CN108819292B - Automatic laying device and method for thermoplastic composite material - Google Patents
Automatic laying device and method for thermoplastic composite material Download PDFInfo
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- CN108819292B CN108819292B CN201810752694.2A CN201810752694A CN108819292B CN 108819292 B CN108819292 B CN 108819292B CN 201810752694 A CN201810752694 A CN 201810752694A CN 108819292 B CN108819292 B CN 108819292B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
- B29C70/386—Automated tape laying [ATL]
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Abstract
The invention discloses an automatic laying device and method for thermoplastic composite materials, wherein the automatic laying device for thermoplastic composite materials comprises a laying device, the laying device is arranged on a support plate, a laser welding head of a laser welding device is fixed on one side of the laying device, and an ultrasonic vibration device is fixed on the other side of the laying device; the thermoplastic prepreg tape wound on the tape reel by the laying device is conveyed to the lower part of the pressurizing roller through the guide wheel, the main driving roller and the auxiliary driving roller, and the pressure of the pressurizing roller is controlled to ensure that the thermoplastic prepreg tape is fully contacted with the base material; the laser beam emitted by the laser welding head obliquely irradiates the junction of the thermoplastic prepreg tape and the base material, the infrared temperature measuring probe detects the processing temperature and feeds the processing temperature back to the computer, and the processing temperature is controlled in real time; the ultrasonic vibration device ultrasonically impacts the thermoplastic prepreg tape behind the pressurizing roller; the laser is used as a heat source, and a heating area is accurate and high in speed; introducing ultrasonic energy to improve the interface connection strength; the temperature is controlled in a closed loop mode, and the quality of the processed formed part is improved.
Description
Technical Field
The invention belongs to the technical field of laser processing, and relates to an automatic laying device and method for a thermoplastic composite material.
Background
The structural member made of the high-performance composite fiber material has the characteristics of high reinforcement, light weight, corrosion resistance and the like, and is widely applied in the fields of space navigation, automobiles, electric appliances, buildings and the like. The thermoplastic resin matrix composite material has the characteristics of short curing time, greatly shortened molding period, strong impact toughness, good welding performance and the like, and is paid more and more attention and researched. However, the resin base material has high melting point and high viscosity, the high temperature and high pressure are required for component forming, and the requirement on forming equipment is severe, so that the further popularization and use of the resin base material are restricted, and the problem can be effectively solved by an automatic laying forming technology.
The laser welding technology is a welding technology which uses a laser beam with high energy density as a welding heat source to melt and bond workpieces so as to achieve the purpose of welding. The laser welding beam has high energy density, high welding speed and accurate processing. The laser welding is non-contact welding, can realize the welding of certain distance, and is nimble convenient, often uses with the robot cooperation, realizes automaticly. By adopting laser welding, refractory materials can be welded, dissimilar materials can be welded, and the welding effect is good. Making it one of the ideal means for automatic placement of high performance composite fiber materials.
When the ultrasonic wave is transmitted in the medium, the phenomena of machinery, cavitation, acoustic flow, thermal effect and the like can be generated, so that the ultrasonic wave has multiple functions of strong dispersion, crushing, activation and the like. In the processing process of the composite material, power ultrasound is used for assisting, bubbles in liquid are broken by the ultrasound, high temperature, high pressure and local action are generated at the same time, and the physical and chemical properties of the composite material are improved.
Chinese patent CN104354302B discloses a device and a method for automatically laying a composite material pre-forming body in a film pasting manner, which is characterized in that fibers and resin films are firstly pressed into semi-prepreg tapes, and then the semi-prepreg tapes are laid on a core mold to obtain the pre-forming body. But the method is not suitable for laying the formed thermoplastic composite material member with small curvature, the laying speed is slow, the interface connection strength of the thermoplastic composite material is low, and the actual use requirement cannot be met.
