CN105299567B - curved surface conformal method for airplane formation lamp - Google Patents
curved surface conformal method for airplane formation lamp Download PDFInfo
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- CN105299567B CN105299567B CN201510871299.2A CN201510871299A CN105299567B CN 105299567 B CN105299567 B CN 105299567B CN 201510871299 A CN201510871299 A CN 201510871299A CN 105299567 B CN105299567 B CN 105299567B
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21S43/00—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights
- F21S43/20—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights characterised by refractors, transparent cover plates, light guides or filters
- F21S43/235—Light guides
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21S43/00—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights
- F21S43/10—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights characterised by the light source
- F21S43/13—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights characterised by the light source characterised by the type of light source
- F21S43/14—Light emitting diodes [LED]
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21S—NON-PORTABLE LIGHTING DEVICES; SYSTEMS THEREOF; VEHICLE LIGHTING DEVICES SPECIALLY ADAPTED FOR VEHICLE EXTERIORS
- F21S43/00—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights
- F21S43/50—Signalling devices specially adapted for vehicle exteriors, e.g. brake lamps, direction indicator lights or reversing lights characterised by aesthetic components not otherwise provided for, e.g. decorative trim, partition walls or covers
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21W—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO USES OR APPLICATIONS OF LIGHTING DEVICES OR SYSTEMS
- F21W2107/00—Use or application of lighting devices on or in particular types of vehicles
- F21W2107/30—Use or application of lighting devices on or in particular types of vehicles for aircraft
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- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Optics & Photonics (AREA)
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
- Shaping Of Tube Ends By Bending Or Straightening (AREA)
Abstract
The invention relates to a curved surface conformal method of an airplane formation lamp, which sequentially executes the following steps of S1, providing formation lamp bodies; step S2, heat treatment; step S3, stopping heating; step S4, negative pressure forming; step S5, cooling; and step S6, secondary forming. The invention has the advantages that: the interlayer bonding has no stress, the curved surface forming is accurate, the brightness uniformity of the surface light source is high, and the vibration resistance and the temperature impact resistance of the formation lamp can be obviously improved.
Description
Technical Field
The invention relates to a formation lamp on an airplane, in particular to a curved surface conformal method of the formation lamp of the airplane.
Background
With the rapid development of military industry in China, the types and the number of military aircrafts are continuously increased. Almost all military aircraft, especially fighters and bombers, are very concerned with formation flight problems. The onboard formation lamp is one of effective safety devices for ensuring the formation of the fleet to fly and conceal an approaching target.
At present, most airborne formation lamps in the industry adopt an EL surface light source embedded in an epoxy glass cloth plate laminating and bonding structure. The epoxy glass cloth plate is a thermosetting material and cannot be subjected to secondary forming because the high-temperature resistance of the EL light source material is poor (less than or equal to 70 ℃). Therefore, the conformal curved surface can be realized only by means of adhesive bonding and forced deformation of tool clamping, so that the stress between epoxy glass cloth plate layers is very large. And when the airplane flies across the sound velocity, shock waves can be generated when the sound barrier is broken through, so that the airplane shakes violently, the failure risk of the adhesive is aggravated, and the formation lamp is damaged.
disclosure of Invention
The invention aims to solve the problem of large stress between epoxy glass cloth plate layers in the prior art and provides a novel curved surface conformal method for an airplane formation lamp.
In order to achieve the purpose, the technical scheme of the invention is realized as follows: a curved conformal method for the formation lights of an airplane formation sequentially comprises the following steps,
step S1, providing formation lamp bodies;
step S2, heat treatment:
the formation lamp bodies are arranged on a forming die in a constant temperature chamber, the temperature of the constant temperature chamber is gradually increased from room temperature, the temperature increasing process meets the following conditions,
(a) If the temperature in the constant temperature cabin is lower than or equal to 100 ℃, controlling the temperature rise speed to be 0.8-1.2 ℃/min;
(b) if the temperature in the constant-temperature cabin is higher than 100 ℃ and lower than 146 ℃, controlling the temperature rise speed to be 1.2-1.5 ℃/min;
(c) If the temperature in the thermostatic chamber reaches 146 ℃, stopping heating and keeping a thermostatic state, wherein the temperature in the thermostatic chamber is stabilized within the range of 146 +/-2 ℃, and preferably, the keeping time is 5 minutes;
Step S3, stop heating:
Judging whether the temperature of the formation lamp bodies reaches the range of 146 +/-2 ℃, if so, stopping heating, and if not, continuously keeping the constant temperature state of the constant temperature cabin;
Step S4, negative pressure forming:
Starting a vacuum pump to change the constant temperature cabin into negative pressure, and matching the formation lamp body with the forming die so as to form a curved surface;
Step S5, cooling process:
(a) if the temperature of the formation lamp bodies is higher than or equal to 100 ℃, keeping the negative pressure state of the constant temperature cabin, and naturally cooling;
(b) if the temperature of the formation lamp bodies is lower than 100 ℃, the negative pressure state of the constant-temperature cabin is released, the cabin door of the constant-temperature cabin is opened, natural ventilation is carried out, and the formation lamp bodies are cooled to the normal temperature;
Step S6, secondary molding:
And (5) carrying out numerical control machining to ensure the required shape and size.
