3D Weave Equipment for Composite Preforms
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Solution Overview
Problem
Existing three-dimensional weave-forming equipment faces challenges in processing complex-shaped preforms with large dimensions, requiring complex fiber layout changes and lacking automation control, and suffers from high porosity and suboptimal resin impregnation, leading to reduced mechanical properties and weather resistance.
Innovation Solution
A three-dimensional weave-forming equipment featuring a controllable digital template with hollow guiding poles and zigzag guiding sleeves, driven by X-axis and Y-axis motors, allows for precise distribution and movement of guiding poles and filaments, enabling complex shape weaving and large dimension processing with high automation and smooth surface formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional two-dimensional layered weaving equipment is used, then the manufacturing process is simple, but the rigidity and strength in the thickness direction are low and the structure is simple
Solution Approach 1:
The patent transitions from traditional two-dimensional layered weaving to three-dimensional weaving by introducing vertical guiding poles and multi-directional yarn feeding systems. This dimensional change enables yarns to interlace in the thickness direction, creating complex 3D woven structures that significantly improve strength and rigidity in the thickness direction while maintaining manufacturability through systematic equipment design.
2Strength
If three-dimensional weaving machines are developed to improve product structure and mechanical properties, then the strength and rigidity are enhanced, but the working efficiency is low
Solution Approach 1:
The patent employs dynamically adjustable guiding poles that can be positioned and repositioned along the weaving direction, allowing the equipment to adapt to different product shapes and sizes. This dynamic capability enables efficient processing of both simple and complex preforms without sacrificing mechanical properties, thereby improving working efficiency while maintaining enhanced strength and rigidity.
Solution Approach 2:
The weaving equipment is designed with universal guiding poles and tensioning devices that can handle various yarn types, weave patterns, and product configurations. This multi-functionality allows a single 3D weaving machine to efficiently produce diverse composite structures with different mechanical requirements, improving overall productivity without compromising on strength enhancement.
3Adaptability or versatility
If existing three-dimensional weave-forming equipment is used for complex-shaped preforms, then the fiber layout can be adjusted, but the processing procedure is complex and automation control is lacking
Solution Approach 1:
The patent incorporates feedback control mechanisms through the controllable digital template system, which monitors and adjusts the positions of guiding poles and yarn feeding in real-time. This automated feedback loop enables precise control of complex fiber layouts for various preform shapes, eliminating the need for manual intervention and simplifying the processing procedure while maintaining high adaptability to different geometries.
4Reliability
If conventional weaving methods are used, then the processing is straightforward, but the porosity is high and resin impregnation is suboptimal
Solution Approach 1:
The patent utilizes controllable digital templates to precisely control the density, spacing, and orientation of guiding poles and yarns during the weaving process. By optimizing these parameters, the 3D weaving structure achieves reduced porosity and improved resin impregnation quality while maintaining relatively simple processing procedures through automated parameter adjustment rather than complex manual operations.
Data Source
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AI summary
A three-dimensional weave forming equipment for composites mainly comprises a main body portion and a specific numerical control software for three-dimensional weaving process. The main body portion comprises a movement system for a controllable digital template, a movement system for a pickup device and a movement control system for a guiding sleeve. Compared with the existing three-dimensional weave-forming equipment, the three-dimensional weave-forming equipment for composites is highly automatic. Products made by the equipment are smooth at inner and outer surfaces, and have advantages of high precise dimension, low porosity and stable performance. And it can be reinforced partially and have directional property according to requirements of design. So problems of simple cross-section of the finished part and too much pores in the products, which manufactured by the existing three-dimensional weave forming equipment are solved. The three-dimensional weave forming equipment for composites is especially suitable for producing products with large dimension and complex external structure.