Chinese patent CN104626611B discloses a six-axis robot-based automatic tape laying device and a method, which are characterized in that a prepreg tape is conveyed to a core mold or a laid surface through a tape laying device and is compressed, and an infrared lamp tube is used for heating, laying and molding. The infrared heating transfers energy through electromagnetic waves, the heat transfer mode is radiation heat transfer, the defects of large heating range, low energy density and the like are caused, the heat accumulation of a compression roller of the laying device influences the forming quality, the laying efficiency is low, and the processing temperature is not easy to control.
Chinese patent CN105904739A discloses a device and a method for quickly and automatically laying a thermoplastic composite material component, wherein an ultrasonic heating device is used for laying and molding a thermoplastic prepreg tape, and the crystallinity and the grain size are controlled through solidification treatment, so that the purpose of optimizing the component performance is achieved. However, the heat source is generated by mechanical vibration, so that the formed structural member has low surface forming quality and needs to be cured, and the processing efficiency is low.
Disclosure of Invention
In order to achieve the purpose, the invention provides an automatic laying device and method for thermoplastic composite materials, and solves the problems that the laying speed is low, the thermoplastic composite material interface connection strength is low, and the processing temperature is not easy to control in the prior art.
In order to solve the technical problem, the technical scheme adopted by the invention is that the automatic laying device for the thermoplastic composite material comprises a laying device, wherein the laying device is fixed on a support plate, a laser welding head of a laser welding device is fixed on one side of the laying device, an ultrasonic vibration device is fixed on the other side of the laying device, and the support plate is connected with an arm of a robot through a flange.
The laying device consists of a belt reel, a tensioning device, a thermoplastic prepreg tape, a first pneumatic cylinder, a pressurizing roller, a guide wheel, a main driving roller, an auxiliary driving roller and a third pneumatic cylinder, wherein the thermoplastic prepreg tape is wound on the belt reel, and the tensioning device is arranged in the center of the belt reel; the guide wheel is fixed below the thermoplastic prepreg tape led out from the tape reel and is contacted with the thermoplastic prepreg tape; the main driving roller and the auxiliary driving roller which are parallel to each other are positioned below the guide wheel, and the thermoplastic prepreg tape passes through the middle of the main driving roller and the auxiliary driving roller and is contacted with the main driving roller and the auxiliary driving roller; the pressurizing roller is positioned below the main driving roller and the auxiliary driving roller, and the thermoplastic prepreg tape is conveyed to the position below the pressurizing roller along the pressurizing roller to be contacted with the substrate; one side of the pressurizing roller is connected with a first air cylinder, and the first air cylinder is provided with a first piston rod, a first air hole positioned above the first piston rod and a second air hole positioned below the first piston rod; the other side of the pressurizing roller is connected with a third pneumatic cylinder, and the third pneumatic cylinder is provided with a second piston rod, a third air hole positioned below the second piston rod and a fourth air hole positioned above the second piston rod.
The laser welding device comprises a laser, a computer, a laser welding head and an infrared temperature measuring probe, wherein an input line of the laser is connected with the computer, an output line of the laser is connected with the laser welding head, the infrared temperature measuring probe is arranged on the laser welding head and is connected with the computer, and a laser beam emitted by the laser welding head obliquely irradiates the junction of the thermoplastic prepreg tape below the pressurizing roller and the substrate.
The ultrasonic vibration device is by supersonic generator, ultrasonic vibration instrument head, the amplitude transformer, the transducer, the second pneumatic cylinder, slider and guide rail are constituteed, ultrasonic vibration instrument head, the amplitude transformer links to each other in proper order with the transducer and constitutes vibration work unit, the transducer passes through signal transmission line and is connected with supersonic generator, the second pneumatic cylinder passes through the third piston and is connected with the transducer, fixed slider one end on the transducer, slider other end joint is on the guide rail, vibration work unit passes through slider along guide rail axis direction linear motion, be equipped with the sixth gas pocket that is located the fifth gas pocket of third piston below and is located the third piston top on the second pneumatic cylinder, guide rail and second pneumatic cylinder are fixed in the backup pad.
The thermoplastic prepreg tape is a composition of a thermoplastic resin and fibers; the thermoplastic resin is one of polypropylene, polyethylene or polyamide; the fiber is one or a combination of more than two of carbon fiber, glass fiber, aramid fiber or basalt fiber.
