A continuous automated slotting system for foam core

Abstract

The utility model discloses a kind of foamed core material continuous automation grooving systems, including first grooving unit, core material turnover mechanism and second grooving unit sequentially linked along foamed core material conveying direction, the core material turnover mechanism is used to convey to second grooving unit after the foamed core material that is processed by first grooving unit is turned over;First grooving unit and second grooving unit all include first grooving station, core material steering mechanism and second grooving station sequentially arranged along foamed core material conveying direction, and the core material steering mechanism is used to convey to second grooving station after the foamed core material that is processed by first grooving station is steered over.The utility model is processed by integration and automation design, realizes the continuous, efficient, high-quality processing of foamed core material double-sided multidirectional grooving, mainly applicable to wind power blade manufacturing field, for setting specific groove type on foamed core material to build it as high permeation medium, to significantly improve resin vacuum infusion effect.

Description

Technical Field

[0001] This utility model relates to the field of mechanical processing technology of foam core materials, specifically to a continuous automated grooving system for foam core materials of wind turbine blades. Background Technology

[0002] In the field of wind turbine blade manufacturing, foam core material, as an important structural material, needs to be constructed into a highly permeable medium by creating specific grooves on its surface. This improves the flowability and penetration of the resin during vacuum infusion, thereby achieving an ideal resin flow design and ensuring the uniformity of internal blade quality and structural reliability. Currently, common grooving methods mainly include single-sided shallow grooves, single-sided cross shallow grooves, double-sided shallow grooves, double-sided cross shallow grooves, and composite groove types on both sides (such as a cross shallow groove on the back + a cross deep groove on the front). Typical parameters for shallow grooves are: groove depth 2±0.5mm, groove width 2±0.5mm, and groove spacing 30mm; typical parameters for deep grooves are: groove depth T-2±0.5mm (T is the sheet thickness), groove width 2±0.5mm, and groove spacing 30mm.

[0003] It is worth noting that deep groove processing has specific requirements for the process sequence. To prevent material fragmentation during grooving, fiber cloth must be pre-attached to the reverse side of the board for structural reinforcement before processing the deep groove on the front side. If shallow grooves also need to be made on the reverse side, the process sequence is as follows: first complete the shallow groove processing on the reverse side, then attach the fiber cloth, and finally process the deep groove on the front side. The fiber cloth attachment process usually uses equipment such as a fabric bonding machine or an electric iron to melt the fiber cloth at high temperature and firmly bond it to the surface of the foam core material, forming a stable whole after cooling.

[0004] Currently, the grooving operation of foam core materials mainly relies on traditional manual operation. Its core is to use a single grooving machine for multi-step processing. Typical production processes include the following modes: For single-sided cross groove processing: the operator needs to manually load the board. After the equipment completes the processing of the straight groove in one direction, the operator removes the board, manually rotates it 90°, and loads it again to perform the second grooving, finally forming the cross groove. For double-sided grooving: After grooving one side, the operator needs to remove the board and manually flip it over before reloading it to perform grooving on the other side.

[0005] In addition, the dust and debris generated during the processing need to be cleaned manually using an air gun, and each grooving machine usually requires two operators, one responsible for loading and the other for unloading.

[0006] This existing model, which heavily relies on manual labor, has the following prominent shortcomings that urgently need to be addressed: Firstly, the level of automation is low, and labor costs are high. Every turning, flipping, and loading / unloading process requires manual intervention, which is not only time-consuming and labor-intensive with low production efficiency, but also easily causes dirt and dents on the surface of the board and damage to the edges and corners during frequent handling and adjustment, affecting product quality. Secondly, the processing parameters need to be adjusted frequently. Each time a new type of groove or a different direction is processed, the processing parameters of the equipment (such as the groove depth) need to be reset, making the processing process cumbersome.

[0007] Taking the processing of a "double-sided cross-grooved" board as an example, if a single machine is used, two operators need to repeat the loading, grooving, and unloading operations four times. If the groove size is different, the parameters also need to be adjusted. Even with a multi-machine collaborative mode (for example, using four machines and eight operators working together, with each machine completing one fixed process), although the parameters of each machine only need to be adjusted once, this mode still requires a large number of operators and still has the drawbacks of high labor costs and a high risk of dirt on the board surface and chipping at the edges.

