Tow Prepreg Resin Control via Roller Speed Feedback
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Solution Overview
Problem
The existing methods for manufacturing tow prepreg, such as the kiss coating method, face challenges in achieving a uniform resin content due to the non-uniform thickness and width of original fibers, leading to difficulties in maintaining a consistent resin content (Rc value) in the wound tow prepreg, and the temperature increase of resin during application causes resin to fall off before impregnation, complicating the control of the desired resin content.
Innovation Solution
A tow prepreg manufacturing apparatus that includes an oiling roller, scraper, resin reservoir, and tube pump, with a controller that adjusts the rotation speed of the oiling roller and the resin discharge to maintain a constant resin supply, ensuring the resin content of the wound tow prepreg converges on a target value, using feedback control mechanisms to stabilize the resin application and maintain consistent quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the clearance between the roller and blade is adjusted to control resin application, then the resin distribution uniformity is improved, but the resin content consistency (Rc value) cannot be maintained due to temperature rise and resin falling
Solution Approach 1:
The patent implements a feedback control system where the actual Rc value is measured and compared with the target Rc value, and the roller rotation speed is automatically adjusted based on the deviation. This closed-loop control ensures that even when temperature rise causes resin to fall, the system compensates by adjusting rotation speed to maintain consistent resin content in the wound tow prepreg.
Solution Approach 2:
The patent transitions from a static clearance adjustment method to a dynamic control method where the roller rotation speed is continuously variable. By making the rotation speed adjustable in real-time based on feedback, the system can adapt to temperature variations and resin flow changes, maintaining Rc value consistency despite environmental fluctuations.
2Productivity
If the roller rotation speed is increased to improve productivity, then the production efficiency is improved, but the resin content control becomes more difficult
Solution Approach 1:
The feedback control system measures the actual Rc value and adjusts the roller rotation speed accordingly. This allows the system to operate at higher speeds for improved productivity while automatically compensating for any resin content variations, thus maintaining manufacturing precision even at elevated production rates.
Solution Approach 2:
The patent replaces manual or mechanical clearance adjustment with an automated control system that uses sensors and actuators. This substitution enables precise control of resin content through electronic regulation of roller speed, allowing high-speed operation without sacrificing control accuracy.
3Ease of operation
If the resin temperature is raised during feeding to the roller, then the resin flow is improved, but resin falls from the roller before impregnation occurs
Solution Approach 1:
The feedback control system detects when resin falls from the roller (indicated by deviation from target Rc value) and responds by adjusting the roller rotation speed. This compensates for the resin loss caused by temperature-induced falling, ensuring that the wound tow prepreg still achieves the desired resin content despite the substance loss during the process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The apparatus effectively stabilizes the resin content throughout the wound tow prepreg, ensuring consistent quality by controlling the rotation speed of the oiling roller and maintaining a constant resin supply, accurately calculating and adjusting the resin content to meet the target Rc value, thereby rectifying the issues of non-uniform resin distribution and temperature-related challenges.
Implementation Method 1
The tube pump discharges resin to the resin reservoir
Implementation Method 2
The oiling roller is supplied with resin while rotating at a predetermined rotation speed
Implementation Method 3
move an original tow of reinforcing fibers over the oiling roller to apply resin to the original tow
Data Source
AI summary
A tow prepreg manufacturing apparatus applies resin to an original tow of reinforcing fibers. The tow prepreg manufacturing apparatus includes an oiling roller, a scraper, a resin reservoir, a tube pump, and a controller. The oiling roller is supplied with resin while rotating at a predetermined rotation speed. The scraper adjusts the shape of the resin supplied onto the oiling roller. The resin reservoir supplies resin to the oiling roller. The tube pump discharges resin to the resin reservoir. The controller controls the tube pump so that the amount of resin held in the resin reservoir remains constant and controls the rotation speed of the oiling roller so that a resin content of a wound tow prepreg becomes equal to a target resin content.