The first air hole, the fourth air hole and the sixth air hole are air inlet holes; the second air hole and the third air hole and the fifth air hole are exhaust holes.
The laying method of the thermoplastic composite material automatic laying device comprises the following steps:
the method comprises the following steps: the robot pulls a support plate for installing the laying device, the laser welding device and the ultrasonic vibration device to the position above the base material, the thermoplastic prepreg tape is conveyed to the position below the pressurizing roller through the guide wheel, the main driving roller and the auxiliary driving roller, the first air hole and the fourth air hole are used for air intake, the second air hole and the third air hole are used for air exhaust, the first piston rod of the first air cylinder and the second piston rod of the third air cylinder push the pressurizing roller, so that the thermoplastic prepreg tape is tightly attached to the base material, and the pressure is kept stable; meanwhile, air is fed into the sixth air hole, air is discharged from the fifth air hole, and a third piston rod of the second pneumatic cylinder pushes the ultrasonic vibration tool head to be in contact with the thermoplastic prepreg tape and keeps the pressure stable;
step two: the computer controls the output power of the laser, the laser releases laser beams through the laser welding head, the junction of the thermoplastic prepreg tape below the pressurizing roller and the base material is heated, the ultrasonic generator is started, the transducer converts high-frequency current energy generated by the ultrasonic generator into mechanical vibration energy, the mechanical vibration energy is amplified and converged through the amplitude transformer and then transferred to the ultrasonic vibration tool head, and the ultrasonic impact of the ultrasonic vibration tool head on the thermoplastic prepreg tape behind the pressurizing roller is realized;
step three: the base material and the robot move synchronously, the speed of the main driving roller for drawing the thermoplastic prepreg tape is kept consistent with the laying speed of the pressurizing roller, the continuous laying and forming of the thermoplastic prepreg tape are realized, the infrared temperature measuring probe detects the processing temperature and feeds the processing temperature back to the computer, the output power of the laser is adjusted in real time, and the power of a laser beam is controlled, so that the processing temperature is controlled;
step four: and (4) adjusting the laying path by changing the pose of the tail end arm of the robot, and repeating the steps from the first step to the third step until the whole thermoplastic composite material member is formed.
In the first step, when the thermoplastic prepreg tape is laid, the pressure of the pressurizing roller to the thermoplastic prepreg tape is 0.6MPa to 1.0MPa, and the pressure of the ultrasonic vibration tool head to the thermoplastic prepreg tape is 0.2MPa to 0.5 MPa.
In the second step, the laser spot is a rectangular spot, the width of the spot is 3-5 mm, the thermoplastic prepreg tape and the base material are heated at the same time, and the temperature of a laser processing area is 150-270 ℃;
in the second step, the amplitude of the ultrasonic vibration tool head is 16-20 mu m, and the vibration frequency is 40-80 kHz;
and after the infrared temperature measuring probe collects the radiation signals of the processing area, the radiation signals are transmitted to a computer through serial port communication.
The device and the method for automatically laying the thermoplastic composite material have the beneficial effects that the device and the method for automatically laying the thermoplastic composite material realize the automatic laying of the thermoplastic composite material by utilizing laser heating, and effectively solve the following problems:
(1) the laser is used as a heat source, the heating area is precise, the heating speed is high, higher laying speed can be provided, and the method has the advantages of high laying efficiency, energy conservation, environmental protection and the like;
(2) high-frequency ultrasonic energy is introduced into welding, cavitation and acoustic flow phenomena are generated after the high-frequency ultrasonic energy is transmitted to a melt, so that bubbles between laying layers of the composite material are removed, ultrasonic impact is carried out on a welded area, the defects of residual stress and the like are obviously eliminated, and the interface connection strength is improved;
(3) in the laying process of the prepreg tape, a temperature closed-loop control system is used for accurately controlling the heating temperature, so that the decomposition of resin materials caused by overhigh heating temperature is avoided, and the quality of processed formed parts is improved;
(4) the mode of continuous in-situ consolidation forming is adopted, the laying forming time is greatly saved, the laying device is matched with the robot, the laying path can be arranged according to the shape of the component, the laying efficiency is high, and the waste of raw materials is reduced.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is an overall equipment layout diagram of an automatic thermoplastic composite material placement device;
FIG. 2 is a schematic view of the placement device configuration;
FIG. 3 is a left side view of the pressure roller;
FIG. 4 is a three-dimensional view of an ultrasonic vibration device;
FIG. 5 is a control flow diagram of an automated thermoplastic composite placement process;
FIG. 6 is a control flow diagram of a closed loop temperature control system.