As a preferred scheme of a curved conformal method of an airplane formation lamp, a formation lamp body comprises a lamp body shell and a light source capable of being curved;
the lamp body shell is provided with a panel, a middle plate and a bottom plate which are sequentially arranged from top to bottom, the panel, the middle plate and the bottom plate are respectively made of glass fiber reinforced polycarbonate plates with corresponding thicknesses, a through hole is formed in the middle plate, so that a space for accommodating a curved surface light source is formed by the panel, the middle plate and the bottom plate in a surrounding mode, further, the glass fiber reinforced polycarbonate PC +30% GF is adopted, and the thicknesses of the panel, the middle plate and the bottom plate are respectively 1mm, 2mm and 1 mm;
The light source with curved surface comprises a flexible circuit board and a light guide plate, wherein the flexible circuit board is combined with a side-emitting LED, the light guide plate is made of optical-grade polycarbonate, light-emitting surfaces of the flexible circuit board are uniformly embossed and partially pasted with shading paper, light-reflecting surfaces of the flexible circuit board are engraved with reflecting points according to optical requirements and screen-printed with flat printing ink to serve as a reflecting film, the thickness of the light guide plate is 1.5mm, and the surface roughness of the light-emitting surfaces is Ra12.5 mu m.
As a preferred scheme of the curved surface conformal method of the airplane formation lamp, the panel, the middle plate and the bottom plate are provided with positioning grooves which are matched with the positioning columns and used for ensuring that adjacent plates are not staggered when being bonded.
as a preferable scheme of the curved conformal method of the airplane formation lights, in step S2, circulating wind is started in the constant temperature cabin, and further, the wind speed is controlled at 5 m/S.
As a preferred scheme of a curved surface conformal method of an airplane formation lamp, in step S3, setting N temperature monitoring points on a formation lamp body along the length direction of the formation lamp body, where N is an integer greater than or equal to 9, sensing the temperature of each temperature monitoring point through an infrared detector, and if the temperatures of the N temperature monitoring points all reach the range of 146 ± 2 ℃, indicating that the temperature of the formation lamp body reaches 146 ± 2 ℃; if one temperature monitoring point does not reach the range of 146 +/-2 ℃, the temperature of the formation lamp bodies does not reach 146 +/-2 ℃.
As a preferable scheme of the curved surface conformal method of the airplane formation lights, in step S4, the vacuum degree of a vacuum pump is 0.1mbar, and the exhaust volume is 300m 3/h.
As a preferred scheme of a curved surface conformal method of an airplane formation lamp, in step S3, setting N temperature monitoring points on a formation lamp body along the length direction of the formation lamp body, where N is an integer greater than or equal to 9, sensing the temperature of each temperature monitoring point through an infrared detector, and if the temperatures of the N temperature monitoring points are all lower than 100 ℃, indicating that the temperature of the formation lamp body is lower than 100 ℃; if one temperature monitoring point is higher than or equal to 100 ℃, the temperature of the formation lamp body is higher than or equal to 100 ℃.
as a preferred scheme of the curved conformal method of the aircraft formation lamp, in step S6, the numerical control middle cutter system selects a polycrystalline diamond (PCD), Polycrystalline Cubic Boron Nitride (PCBN) or tungsten-cobalt (YG) type hard alloy substrate coating (TiC or TiN) cutter; the type of the tool: the cutting edge is sharp; cutting requirements: machining along the tool, and properly reducing the feed amount during cutting in and cutting out; cutting speed: 40-80 m/min (CVD process) or 80-120 m/min (PCD process); feeding: 0.2 to 0.5 mm/r. The secondary forming process can ensure that the cutting section is smooth, has no rough edges and no edge breakage phenomenon, and is easy to carry out surface treatment.
Compared with the prior art, the advantages of the invention at least comprise the following: the interlayer bonding has no stress, the curved surface forming is accurate, the brightness uniformity of the surface light source is high, and the vibration resistance and the temperature impact resistance of the formation lamp can be obviously improved.