[0008] Therefore, there is an urgent need in this field for a foam core material grooving device that can achieve continuous and automated production, reduce manual intervention, improve processing efficiency and consistency, and flexibly adapt to various grooving process requirements. Utility Model Content

[0009] To address the issues of low automation, discontinuous processing, and reliance on manual labor in existing technologies, this invention provides a continuous automated grooving system for foam core materials. This system aims to achieve continuous automated production, significantly reduce manual intervention, and flexibly adapt to various grooving process requirements.

[0010] To achieve the above objectives, the technical solution adopted by this utility model is as follows: a continuous automated grooving system for foam core material, comprising a first grooving unit and a second grooving unit connected sequentially along the foam core material conveying direction; and a core material flipping mechanism disposed at the connection between the first grooving unit and the second grooving unit, for flipping the foam core material processed by the first grooving unit and conveying it to the second grooving unit. The first grooving unit and the second grooving unit each include a first grooving station and a second grooving station arranged sequentially along the conveying direction of the foam core material; and a core material turning mechanism provided at the junction of the first grooving station and the second grooving station, for turning the foam core material processed by the first grooving station and conveying it to the second grooving station.

[0011] As a limitation of this utility model, the core material flipping mechanism includes a first driving component and a clamping plate assembly connected to the output shaft of the first driving component; the clamping plate assembly has a receiving portion for receiving and flipping the foam core material.

[0012] As a further limitation of this utility model, the clamping plate assembly has two receiving portions arranged back to back.

[0013] As another limitation of this utility model, the core material turning mechanism includes: a positioning part, disposed on one side of the conveying path, used to limit one end of the foam core material to form a rotation fulcrum when the foam core material is conveyed to the position; A guide section is located on the other side of the conveying path relative to the positioning section. Its outline is formed as an arc-shaped guide surface to guide the foam core material to turn. It is used to guide the tail end of the foam core material to move along an arc-shaped trajectory, so that the foam core material completes a 90° turn around the rotation fulcrum.

[0014] As a further limitation of this utility model, the positioning part is a spherical ball, which is assembled through a limiting groove with an opening facing the conveying path, and part of the spherical ball protrudes out of the conveying plane.

[0015] As a further limitation of this utility model, the distance between the highest point of the positioning part and the guide part is greater than the diagonal length of the foam core material to be processed.

[0016] As a third limitation of this utility model, both the first grooving station and the second grooving station include a frame and a conveying mechanism, a grooving execution mechanism and a dust collection mechanism disposed on the frame; the grooving execution mechanism is mounted above the conveying mechanism and includes a height-adjustable grooving saw blade and a rolling pressure roller, with the rolling pressure roller located in front of the grooving saw blade; the dust collection mechanism is covered above the grooving execution mechanism.

[0017] As a further limitation of this utility model, the dust collection mechanism includes a housing covered on the grooving execution mechanism, a dust suction port fixed on the housing and facing the grooving processing area, and a vacuum cleaner connected to the dust suction port through a dust suction pipe.

[0018] As a further limitation of this utility model, both ends of the grooving saw blade and both ends of the rolling pressure roller are mounted on the inner side wall of the box body through a height adjustment mechanism; The height adjustment mechanism includes a slide rail vertically mounted on the inner wall of the housing, a seated bearing that slides with the slide rail, and a linear drive component for driving the seated bearing to move along the slide rail.

[0019] As a further limitation of this utility model, a guide ruler for guiding the foam core material is provided on the side of the conveying mechanism, and the two ends of the guide ruler are smoothly transitioned arc shapes.