In the figure, 1, a laser, 2, a computer, 3, a flange, 4, a support plate, 5, a tape disk, 6, a tensioning device, 7, a laser welding head, 8, an ultrasonic generator, 9, an infrared temperature measuring probe, 10, a thermoplastic prepreg tape, 11, a first air cylinder, 12, a pressurizing roller, 13, a base material, 14, an ultrasonic vibration tool head, 15, an amplitude transformer, 16, a transducer, 17, a second air cylinder, 18, a robot, 19, a laser beam, 20, a guide wheel, 21, a main driving roller, 22, an auxiliary driving roller, 23, a sliding block, 24, a guide rail, 25, a first air hole, 26, a second air hole, 27, a first piston rod, 28, a third air cylinder, 29, a third air hole, 30, a second piston rod, 31, a fourth air hole, 32, a third piston rod, 33, a fifth air hole, 34 and a sixth air hole are arranged.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
As shown in fig. 1, the automatic laying device for thermoplastic composite materials comprises a laying device fixed on a support plate 4 and used for laying and compacting a thermoplastic prepreg tape 10; a laser welding head 7 of the laser welding device is fixed on one side of the laying device and used for heating the thermoplastic prepreg tape 10 and the base material 13, an ultrasonic vibration device is fixed on the other side of the laying device and used for inputting ultrasonic energy in the laying process, and the support plate 4 is connected with the arm of the robot 18 through the flange 3;
as shown in fig. 2 and 3, the laying device comprises a reel 5, a tensioning device 6, a thermoplastic prepreg tape 10, a first pneumatic cylinder 11, a pressurizing roller 12, a guide wheel 20, a main driving roller 21, an auxiliary driving roller 22 and a third pneumatic cylinder 28, wherein the thermoplastic prepreg tape 10 is wound on the reel 5, and the tensioning device 6 is arranged at the center of the reel 5 to ensure that the thermoplastic prepreg tape 10 is tensioned during processing; a guide wheel 20 is positioned below the thermoplastic prepreg tape 10 drawn out from the left side below the tape reel 5 and is in contact with the thermoplastic prepreg tape 10; a main driving roller 21 and a sub-driving roller 22 which are parallel to each other are positioned below the guide wheel 20, and the thermoplastic prepreg tape 10 passes through the middle of the main driving roller 21 and the sub-driving roller 22 and is in contact with the main driving roller 21 and the sub-driving roller 22; the pressure roller 12 is positioned at the left lower part of the main driving roller 21 and the auxiliary driving roller 22, and the thermoplastic prepreg tape 10 is fed along the right side of the pressure roller 12 to the lower part of the pressure roller 12 to contact the base material 13; one side of the pressurizing roller 12 is connected with a first air cylinder 11, and the first air cylinder 11 is provided with a first piston rod 27, a first air hole 25 positioned above the first piston rod 27 and a second air hole 26 positioned below the first piston rod 27; the other side of the pressurizing roller 12 is connected with a third pneumatic cylinder 28, the third pneumatic cylinder 28 is provided with a second piston rod 30, a third air hole 29 positioned below the second piston rod 30 and a fourth air hole 31 positioned above the second piston rod 30, the pressurizing roller 12 applies pressure to the thermoplastic prepreg tape 10 by using the first pneumatic cylinder 11 and the third pneumatic cylinder 28, and a stable pressure value is maintained in the processing process;
the laser welding device is composed of a laser 1, a computer 2, a laser welding head 7 and an infrared temperature measuring probe 9, wherein the laser 1 is connected with the computer 2 through an input line, the computer 2 controls the output power of the laser 1, an output line of the laser 1 is connected with the laser welding head 7, the infrared temperature measuring probe 9 is installed on one side of the laser welding head 7, the infrared temperature measuring probe 9 is connected with the computer 2, and a laser beam 19 emitted by the laser welding head 7 obliquely irradiates the junction of a thermoplastic prepreg tape 10 and a base material 13 below a pressurizing roller 12;