Drawings
FIG. 1 is a flowchart of a method according to an embodiment of the present invention.
fig. 2 is a schematic structural view of a thermostatic chamber according to an embodiment of the present invention.
fig. 3 is a schematic structural diagram of a formation lamp body according to an embodiment of the present invention.
fig. 4 is a schematic structural diagram of a light source with a curved surface according to an embodiment of the invention.
Detailed Description
the present invention will be described in detail below with reference to the accompanying drawings and examples.
Referring to fig. 1-4, a method of conforming aircraft formation lights to a curved surface is shown, the following steps being performed in sequence,
step S1, the formation lamp bodies 1 are provided.
The formation lamp body 1 comprises a lamp body shell and a light source 14 with a curved surface.
The lamp housing has a panel 11, a middle plate 12 and a bottom plate 13 sequentially arranged from top to bottom. The face plate 11, the middle plate 12 and the bottom plate 13 are made of glass fiber reinforced polycarbonate plates with corresponding thicknesses. The final quality of the curved surface forming is greatly related to the thickness, the thickness proportion and the material selection of each plate. In this example, the thicknesses of the face plate 11, the middle plate 12, and the bottom plate 13 were 1mm, 2mm, and 1mm, respectively, and the glass fiber reinforced polycarbonate type PC +30% GF was found to be the most effective. The middle plate 12 is formed with a through hole, so that the panel 11, the middle plate 12 and the bottom plate 13 enclose a space for accommodating the bendable surface light source 14.
the light source 14 has a flexible circuit board 141 and a light guide plate 142. The flexible circuit board 141 is combined with side-emitting LEDs, each branch LED is driven by a series constant current, and each branch is connected in parallel to share a power supply PWM to adjust the brightness, so that the brightness uniformity of the surface light source is ensured. In addition, the starting voltage may vary slightly due to the uniformity of the LEDs themselves. Meanwhile, the LED belongs to a current type driving element, and the brightness is easy to control by adjusting the magnitude of the driving current. Through calculation, 24 LED light sources meeting the brightness requirement of the formation lamp need to be divided into 4 groups which are connected in series to form a group and share a constant current source branch, and 6 groups of branches are connected in parallel and share a PWM voltage source for brightness adjustment.
The light guide plate 142 is made of optical grade polycarbonate, in this embodiment, the thickness of the light guide plate 142 is 1.5mm, and the surface roughness ra12.5 μm is uniformly embossed on the light-emitting surface. Then processing the shape, laser engraving reflection points on the reflection surface (the surface opposite to the light-emitting surface) according to the optical requirement, then silk-screen printing plain ink on the surface as a reflection film, and finally secondary forming processing and pasting a shading film on the light-emitting surface. Since the light guide plate 142 has no off-shape reflective film and no light-scattering mode, no wrinkles appear during the formation of the heating quadric surface, which affects the light-homogenizing effect. Meanwhile, the laser engraving reflection points are engraved at variable intervals when the curved surface is developed into a plane, and then the curved surface is subjected to light simulation, so that the uniform light effect is not influenced after the quadric surface is formed. The light guide plate 142 and the panel 11 are bonded by an optical film adhesive, so that the light transmission is not influenced.
The panel 11, the middle plate 12 and the bottom plate 13 are all provided with positioning grooves which are matched with the positioning columns 4 to ensure that adjacent plates are not staggered when being bonded. The gap between the flexible circuit board 141 and the light guide plate 142 is filled with optical LED packaging silica gel, and is naturally cured at normal temperature.
Step S2, heat treatment.
And (3) placing the formation lamp body 1 on a forming die 3 in a constant temperature cabin 2, gradually raising the temperature of the constant temperature cabin 2 from room temperature, starting circulating air, and further controlling the air speed to be 5 m/s. The temperature rise process meets the following conditions,
(a) if the temperature in the constant temperature chamber 2 is lower than or equal to 100 ℃, the temperature rise speed is controlled to be 0.8-1.2 ℃/min;
(b) If the temperature in the constant temperature cabin 2 is higher than 100 ℃ and lower than 146 ℃, controlling the temperature rise speed to be 1.2-1.5 ℃/min;
(c) If the temperature in the constant temperature chamber 2 reaches 146 ℃, stopping heating and keeping the constant temperature state, wherein the temperature in the constant temperature chamber 2 is stabilized within the range of 146 +/-2 ℃ (i.e. 144-;
in step S3, heating is stopped.
whether the temperature of the formation lamp body 1 reaches the range of 146 +/-2 ℃ or not is judged, N temperature monitoring points are set on the formation lamp body 1 along the length direction of the formation lamp body 1, N is an integer greater than or equal to 9, and N is 9 in the embodiment. The temperature of each temperature monitoring point is sensed through the infrared detector, if the temperature of 9 temperature monitoring points reaches the range of 146 +/-2 ℃, the temperature of the formation lamp bodies 1 reaches the range of 146 +/-2 ℃, and heating is stopped. If one temperature monitoring point does not reach the range of 146 +/-2 ℃, the temperature of the formation lamp bodies 1 does not reach 146 +/-2 ℃, and the constant temperature cabin 2 is kept in a constant temperature state.
