CN102143835A - 生产复合结构的方法和设备 - Google Patents
生产复合结构的方法和设备 Download PDFInfo
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Abstract
通过将多个带(86)层合在基底上的复合带应用机械(50)来形成复合构件。当带被层合时可以调整带的横向位置。
Description
技术领域
本发明大体涉及层合复合带的自动化机械和方法。
背景技术
如那些用于车辆、海运和航空航天工业的复合结构可以用自动复合材料应用/施加机械(application machine)制造,通常被称作自动纤维铺放(AFP)机械。例如,AFP机械可以被用于飞机工业,以通过在制造工具上层合被对准在较宽带材内的相对窄条的复合带或“束”,来制造结构形状和蒙皮组件(skin assembly)。AFP机械将多个带条(通常六个或更多个)对齐并放置成连续的边-边接触,从而形成被放置在工具上并被压抵于工具的单个共形带。
为了制造大的复杂层压组件,使用纤维铺放头的现有的AFP机械可以具有相对高的操作灵活度。例如,现有的铺放头通过为每个带条提供单独的独立受控的刀具,从而能够彼此之间独立地来添加、减少或剪切连续带条中的任意带条或所有带条。
在具有高度的灵活性和有效性的同时,现有的AFP机械可能就其生产率而言具有限制。例如,现有的AFP机械使用具有多带供给的单头,其边-边地铺设对齐的带进程以形成单个带宽。在那些已经优化了头的速度的应用中,生产率的额外增加(即每单位时间铺设的带的数量)可能要求在铺放头上提供额外的带供给的供应以增加带宽。增加带供给不仅导致更大且更复杂的铺放头,而且例如由于难以操纵更大的头而可能限制在一些应用中的灵活性。
因此,持续需要增加复合带的铺放率的改进方法和设备。
发明内容
根据一些公开的实施例,提供铺设带以形成复合构件的方法。该方法包括当带被模块铺设时,调整多个带控制模块中的至少一个带控制模块的横向位置。调整带控制模块的横向位置被执行从而改变相邻带之间的距离,所述横向位置基本上正交于多个带控制模块的行进方向。调整带控制模块的横向位置可以根据一组预编程指令被自动执行。
根据一些其它的实施例,提供通过层合多个复合带来形成复合构件的方法。在层合期间,至少一个带的横向位置被自动调整并且带被聚集成一定带宽。使用被编程的控制系统执行横向位置的自动调整。调整步骤可以包括调整两个相邻带的横向位置。
根据其它实施例,提供将复合带构成的带材应用到基底上的方法。该方法包括在基底上移动带应用头并从多个位置在基底上铺设复合带的多个进程,其中所述位置沿头的行进方向错开。当头在基底上方移动时,至少某些进程的横向位置被调整。根据一组预编程指令并通过调整在带应用头上的带控制模块的横向位置来自动执行对进程的横向位置的调整。
根据其它实施例,提供形成复合构件的带层合机械。该机械包括用于层合带的多个带控制模块和与这些模块相连的用于调整至少某些模块的横向位置的装置。该机械进一步包括控制系统和程序,其中在带被模块层合时该程序被控制系统用来调整所述至少某些模块的横向位置。
根据另一个实施例,提供在基底上层合复合带的带应用机械。该机械包括在基底上方沿行进方向可移动的头和安装在头上的载体。多个带控制模块被安装在载体上用来在基底上层合带的多个进程。马达被安装在头上,连接在马达与模块之间的驱动是可操作的以便调整至少某些模块在头上的横向位置。
根据对下述详细介绍连同相应的附图的考虑,本发明的其它特征和优点对于本领域的技术人员将会很清楚。
附图说明
图1是用于生产复合层压件的系统的总体方框图的图示;
图2是安装在自动控制台架上的一对带应用头的透视图的图示;
图3是使用图2中所示类型的台架生产层压件的系统的功能方框图的图示;
图4是功能方框图的图示,其显示带控制模块与应用头的其它元件之间的关系;
图5是一组带控制模块的透视图的图示,包括用于铺设窄带条的带材的带控制模块的可替换形式;
图6是带的进程的平面图的图示,其形成单条带材并显示带控制模块的错开组之间的偏置;
图7是类似于图6的图示,但其显示铺设由带的窄条形成的带材的带模块的附加部分;