the ultrasonic vibration device is shown in fig. 1 and 4, and comprises an ultrasonic generator 8, an ultrasonic vibration tool head 14, an amplitude transformer 15, a transducer 16, a second pneumatic cylinder 17, a sliding block 23 and a guide rail 24, wherein the ultrasonic vibration tool head 14, the amplitude transformer 15 and the transducer 16 are sequentially connected to form a vibration working unit, the transducer 16 is connected with the ultrasonic generator 8 through a signal transmission line, the second pneumatic cylinder 17 is connected with the transducer 16 through a third piston 32, one end of the sliding block 23 is fixed on one side of the transducer 16, the other end of the sliding block 23 is clamped on the guide rail 24, the vibration working unit linearly moves along the axial direction of the guide rail 24 through the sliding block 23, a fifth air hole 33 positioned below the third piston 32 and a sixth air hole 34 positioned above the third piston 32 are arranged on the second pneumatic cylinder 17, and the guide rail 24 and the second pneumatic cylinder 17 are fixed on the support;
the first air hole 25, the fourth air hole 31 and the sixth air hole 34 are used for air intake, and the second air hole 26 and the third air hole 29 are used for air exhaust; the first piston rod 27 and the second piston rod 30 push the pressurizing roller 12; the third piston rod 32 is used to push the ultrasonically-vibratable tool bit 14.
A thermoplastic prepreg tape 10 which is a composition of a thermoplastic resin and fibers; the thermoplastic resin is one of polypropylene, polyethylene or polyamide, and the fiber is one or a combination of more than two of carbon fiber, glass fiber, aramid fiber or basalt fiber.
The invention also relates to an automatic laying method of thermoplastic composite material, as shown in figure 5, comprising the following steps:
the method comprises the following steps: the robot 18 draws the support plate 4 of the mounting and laying device, the laser welding device and the ultrasonic vibration device to the position above the base material 13, the thermoplastic prepreg tape 10 is conveyed to the position below the pressurizing roller 12 through the guide wheel 20, the main driving roller 21 and the auxiliary driving roller 22, air is supplied to the first air hole 25 and the fourth air hole 31, air is discharged to the second air hole 26 and the third air hole 29, the first piston rod 27 and the second piston rod 30 push the pressurizing roller 12, the thermoplastic prepreg tape 10 and the base material 13 are tightly attached, the pressure is kept stable, air is supplied to the sixth air hole 34, air is discharged to the fifth air hole 33, and the third piston rod 32 of the second pneumatic cylinder 17 pushes the ultrasonic vibration tool head 14 to be in contact with the thermoplastic prepreg tape 10, and the pressure is kept stable;
step two: the computer 2 controls the output power of the laser 1, the laser 1 releases a laser beam 19 through a laser welding head 7, the junction of the thermoplastic prepreg tape 10 below the pressurizing roller 12 and the base material 13 is heated, meanwhile, an ultrasonic generator 8 is started, a transducer 16 converts high-frequency current energy generated by the ultrasonic generator 8 into mechanical vibration energy, the mechanical vibration is amplified and converged through an amplitude transformer 15, and then the mechanical vibration energy is transferred to an ultrasonic vibration tool head 14, so that the ultrasonic vibration tool head 14 performs ultrasonic impact on the thermoplastic prepreg tape 10 behind the pressurizing roller 12;
step three: the base material 13 and the robot 18 move synchronously, and the speed of the main driving roller 21 for drawing the thermoplastic prepreg tape 10 is kept consistent with the laying speed of the pressurizing roller 12, so that the continuous laying and forming of the thermoplastic prepreg tape 10 are realized; the infrared temperature measuring probe 9 detects the processing temperature and feeds the processing temperature back to the computer 2, adjusts the output power of the laser 1 in real time, and controls the power of the laser beam 19, thereby controlling the heating temperature, as shown in fig. 6 specifically;
step four: and (4) adjusting the laying path by changing the pose of the arm at the tail end of the robot 18, and repeating the steps from the first step to the third step until the whole thermoplastic composite material member is formed.