Step S4, negative pressure forming.
starting a vacuum pump, changing the interior of the constant temperature cabin 2 into negative pressure, matching the formation lamp body 1 with the forming die 3, and forming the curved surface by the aid of the negative pressure, wherein the vacuum degree of the vacuum pump is 0.1mbar, and the exhaust volume is 300m 3/h.
Step S5, cooling process.
(a) If one temperature monitoring point in 9 is higher than or equal to 100 ℃, the temperature of the formation lamp body 1 is higher than or equal to 100 ℃, the negative pressure state of the constant temperature cabin 2 is maintained, and the formation lamp body is slowly cooled.
(b) If the temperatures of the 9 temperature monitoring points are all lower than 100 ℃, the temperature of the formation lamp body 1 is lower than 100 ℃, the negative pressure state of the constant temperature cabin 2 is released, the cabin door of the constant temperature cabin 2 is opened, and the air is naturally ventilated and cooled to the normal temperature.
The above process can ensure stress relief of the lamp body 1 after thermoforming.
and step S6, secondary forming.
After thermoforming, CNC numerical control machining is carried out on the formation lamp body 1, the required shape and size are guaranteed, and meanwhile uncontrollable errors caused by thermal deformation are eliminated. Because the shell part of the lamp body contains glass fiber, the processing technology needs to be adjusted as follows, and the numerical control middle cutter is a polycrystalline diamond (PCD), Polycrystalline Cubic Boron Nitride (PCBN) or tungsten-cobalt (YG) hard alloy substrate coating (TiC or TiN) cutter; the type of the tool: the cutting edge is sharp; cutting requirements: machining along the tool, and properly reducing the feed amount during cutting in and cutting out; cutting speed: 40-80 m/min (CVD process) or 80-120 m/min (PCD process); feeding: 0.2 to 0.5 mm/r. The secondary forming process can ensure that the cutting section is smooth, has no rough edges and no edge breakage phenomenon, and is easy to carry out surface treatment.
the above description is only intended to represent the embodiments of the present invention, and the description is more specific and detailed, but not to be construed as limiting the scope of the invention. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the inventive concept, which falls within the scope of the present invention. Therefore, the protection scope of the present patent shall be subject to the appended claims.
Claims (7)
1. A curved conformal method for airplane formation lamps is characterized in that the following steps are sequentially carried out,
Step S1, providing formation lamp bodies;
Step S2, heat treatment: the formation lamp bodies are arranged on a forming die in a constant temperature chamber, the temperature of the constant temperature chamber is gradually increased from room temperature, the temperature increasing process meets the following conditions,
(a) If the temperature in the constant temperature cabin is lower than or equal to 100 ℃, controlling the temperature rise speed to be 0.8-1.2 ℃/min;
(b) if the temperature in the constant-temperature cabin is higher than 100 ℃ and lower than 146 ℃, controlling the temperature rise speed to be 1.2-1.5 ℃/min;
(c) If the temperature in the thermostatic chamber reaches 146 ℃, stopping heating and keeping a thermostatic state, wherein the temperature in the thermostatic chamber is stabilized within the range of 146 +/-2 ℃ and the keeping time is 5 minutes;
Step S3, stop heating: judging whether the temperature of the formation lamp bodies reaches the range of 146 +/-2 ℃, if so, stopping heating, and if not, continuously keeping the constant temperature state of the constant temperature cabin;
step S4, negative pressure forming: starting a vacuum pump to change the constant temperature cabin into negative pressure, and matching the formation lamp body with the forming die so as to form a curved surface;
Step S5, cooling process:
(a) if the temperature of the formation lamp bodies is higher than or equal to 100 ℃, keeping the negative pressure state of the constant temperature cabin, and naturally cooling;
(b) if the temperature of the formation lamp bodies is lower than 100 ℃, the negative pressure state of the constant-temperature cabin is released, the cabin door of the constant-temperature cabin is opened, natural ventilation is carried out, and the formation lamp bodies are cooled to the normal temperature;
Step S6, secondary molding:
And (5) carrying out numerical control machining to ensure the required shape and size.