图8是具有错开的带控制模块的带应用头的透视图的图示;
图9是平面视图的图示,其显示被具有十六个带控制模块的应用头铺设的带的进程;
图10是可以形成图8所示的带应用头的一部分的三个带控制模块的正视图的图示;
图11是用于调整带控制模块的横向位置的系统的方框图的图示;以及
图12是流程图的图示,其显示层合复合带的方法的步骤。
具体实施方式
特别参考附图的图1和图2,一些实施例涉及用数字50标示的一种设备,该设备50通过将复合带86构成的带材87应用/施加到工具59或其它基底上方来生产复合部件或复合结构,例如层压结构57。在许多实施例中,复合制造设备50可以被配置成通过响应要被制造的复合结构(有时在这里也被称为“构件”57)的轮廓(未显示)来调整带的位置从而生产该构件57。
设备50可以包括一个或更多个带应用头58,每一个带应用头58均包括至少第一组和第二组带控制模块60a、60b。每个应用头58均被安装在操作器52上,操作器52能够沿一个或更多个轴线移动相应的头58以便引导应用/施加由带构成的带材的方向。操作器52可以被安装在机械工具系统54上用于沿多个轴线运动,机械工具系统54可以包括通常用于沿多个轴线移动工具的各种任意已知系统。操作器52、机械工具系统54和应用头58可以被一个或更多个控制系统56控制,控制系统56可以包括(例如并且不限于)NC或CNC控制器。
现在具体参考图2,设备50可以包括(例如并且不限于)台架系统(gantry system)55,台架系统55包括带有相对端的台架梁62,台架梁62的相对端被安装在高架轨道68上以在其上线性移动。台架梁62可以包括配备有齿轮传动(未显示)的马达70,以沿轨道68给台架梁62提供动力。一个或更多个操作器52可以被可操作地并可移动地安装在台架梁62上,每个操作器52设有一个带应用头58。在图2所示的示例中,两个操作器52和头58被安装在单个台架梁62的相对侧上。一个(多个)操作器52可以由马达(未显示)提供动力,该马达沿台架梁62驱动操作器52。各种电的和其它方式的线和缆绳(未显示)可以被封入管道(未显示)中以便将马达、操作器52和应用头58连接到图1的控制系统56和/或其它系统(未显示)。
现在将注意力指向图3,其以方框图的形式显示了设备50的附加部件。在许多实施例中,应用头58可以广义上包括材料传输系统58a以及带对齐和应用头58b。材料传输系统58a将带或被称作束的纵切带传输到带对齐和应用头58b,该带对齐和应用头58b将纵切带应用到基底,从而形成层压带宽74。如此处所用的,“复合纤维带”、“纤维带”、“带”和“带条”意欲包括广泛的具有各种宽度的带和束。复合带从合适的原料供应76被供给到材料传输系统58a。如之前提及的,台架系统54a和带对齐和应用头58b的操作被控制系统56(图1)控制。
带对齐和应用头58b的附加细节如图4所示。每个带对齐和应用头58b均可以包括多个带控制模块84,带控制模块84将带进程/带路线(tape course)86(见图6)输出到基底(未显示)上。后面将更详细地介绍,每个带控制模块84均可以被可移除地安装在带对齐和应用头58b上,从而允许快速改变模块84。每个模块84均可以通过任何合适的手段被连接到合适的动力、控制和传感器接头94。每个带控制模块84还可以通过连接器96被连接到重新喂料驱动(rethread drive)88或者用于用由材料传输系统58a供给的带给模块84重新喂料的独立伺服驱动。带控制模块84的示例可以在美国专利No.4,699,683和美国专利公开No.2007/0029030A1中找到,这两个文献的整个内容作为参考被合并至此。
现在参考图5、图6和图7,后面将更详细地介绍,根据公开的实施例,带控制模块84被布置成沿应用头58的行进方向110错开或偏置的两个可交替组84a、84b(见图2)。如图5所示,组84a中的模块84基本上沿第一轴线121对齐,第一轴线121在横于行进方向110的方向126上延伸,组84b中的模块84基本上沿第二轴线123对齐,第二轴线123基本上平行于第一轴线121延伸。由于两组模块84之间的这种对齐和偏置关系,如最好从图6所见,关联于相应模块84a、84b的压紧滚轮112a、112b的中心线“A”和“B”在行进方向110上被分开了一个距离“d”。可以使用预编程的数值由之前讨论的控制系统56(图1)来自动调整相邻的带控制模块84之间偏置或错开的量(距离“d”)。