[0020] By adopting the above-mentioned technical solution, the beneficial effects achieved by this utility model compared with the prior art are as follows: (1) This utility model integrates the first grooving unit, the second grooving unit, the core material flipping mechanism, and the core material turning mechanism into a highly automated grooving processing system, realizing the continuous automated operation of all core processing steps (including double-sided grooving, 90° automatic turning, and 180° automatic flipping) of the foam core material after loading and before unloading. This completely eliminates the discrete mode of repeated manual intervention for flipping and turning in traditional single-machine operation. For the most complex double-sided cross groove processing, the original process that required 4 manual interventions (a total of 4 loading and unloading operations, accompanied by multiple parameter adjustments) is integrated into "one loading, no parameter adjustment required, and automatic completion of all core grooving steps", which improves the effective processing time and production efficiency by orders of magnitude, while greatly reducing labor costs and labor intensity. In addition, it effectively avoids problems such as dirt and damage to the boards caused by manual handling and flipping, fundamentally eliminates the setting errors that may be caused by repeated manual parameter adjustments, ensures processing accuracy, and significantly improves product quality.

[0021] (2) Each slotting station in this utility model is equipped with a high-efficiency dust collection mechanism, which can collect and remove dust and debris at the source during slotting, completely changing the backward method of relying on manual cleaning in the later stage, greatly improving the working environment, protecting the health of employees, and meeting the requirements of modern clean production.

[0022] This invention achieves continuous, efficient, and high-quality processing of double-sided multi-directional grooving in foam core materials through integrated and automated design. It is mainly applicable to the field of wind turbine blade manufacturing, and is used to create specific grooves in foam core materials to construct them as high-permeability media, thereby significantly improving the resin vacuum infusion effect. Attached Figure Description

[0023] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0024] Figure 1 This is a three-dimensional structural diagram of an embodiment of the present utility model (the arrow in the figure indicates the direction of foam core material conveying). Figure 2 This is a three-dimensional structural diagram of the first slotted unit in an embodiment of the present utility model; Figure 3This is a top view showing the structural relationship of the first slotted unit in this embodiment of the present invention; Figure 4 This is a three-dimensional structural diagram of the first slotting station in an embodiment of the present utility model; Figure 5 This is a schematic diagram of the internal structure of the first slotting station in an embodiment of the present invention; Figure 6 This is a three-dimensional structural diagram of the grooving saw blade in an embodiment of the present invention; Figure 7 This is a three-dimensional structural diagram of the core material flipping mechanism in an embodiment of the present utility model; Figure 8 This is a three-dimensional structural diagram of the core material flipping mechanism in another state in an embodiment of this utility model; Figure 9 This is a three-dimensional structural diagram of the core material steering mechanism in an embodiment of this utility model; Figure 10 for Figure 9 A magnified view of a portion of point A in the middle.

[0025] In the diagram: 1. First grooving unit; 2. Second grooving unit; 3. Core material flipping mechanism; 4. Foam core material; 5. First grooving station; 6. Second grooving station; 7. Core material turning mechanism; 101. Conveying mechanism; 102. Straightedge; 103. Grooving saw blade; 104. Rolling pressure roller; 105. Slide rail; 106. Main shaft; 107. Saw blade; 108. Clamping device; 109. Air vent; 110. Housing; 111. Dust suction port; 201. Positioning part; 202. Guide part; 203. Spherical ball; 204. Limiting groove; 301. First drive assembly; 302. Clamping plate assembly; 303. Receiving part. Detailed Implementation

[0026] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the present invention.

[0027] This embodiment discloses a continuous automated grooving system for foam core materials. Its core lies in constructing a continuous production line capable of automatically completing double-sided, multi-directional grooving of foam core materials. For example... Figure 1 As shown, the system includes a first slotting unit 1, a core material flipping mechanism 3, and a second slotting unit 2, which are sequentially connected along the conveying direction of the foam core material 4.

[0028] The first slotted unit 1 and the second slotted unit 2 have the same structure. This embodiment takes the first slotted unit 1 as an example to describe its structure in detail: Figure 2 and Figure 3 As shown, the first grooving unit 1 includes a first grooving station 5 and a second grooving station 6 arranged sequentially along the conveying direction of the foam core material 4, and a core material turning mechanism 7 arranged at the junction of the two. In this embodiment, both the first grooving station 5 and the second grooving station 6 are composed of foam core material grooving equipment in the prior art. Taking the first grooving station 5 as an example, as... Figure 4 and Figure 5 As shown, it includes a frame and a conveying mechanism 101, a slotting actuator and a dust collection mechanism mounted on the frame.