2. The method of claim 1, wherein the formation lamp body comprises a lamp body shell and a light source capable of curving;
The lamp body shell is provided with a panel, a middle plate and a bottom plate which are sequentially arranged from top to bottom, the panel, the middle plate and the bottom plate are respectively made of glass fiber reinforced polycarbonate plates with corresponding thicknesses, a through hole is formed in the middle plate, so that a space for accommodating a curved surface light source is formed by the panel, the middle plate and the bottom plate in a surrounding mode, the glass fiber reinforced polycarbonate PC +30% GF is formed, and the panel, the middle plate and the bottom plate are respectively 1mm, 2mm and 1mm in thickness;
the light source with curved surface comprises a flexible circuit board and a light guide plate, wherein the flexible circuit board is combined with a side-emitting LED, the light guide plate is made of optical-grade polycarbonate, light-emitting surfaces of the flexible circuit board are uniformly embossed and partially pasted with shading paper, reflection points are engraved on a reflection surface of the light guide plate according to optical requirements, screen printing flat printing ink is used as a reflection film, the thickness of the light guide plate is 1.5mm, and the surface roughness of the light-emitting surfaces is Ra12.5 mu m.
3. The method as claimed in claim 2, wherein the front panel, middle panel and bottom panel are provided with positioning slots for engaging with the positioning posts to ensure that adjacent panels are not misaligned when bonded.
4. The method of claim 1, wherein in step S2, circulating wind is started in the thermostatic chamber, and the wind speed is controlled at 5 m/S.
5. the method as claimed in claim 1, wherein in step S3, N temperature monitoring points are set on the formation lamp body along the length direction of the formation lamp body, where N is an integer greater than or equal to 9, the temperature of each temperature monitoring point is sensed by an infrared detector, and if the temperatures of the N temperature monitoring points all reach 146 ± 2 ℃, it indicates that the temperature of the formation lamp body reaches 146 ± 2 ℃; if one temperature monitoring point does not reach the range of 146 +/-2 ℃, the temperature of the formation lamp bodies does not reach 146 +/-2 ℃.
6. the method of claim 1, wherein in step S4, the vacuum pump has a vacuum of 0.1mbar and an exhaust rate of 300m 3/h.
7. The method of claim 1 wherein the light source is a light source for forming a formation of an aircraft,
in the step S5, setting N temperature monitoring points on the formation lamp body along the length direction of the formation lamp body, wherein N is an integer greater than or equal to 9, sensing the temperature of each temperature monitoring point through an infrared detector, and if the temperature of the N temperature monitoring points is lower than 100 ℃, indicating that the temperature of the formation lamp body is lower than 100 ℃; if one temperature monitoring point is higher than or equal to 100 ℃, the temperature of the formation lamp body is higher than or equal to 100 ℃.
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| CN201510871299.2A CN105299567B (en) | 2015-12-02 | 2015-12-02 | curved surface conformal method for airplane formation lamp |
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| CN105299567B true CN105299567B (en) | 2019-12-10 |
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| CN106671584B (en) * | 2016-12-22 | 2018-11-30 | 华中科技大学 | A kind of more contact pin transfer printing heads suitable for the conformal transfer of flexible electronic curved surface |
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| CN1947988A (en) * | 2006-11-04 | 2007-04-18 | 许小飞 | Method for producing thermal-formation products of plastic sheet material |
| CN101554761A (en) * | 2008-04-09 | 2009-10-14 | 深圳市德仓科技有限公司 | Processing method of light guide plate of hot press molding liquid crystal display backlight module illuminating system |
| CN101826572A (en) * | 2009-08-20 | 2010-09-08 | 英利能源（中国）有限公司 | Method for manufacturing photovoltaic cell panel |
| CN104633536A (en) * | 2013-11-14 | 2015-05-20 | 上海航空电器有限公司 | Large curved surface formation light with same shape of wing |
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2015
- 2015-12-02 CN CN201510871299.2A patent/CN105299567B/en active Active
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1947988A (en) * | 2006-11-04 | 2007-04-18 | 许小飞 | Method for producing thermal-formation products of plastic sheet material |
| CN101554761A (en) * | 2008-04-09 | 2009-10-14 | 深圳市德仓科技有限公司 | Processing method of light guide plate of hot press molding liquid crystal display backlight module illuminating system |
| CN101826572A (en) * | 2009-08-20 | 2010-09-08 | 英利能源（中国）有限公司 | Method for manufacturing photovoltaic cell panel |
| CN104633536A (en) * | 2013-11-14 | 2015-05-20 | 上海航空电器有限公司 | Large curved surface formation light with same shape of wing |
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