模块组84a、84b可以基本上边-边对齐地应用带86a、86b的进程以形成具有带宽“W”的带材87(图7)。由于错开带控制模块84的组84a、84b,所以带进程中在前数字86a在空间上被放置在带进程中在后数字86b之前,带的带宽87放置成作为在带进程86中在后数字的后边缘119处的多个带进程86的累积。
图7显示了可替换实施例,其中一个或更多个带控制模块84c(图5)可以被安装在带对齐和应用头58b上、与模块组84a、84b中的任一个对齐。带控制模块84c应用由带片段116构成的带宽114,其中每个带片段116均具有小于带进程86a、86b的宽度。更窄的单独的带片段116允许在带材87的任一端上实现具有更高分辨率的轮廓117。
现在将注意力指向图8,其说明了带应用头58的可替换形式,其中两个或更多个带控制模块84的中心线125之间的距离(也被称为“节距”)可以被调整以控制累积带宽并由此有助于“操纵”带进程86或为了其它目的。在说明的实施例中,应用头58包括带控制模块84的两个组84a、84b,组84a、84b在头58的行进方向110上错开并分别应用带进程86a、86b,与图5中所示的带控制模块84的组84a、84b相似。应用头58可以包括连接到一个或更多个带控制模块84的合适的带模块调整系统120,其中带模块调整系统120可以被控制系统56(图1)控制并操纵。如将在下面讨论的,带模块调整系统120可以包括任何各种已知的机械的和/或机电的装置和/或组件,且其用来沿横向方向126横向移动一个或更多个带控制模块84,由此调整一个或更多个带进程86的横向位置,其中横向方向126基本上与应用头58的行进方向110正交。一个或更多个带控制模块84的横向移动相应地改变了带进程86a、86b的横向位置。在几个实施例中的一个实施例中,带控制模块84的组84a、84b可以在形成部分控制系统56(图1)的一组预编程指令的基础上被调整机构120相对彼此自动地横向调整,而在其它实施例中,组84a、84b中的任一个或两个组中的带控制模块84可以是被独立地横向调整的。带模块84之间的节距可以在带宽87被铺设之前被自动调整,并且/或者可以当带宽87被铺设时被动态地“联机”调整。
如上所述,带控制模块84的横向位置的自动可调性允许对每个带材87中相应的带进程86a、86b的横向位置进行相对精确的控制。例如,如图9所示,可以对带模块84之间的节距进行自动调整以调整相邻带进程86a、86b的中心线127之间的距离,以便带进程86a、86b的边缘实质上是相连的。通过带模块84之间的节距的动态调整,对相邻带进程86a、86b的横向位置进行了自动控制,从而可以提高“操纵”带材87的能力,特别是对于具有复杂轮廓的表面而言。因此,带控制模块84的横向或横切位置可以被调整以适应被层合的构件57的轮廓或为了各种其它目的。由带控制模块84通过压紧滚轮112所施加的压紧力可以被预设置,而在其它实施例中,可以基于将要铺设的带进程的基底的一个或更多个轮廓来调整压力。
图10说明了带控制模块84可以被自动并且独立调整的方向。形成第一组84b的一部分的带控制模块84b相对于形成第二组84a的一部分的两个带控制模块84a被轴向偏置或错开。模块84a沿第一公共X轴线122的任一个方向(X,-X)横向可调,模块84b沿XX轴线124的任一个方向(XX,-XX)横向可移动,XX轴线124沿带应用头58的行进方向110(图8)偏置于X轴线122。如上述提及的,当带进程86被应用/施加时带控制模块84可以被动态地联机地横向调整以辅助操纵被应用的带材87(图5)和/或覆盖复杂基底形状和/或轮廓。
现在将注意力指向图11,其进一步说明了用来自动调整带控制模块84的横向位置的系统的细节。在说明的示例中,显示了带控制模块84的两个错开组84a、84b,然而,在其它实施例中,当仅使用带控制模块84的单个组时可以有利地对带模块84之间的节距进行自动横向调整。
