 2-2 and the heating base 2-1 are equipped with heating elements. Specifically, the heating element in the heating base 2-1 has a three-dimensional surround design at the bottom and around the periphery of the cavity 2-3, working in conjunction with the heating cover 2-2 to achieve full-encirclement heating of the molding sub-mold 1-1. The heating element can be selected from electric heating elements (such as heating rods or heating tubes) or oil temperature heating mode with built-in circulating oil circuit (connected to an external mold temperature controller to provide constant temperature circulating hot oil) according to process requirements. Both heating methods can achieve precise local heating of the mold cavity 2-3 area, and different heating methods such as flat oil circuit heating or electric heating plates can also be used.

[0024] It also includes an intelligent control module, which integrates a programmable timer and an audible and visual alarm module, and is electrically linked to the air valve control circuit. The heating mold is equipped with a temperature measuring device (such as a thermocouple) to monitor and provide feedback on the mold temperature in real time.

[0025] Preferably, the heating module also includes a positioning module for fixing the steering wheel frame. In this embodiment, positioning block 3 is preferably used to position the steering wheel frame, such as... Figure 6 As shown, the positioning method of embedding the heating part 2 into the molding sub-mold 1-1 accurately positions the steering wheel relative to the molding sub-mold 1-1. The positioning module can also use pin positioning, tapered positioning, or magnetic positioning to position parts of the steering wheel frame such as spokes and center base.

[0026] To facilitate the opening and closing of the heating module, the two heating covers 2-2 are connected and fixed by a connecting plate 2-4, and the two heating bases 2-1 are integrated into one structure. The heating module also includes a pressure boosting module, which in this embodiment is preferably elastic rubber 4. This elastic rubber 4 is installed on the lower part of the connecting plate 2-4 and can abut against the steering wheel when the heating module is closed, applying appropriate downward pressure to the steering wheel frame. Specifically, the elastic rubber 4 presses the steering wheel frame tightly onto the positioning block 3, maintaining the stability of the steering wheel frame during the molding process and ensuring that the position and quality of each molded product are highly consistent. Preferably, the pressure boosting module can also be replaced by a pneumatic spring, hydraulic cylinder, or disc spring, as long as it can apply appropriate downward pressure to the steering wheel frame when the mold is closed.

[0027] To further reduce heat loss and improve energy efficiency, the heating module is covered with a heat insulation plate 5. The heat insulation plate 5 is preferably made of a material with low thermal conductivity, such as bakelite. The heat insulation plate 5 not only ensures operational safety and prevents employee burns, but also forms a heat insulation layer around the heating module, reducing heat loss to the surrounding environment and lowering energy consumption.

[0028] like Figure 7As shown, the molding sub-mold 1-1 includes an upper mold 1-11 and a lower mold 1-12. The upper mold 1-11 and the lower mold 1-12 are quick-disassembly structures, preferably connected by bolts after mold closing. A slot 1-2 is provided at the port of the molding sub-mold 1-1, and a limiting card 1-3 is engaged in this slot 1-2. For example, the gap between the foam structure at the 3 o'clock and 9 o'clock positions (hand grip area) of the steering wheel and the carbon fiber structure at the 6 o'clock position (lower wheel rim) and 12 o'clock position (upper wheel rim) is small. Specifically, the upper mold 1-11 has an upper slot 1-2, and the lower mold 1-12 has a lower slot 1-2; the limiting card 1-3 includes an upper card and a lower card, which are inserted into the upper slot 1-2 and the lower slot 1-2 respectively. Preferably, the upper card and the lower card are both fixedly connected to the upper mold 1-11 and the lower mold 1-12 respectively by locking blocks 1-4. One end of the upper slot 1-2 is provided with a groove 1-5, and the locking block 1-4 is placed in the groove 1-5 and connected to the upper mold 1-11 by bolts; one end of the lower slot 1-2 is provided with a groove 1-5, and the locking block 1-4 is placed in the groove 1-5 and connected to the lower mold 1-12 by bolts; at this time, the locking block 1-4 clamps the upper and lower cards together. The fixing hole on the limiting card 1-3 is adapted to the cross-sectional shape of the steering wheel frame (workpiece) to fix the steering wheel frame.

[0029] The heating module is equipped with a handle 6, which is connected by a screw-in screw. This allows for easy manual pulling out or pushing back of the heating base 2-1. Preferably, a snap-on quick-release handle 6, a magnetic handle 6, or a sliding rail handle 6 can also be used, as long as it allows for quick pulling out of the heating base 2-1 by a single person. To facilitate quick replacement of the molding sub-mold 1-1, multiple sets of screw holes can be pre-set on the molding sub-mold 1-1. By screwing the handle into these screw holes, a single person can quickly change the mold, suitable for small and micro-sized enterprises with low production volumes. Alternatively, a magnetic handle can be used for quick replacement via a robotic arm, suitable for medium and large enterprises with high production volumes. This reduces the difficulty of operation and the reliance on large auxiliary equipment such as forklifts.