[0029] The conveying mechanism 101 is typically a motor-driven conveyor belt used to carry and transport the foam core material 4. A guide 102 is fixedly installed on its side to guide the foam core material 4 and prevent it from deviating during transport. The ends of the guide 102 are machined into smooth transition arcs to avoid the sharp edges of the ends from bumping into the foam core material 4 during loading and unloading.

[0030] The grooving actuator is mounted above the conveying mechanism 101 and includes a grooving saw blade 103 and a rolling pressure roller 104. The rolling pressure roller 104 is located in front of the feeding position of the grooving saw blade 103 and is used to press the foam core material 4 tightly before grooving to prevent it from moving. Both ends of the grooving saw blade 103 and the rolling pressure roller 104 are mounted on the inner side wall of the dust collection mechanism's housing 110 via a height adjustment mechanism.

[0031] The height adjustment mechanism includes a slide rail 105 vertically fixed to the inner wall of the housing 110, a bearing with a mounting plate that slides in cooperation with the slide rail 105, and a linear drive component for driving the bearing with the mounting plate along the slide rail 105 (the bearing with the mounting plate and the linear drive component are not shown in the accompanying drawings of this embodiment). The linear drive component is prior art. In this embodiment, the linear drive component is preferably a combination of a screw and a nut, and works in conjunction with a drive component (such as a servo motor). The drive component is fixed to the inner wall of the housing 110, the nut is fixed to the bearing with the mounting plate, and the screw is connected to the drive component and screwed to the nut. The drive component drives the screw to rotate, thereby driving the bearing with the mounting plate and the rotating shaft of the grooving saw blade 103 (or rolling pressure roller 104) mounted thereon to precisely rise and fall along the slide rail 105 through the nut, realizing stepless adjustment of the grooving depth.

[0032] The structure of the grooving saw blade 103 is as follows Figure 6As shown, the assembly includes a main shaft 106 and several saw blades 107 spaced apart on the main shaft 106 by clamping devices 108 (such as bushings). The main shaft 106 is a hollow structure, and multiple air holes 109 are provided on both sides of each saw blade 107. Rotary joints are installed at both ends of the main shaft 106, with the other end connected to an air pump via a flexible hose. During operation, high-pressure air is supplied by the air pump. This high-pressure air flows within the hollow main shaft 106 and is then ejected from the air holes 109, rapidly cooling the saw blades 107 and preventing deformation, instability, or even breakage due to high temperatures. In this embodiment, the saw blades 107 are abrasive saw blades, meaning both sides of the saw blade 107 have abrasive particles. During processing, this abrasive structure can sand the cut surface, ensuring a smooth groove opening and facilitating resin flow.

[0033] The dust collection mechanism includes a housing 110 covering the grooving actuator, a dust suction port 111 fixed on the housing 110 and facing the processing area of ​​the grooving saw blade 103, and a vacuum cleaner (not shown in the figure) connected to the dust suction port 111 via a dust suction pipe. The dust generated during grooving can be sucked in and collected instantly, ensuring a clean working environment.

[0034] The core material turning mechanism 7 is located at the junction of two stations within the same slotting unit, used to achieve a 90° automatic turning of the foam core material 4. For example... Figure 9 As shown, the core material steering mechanism 7 includes a positioning part 201 and a guiding part 202, wherein the positioning part 201 is located on one side of the conveying path, and the guiding part 202 is located on the opposite side. In this embodiment, the positioning part 201 is a spherical ball 203, such as... Figure 10 As shown, it is assembled through a limiting slot 204 with an opening facing the conveying path, and a portion of the ball protrudes from the conveying plane. When the foam core material 4 moves along the conveying direction, one corner of it will contact and be blocked by the spherical ball 203, thus forming a rotation fulcrum.

[0035] The guide section 202 is a fixed arc-shaped guide rail, the outline of which is an arc concentrically arranged with the rotation fulcrum, that is, an arc-shaped guide surface that guides the foam core material 4 to rotate. Figure 9 As shown, under the drive of the conveying power, the tail end of the foam core material 4 will slide along this arc-shaped guide surface, thereby completing a precise 90° turn around the fulcrum of the positioning part 201.

[0036] To ensure smooth turning, the distance between the highest point of the positioning part 201 and the guide part 202 is greater than the diagonal length of the foam core material 4 to be processed.