带控制模块84的每个组84a、84b被安装在头58(图1和图2)上用来在相应的载体128a、128b上横向调整。每个载体128a、128b均可以包括(不限于)任何各种已知类型的机械支撑件、托盘、滑道、轨道或相似装置,且其用于安装并支撑带控制模块以在头58上基本上横于头58的行进方向110(图5)横向移动。每个带模块调整系统120a、120b均被安装在头58上,并包括与相应的机械驱动132a、132b相连的马达130a、130b。每个马达132a、132b均可以是(不限于)气动的、液动的或电动的,例如步进器或伺服马达(未显示)。每个机械驱动132a、132b均可以包括(不限于)螺杆传动、齿轮传动、连杆组件或任何各种其它已知的机械传动机构。马达130a、130b可以被控制系统56或其它编程控制器(未显示)控制和操作。
控制系统56或其它控制器在形成部分控制程序134的一组被编程指令的基础上控制并调整带控制模块84的横向位置。这些被编程的指令可以部分地以将要制造的复合结构57(图1)的几何和/或层板构成为基础。每个机械驱动132a、132b均与相应组84a、84b中的带控制模块84相连。每个调整系统120a、120b可以独立地或成组地调整组84a、84b中的一个或更多个带控制模块84的横向位置。如上述提及的,当带进程86的带宽87被铺设时,一个或更多个带控制模块84的横向位置可以被动态地调整。
图12显示了使用之前介绍的技术层合复合带的方法的步骤。在步骤136,使用上述提及的带控制模块84层合带86进程。在步骤138,当带进程被铺设时,调整至少一个模块84的横向位置,从而调整至少一个带进程86的横向位置。
公开的实施例可以用于各种潜在应用,特别是在运输工业,包括例如航空、海运和车辆应用。本领域的技术人员将会明白本发明的上述实施例为许多可替换物和修改提供了基础。这些其它修改仍在本发明的范围之内。因此,本发明不限于在本发明中准确地显示和描述的内容。
Claims (15)
1.铺设复合带(86)以形成复合构件(57)的方法,其包括当带(86)被多个带控制模块(84a,84b)铺设时调整所述多个带控制模块(84a,84b)中的至少一个带控制模块(84)的横向位置。
2.根据权利要求1所述的方法,其中调整步骤包括调整所述带控制模块(84)的所述横向位置以便改变相邻的带(86)的中心线(127)之间的距离,所述横向位置基本上横于(126)所述多个带控制模块(84a,84b)的行进方向(110)。
3.根据权利要求1所述的方法,其中调整所述至少一个带控制模块(84)的位置是根据一组被编程指令(134)被自动执行的。
4.根据权利要求1所述的方法,进一步包括调整相邻带控制模块(84)的错开度。
5.根据权利要求1所述的方法,进一步包括沿基本横于所述带控制模块(84)的行进方向(110)的方向(126),调整带控制模块(84)的第一和第二错开组(84a,84b)相对彼此的位置。
6.根据权利要求1所述的方法,进一步包括将被所述多个带控制模块(86a,86b)铺设的带(86)累积成一定带宽(87)。
7.根据权利要求1所述的方法,进一步包括层合所述带(86)以便所述带(86)中在前数字(86a)在空间上沿行进方向(110)被层合在所述带(86)中在后数字(86b)之前。
8.形成复合构件(57)的带层合机械(50),包括:
用来层合带(86)的多个带控制模块(84);
与所述模块(84)相连以便用来调整至少某些所述模块(84)的横向位置的装置(120a,120b);
控制系统(56);以及
程序(134),当带(86)被所述模块(84)层合时所述程序(134)被所述控制系统(56)用来调整所述至少某些模块(84)的横向位置。
9.根据权利要求8所述的机械(50),其中所述带控制模块(84)包括沿所述模块(84)的行进方向(110)相对彼此错开的第一和第二组(84a,84b)。