[0030] Preferably, the drive device can also be a motor drive (such as an electric cylinder, a lead screw and nut mechanism), a hydraulic drive, or a manual mechanical drive; the pressure regulating element can be an electrically controlled pressure regulating element such as an electric proportional valve.

[0031] The workflow is as follows: Step 1: Turn on the mold temperature controller to preheat the heating module; turn on the main air supply valve and adjust the air pressure to the specified value through the adjustable valve 9 with pressure gauge; Step 2: After monitoring the temperature with a temperature measuring device and waiting for the temperature to reach the process set temperature, raise the upper heating cover 2-2 to a safe height and place the prepared workpiece and forming sub-mold 1-1 on the heating base 2-1; then drive the heating cover 2-2 to descend and apply the set forming pressure to the workpiece.

[0032] Step 3: After mold closing and pressurization, the operator sets the pressure holding and curing time in the intelligent control module according to the composite material process specifications. After the pressure holding timer ends, a signal is sent to the air valve control circuit to drive cylinder 8 to lift the heating cover 2-2, and at the same time triggers an audible and visual alarm to prompt the operator to come and retrieve the part. After the operator removes the workpiece and the molding sub-mold 1-1, one molding operation cycle is completed.

[0033] Therefore, this application uses an array of 8 cylinders (multi-station parallel arrangement) to drive mold closing, replacing the traditional hydraulic / autoclave solution. The entire machine structure consists of a steel forming frame + multiple sets of 8 cylinders + upper and lower heating molds + heat insulation plate 5 + air valve switch + timer alarm device; 1. It is relatively energy-saving, as it does not require heating the air inside the autoclave as a whole, nor does it require heating the entire panel of the press. With the reasonable selection of heating equipment and the setting of heat insulation plate 5, point-to-point heating and forming of sub-molds 1-1 and materials: 2. Multi-station parallel operation, unlike the traditional single-station press, this application can install multiple sets of different molds on the same frame at the same time, realizing the simultaneous pressing of different products, which greatly improves the equipment utilization rate; 3. Each set of molds is designed as an independent module, which can be quickly moved in and out of the worktable. Combined with the vertical lifting of cylinder 8, the mold replacement and maintenance are very convenient, making it suitable for flexible production of multiple varieties and small batches; the timed automatic alarm device is linked with the air valve control circuit to realize semi-automatic operation of automatic mold opening and alarm; the entire pressure holding process does not require on-site operation by operators, effectively reducing the frequency of operators' contact with high-temperature molds and the operational risks, and simplifying the production process.

[0034] The above descriptions are merely embodiments of the present invention, and common knowledge regarding specific structures and characteristics in the solutions is not described in detail here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the structure of the present invention, and these should also be considered within the scope of protection of the present invention. These modifications and improvements will not affect the effectiveness of the implementation of the present invention or the practicality of the patent.

Claims

1. A multi-station molding machine for small and medium-sized composite materials, comprising a support frame, wherein multiple sets of modules are mounted on the support frame, characterized in that: The modules are arranged in an array, and each module is equipped with a separate drive device and pressure regulating element; it also includes an intelligent control module for controlling the drive device; the module includes a heating module and a molding module; The molding module includes multiple molding sub-molds, the number of which is the same as the number of parts of the workpiece to be molded. Each molding sub-mold only covers the parts of the workpiece to be molded, and the rest of the workpiece extends out from the port of the molding sub-mold. The port of the molding sub-mold is provided with a limiting card for fixing the workpiece. The heating module includes multiple heating sections spaced apart; each heating section has a cavity into which a molding sub-mold can be embedded; each heating section includes a heating base and a heating cover. The heating module also includes a positioning module for the product.

2. The multi-station molding equipment for small and medium-sized composite materials according to claim 1, characterized in that: It also includes a heat insulation plate that covers the outside of the heating module.

3. The multi-station molding equipment for small and medium-sized composite materials according to claim 1, characterized in that: The cavity is located on the heating base, and the side wall of the cavity is provided with an inclination angle; the outer wall of the molding sub-mold is provided with an inclination angle that matches the cavity.

4. The multi-station molding equipment for small and medium-sized composite materials according to claim 3, characterized in that: Both the heating cover and the heating base are equipped with heating elements; the heating elements in the heating base are arranged in a three-dimensional surrounding cavity.

5. The multi-station molding equipment for small and medium-sized composite materials according to claim 1, characterized in that: The heating cover is connected and fixed by a connecting plate; the heating module is also equipped with a pressurization module, one end of which is fixedly connected to the connecting plate, and the other end can abut against the steering wheel.

6. The multi-station molding equipment for small and medium-sized composite materials according to claim 1, characterized in that: The molded sub-mold has a slot at its port, and the limiting card is engaged in the slot.

7. The multi-station molding equipment for small and medium-sized composite materials according to claim 1, characterized in that: It also includes a handle, which is mounted on the heating module.

8. The multi-station molding equipment for small and medium-sized composite materials according to claim 1, characterized in that: The heating cover is also provided with relief grooves corresponding to the spokes.

9. The multi-station molding equipment for small and medium-sized composite materials according to claim 1, characterized in that: The intelligent control module also has temperature measurement and alarm functions.

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