[0037] The core material flipping mechanism 3 is located at the junction of the first slotting unit 1 and the second slotting unit 2, and is used to realize the 180° automatic flipping of the foam core material 4. Figure 7 and Figure 8 As shown, the core material flipping mechanism 3 includes a first drive assembly 301 (such as a rotary cylinder or motor) and a clamping plate assembly 302 connected to the output shaft of the first drive assembly 301. The clamping plate assembly 302 has two back-to-back receiving portions 303 for receiving and flipping the foam core material 4. Normally, the clamping plate assembly 302 is horizontally positioned so that the two receiving portions 303 face the output end of the first slotting unit 1 and the input end of the second slotting unit 2, respectively. When the first slotting unit 1 conveys the foam core material 4 with one side processed to the core material flipping mechanism 3, the foam core material 4 directly enters the receiving portion 303 facing the output end of the first slotting unit 1; subsequently, the first drive assembly 301 drives the clamping plate assembly 302 to rotate 180°, so that the other side of the foam core material 4 faces upwards, and it is precisely placed on the conveyor line of the second slotting unit 2, achieving automatic flipping.

[0038] The first grooving station 5 of the first grooving unit 1 is defined as "machine 1", the second grooving station 6 of the first grooving unit 1 is defined as "machine 2", the first grooving station 5 of the second grooving unit 2 is defined as "machine 3", and the second grooving station 6 of the second grooving unit 2 is defined as "machine 4". This is to more clearly illustrate the processing flow for different groove types in this embodiment: 1. Single-sided straight groove: Machine 1 starts; Machines 2, 3, and 4 stop working. The loading personnel place the foam core material 4 tightly against the ruler 102 at the feeding end of Machine 1; the foam core material 4 is fed into the grooving processing area of ​​Machine 1 by the conveyor mechanism 101, and after the processing of the single-sided straight shallow or deep groove is completed, it is output through the discharge end and removed and stacked by the unloading personnel; II. Single-sided cross groove: Machines 1 and 2 are started; machines 3 and 4 are suspended. Foam core material 4 is fed into machine 1, where it completes the first-direction slotting process; after discharge, it undergoes a 90° horizontal turn via core material turning mechanism 7; subsequently, it enters machine 2 to complete the second-direction slotting, thus forming a single-sided cross groove. The final finished product is removed and stacked by the unloading personnel at the discharge end of machine 2. III. Double-sided shallow groove processing: Machines 1 and 4 are started; Machines 2 and 3 are suspended, but conveyor mechanism 101 is running. After the foam core material 4 completes the first side groove processing on Machine 1, it undergoes a 90° horizontal turn via core material turning mechanism 7, and then sequentially passes through Machine 2 (no groove), core material flipping mechanism 3 (completes a 180° vertical flip), Machine 3 (no groove), and core material turning mechanism 7 again to complete a 90° horizontal turn, finally entering Machine 4 to complete the second side groove processing. The finished product is removed and stacked by the unloading personnel at the discharge end of Machine 4. IV. Double-sided shallow cross groove: Machines 1, 2, 3, and 4 are all started. This is the most complete automated process. Foam core material 4 first has its first side grooved in the first direction on machine 1, then, after turning, enters machine 2 to have its first side grooved in the second direction (forming a cross groove on the first side). Subsequently, foam core material 4 is automatically flipped by core material flipping mechanism 3, enters machine 3 to have its second side grooved in the first direction, and then, after turning again, enters machine 4 to have its second side grooved in the second direction (forming a cross groove on the second side). The final finished product is output from machine 4 and collected and stacked by the unloading personnel. V. Shallow Cross Groove on the Back + Deep Cross Groove on the Front: Machines 1, 2, 3, and 4 are all started. The foam core material 4 first completes the shallow cross groove processing on the back continuously on machines 1 and 2. Afterwards, intermediate manual intervention is required: the operator removes the foam core material 4, adheres fiber cloth to the back of the already grooved surface, then flips the foam core material 4 so that the front side to be grooved faces upwards, and places it back onto the conveyor mechanism 101 of machine 3, close to the ruler 102. The foam core material 4 then passes through machines 3 and 4 sequentially, automatically completing the deep cross groove processing on the front. VI. Shallow groove on the back + deep groove on the front: Machines 1, 3, and 4 are started; Machine 2 is paused. The foam core material 4 first completes the shallow groove processing on the back on machine 1. Afterwards, intermediate manual intervention is required: the operator removes the foam core material 4, adheres fiber cloth to the back with the shallow groove, then flips it over and reloads it onto machine 3. The foam core material 4 then sequentially passes through machine 3 (completing the first direction deep groove on the front), the steering mechanism, and machine 4 (completing the second direction deep groove on the front), ultimately forming a combined structure of a shallow groove on the back and a deep groove on the front.