10.根据权利要求8所述的机械(50),其中所述第一和第二错开组(84a,84b)中的所述带控制模块(84)被交替地布置在基本横于所述模块(84)的所述行进方向(110)的方向(126)内。
11.根据权利要求8所述的机械(50),其中所述调整装置(120a,120b)包括:
马达(130a,130b);以及
将所述马达(130a,130b)与所述至少某些模块(84)相连的驱动(132a,132b);以及
用来控制所述马达(130a,130b)的运行的编程控制系统(56)。
12.根据权利要求8所述的机械(50),其中所述带控制模块(84)被布置在沿所述模块(84)的所述行进方向(110)相对彼此错开的第一和第二组(84a,94b)中。
13.根据权利要求12所述的机械(50),其中在所述第一和第二组(84a,84b)中的所述带控制模块(84)被交替地布置在基本横于所述模块(84)的所述行进方向(110)的方向(126)内。
14.根据权利要求11所述的机械(50),进一步包括被所述控制系统(56)用来调整所述至少某些模块(84)的横向位置的程序(134)。
15.根据权利要求8所述的机械(50),进一步包括载体(128a,128b),所述载体(128a,128b)具有被安装在其上的所述模块(84),以便在基本横于所述模块(84)的所述行进方向(110)的方向(126)内横向调整。
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- 2009-07-07 WO PCT/US2009/049850 patent/WO2010005996A2/en active Application Filing
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Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
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CN102310572A (zh) * | 2011-09-16 | 2012-01-11 | 南京航空航天大学 | 双带铺放装置及方法 |
CN103029309A (zh) * | 2011-09-28 | 2013-04-10 | 波音公司 | 材料布置系统 |
CN103029309B (zh) * | 2011-09-28 | 2017-04-05 | 波音公司 | 材料布置系统 |
CN104570955A (zh) * | 2014-11-24 | 2015-04-29 | 中国科学院自动化研究所 | 一种复合材料自动铺丝机控制系统及控制方法 |
CN104570955B (zh) * | 2014-11-24 | 2018-06-22 | 中国科学院自动化研究所 | 一种复合材料自动铺丝机控制系统及控制方法 |
Also Published As
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EP2310191B1 (en) | 2012-09-05 |
WO2010005996A3 (en) | 2010-04-01 |
JP2011527648A (ja) | 2011-11-04 |
CA2730091A1 (en) | 2010-01-14 |
JP5607043B2 (ja) | 2014-10-15 |
US8986482B2 (en) | 2015-03-24 |
US20100006205A1 (en) | 2010-01-14 |
ES2390914T3 (es) | 2012-11-19 |
EP2310191A2 (en) | 2011-04-20 |
WO2010005996A2 (en) | 2010-01-14 |
CA2730091C (en) | 2015-06-09 |
CN102143835B (zh) | 2015-12-09 |
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