[0039] It should be noted that the above description is merely a preferred embodiment of the present utility model and is not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the above embodiments, those skilled in the art can still modify the technical solutions described in the above embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A continuous automated grooving system for foam core materials, characterized in that: It includes a first grooving unit and a second grooving unit connected sequentially along the conveying direction of the foam core material; and a core material flipping mechanism provided at the connection between the first grooving unit and the second grooving unit, used to flip the foam core material processed by the first grooving unit and convey it to the second grooving unit; The first grooving unit and the second grooving unit each include a first grooving station and a second grooving station arranged sequentially along the conveying direction of the foam core material; and a core material turning mechanism provided at the junction of the first grooving station and the second grooving station, for turning the foam core material processed by the first grooving station and conveying it to the second grooving station.

2. The continuous automated grooving system for foam core materials according to claim 1, characterized in that: The core material flipping mechanism includes a first drive assembly and a clamping plate assembly connected to the output shaft of the first drive assembly; the clamping plate assembly has a receiving portion for receiving and flipping the foam core material.

3. The continuous automated grooving system for foam core material according to claim 2, characterized in that: The clamp assembly has two receiving portions arranged back to back.

4. A continuous automated grooving system for foam core materials according to any one of claims 1-3, characterized in that: The core material steering mechanism includes: a positioning part, located on one side of the conveying path, used to limit one end of the foam core material when it is conveyed into place to form a rotation fulcrum; A guide section is located on the other side of the conveying path relative to the positioning section. Its outline is formed as an arc-shaped guide surface to guide the foam core material to turn. It is used to guide the tail end of the foam core material to move along an arc-shaped trajectory, so that the foam core material completes a 90° turn around the rotation fulcrum.

5. The continuous automated grooving system for foam core material according to claim 4, characterized in that: The positioning part is a spherical ball bearing, which is assembled through a limiting groove with an opening facing the conveying path, and part of the ball bearing protrudes from the conveying plane.

6. The continuous automated grooving system for foam core materials according to claim 5, characterized in that: The distance between the highest point of the positioning part and the guide part is greater than the diagonal length of the foam core material to be processed.

7. A continuous automated grooving system for foam core materials according to any one of claims 1-3, 5, and 6, characterized in that: Both the first grooving station and the second grooving station include a frame and a conveying mechanism, a grooving execution mechanism, and a dust collection mechanism mounted on the frame. The grooving execution mechanism is mounted above the conveying mechanism and includes a height-adjustable grooving saw blade and a rolling pressure roller, with the rolling pressure roller located in front of the grooving saw blade. The dust collection mechanism is mounted above the grooving execution mechanism.

8. The continuous automated grooving system for foam core material according to claim 7, characterized in that: The dust collection mechanism includes a housing covered on the grooving actuator, a dust inlet fixed on the housing and facing the grooving processing area, and a vacuum cleaner connected to the dust inlet via a dust suction pipe.

9. The continuous automated grooving system for foam core material according to claim 8, characterized in that: Both ends of the grooving saw blade and both ends of the rolling pressure roller are mounted on the inner side wall of the box body through a height adjustment mechanism; The height adjustment mechanism includes a slide rail vertically mounted on the inner wall of the housing, a seated bearing that slides with the slide rail, and a linear drive component for driving the seated bearing to move along the slide rail.

10. A continuous automated grooving system for foam core materials according to claim 8 or 9, characterized in that: The conveying mechanism is provided with a guide ruler on the side for guiding the foam core material, and the two ends of the guide ruler are smoothly transitioned arcs.

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