In the first step, when the thermoplastic prepreg tape 10 is laid, the pressure of the first pneumatic cylinder 11 and the third pneumatic cylinder 28 is adjusted, so that the pressure of the pressurizing roller 12 on the thermoplastic prepreg tape 10 is 0.6MPa to 1.0MPa, and the interface strength of the thermoplastic prepreg tape 10 after being connected with the base material 13 is ensured; adjusting a second pneumatic cylinder 17 to ensure that the pressure of the ultrasonic vibration tool head 14 on the thermoplastic prepreg tape 10 is 0.2 MPa-0.5 MPa;
in the second step, the laser spot is a rectangular spot, the width of the spot is 3-5 mm, the thermoplastic prepreg tape 10 and the base material 13 are heated at the same time to melt the two, and the temperature of a laser processing area is 150-270 ℃; the amplitude of the ultrasonic vibration tool head 14 is 16-20 mu m, and the vibration frequency is 40-80 kHz; after collecting the radiation signal of the processing area, the infrared temperature measuring probe 9 transmits the radiation signal to the computer 2 through serial port communication, and the computer 2 adjusts the output power of the laser 1 according to the closed-loop control system, controls the power of the laser beam 19 and ensures the processing temperature.
Example 1
The method is used for automatically laying the aramid fiber/PA prepreg tape 10 with the size of 0.5mm multiplied by 12mm by using an automatic composite material laying device, and specifically comprises the following steps:
the method comprises the following steps: the robot 18 draws, installs and lays the backup pad 4 of the device, the laser welding device and the ultrasonic vibration device to the upper side of the substrate 13, the aramid fiber/PA prepreg tape 10 is conveyed to the lower side of the pressure roller 12 through the guide wheel 20, the main driving roller 21 and the auxiliary driving roller 22, the first air hole 25 and the fourth air hole 31 are filled with air, the second air hole 26 and the third air hole 29 are filled with air, the first piston rod 27 and the second piston rod 30 push the pressure roller 12 to make the aramid fiber/PA prepreg tape 10 and the substrate 13 tightly fit, the pressure of the first pneumatic cylinder 11 and the third pneumatic cylinder 28 is adjusted to make the pressure roller 12 to the aramid fiber/PA prepreg tape 10 be 1.0MPa, meanwhile, the sixth air hole 34 is filled with air, the fifth air hole 33 is exhausted, the third piston rod 32 of the second pneumatic cylinder 17 pushes the ultrasonic vibration tool head 14 to be in contact with the aramid/PA prepreg tape 10, and the pressure of the ultrasonic vibration tool head 14 to the aramid fiber/PA prepreg tape 10 is 0.5 MPa;
step two: the computer 2 controls the output power of the laser 1, the laser 1 releases a laser beam 19 through a laser welding head 7, the junction of the aramid fiber/PA prepreg tape 10 and the base material 13 below the pressurizing roller 12 is heated, the aramid fiber/PA prepreg tape 10 and the base material 13 are heated simultaneously, the laser spot is a rectangular spot, the spot width is 5mm, and the temperature of a laser processing area is 270 ℃; simultaneously, the ultrasonic generator 8 is started, the transducer 16 converts high-frequency current energy generated by the ultrasonic generator 8 into mechanical vibration energy, the mechanical vibration is amplified and converged through the amplitude transformer 15 and then transferred to the ultrasonic vibration tool head 14, the ultrasonic vibration tool head 14 ultrasonically impacts the aramid fiber/PA prepreg tape 10 behind the pressurizing roller 12, the amplitude of the ultrasonic vibration tool head 14 is 20 microns, and the vibration frequency of the ultrasonic vibration tool head 14 is 40 kHz;
step three: the base material 13 and the robot 18 move synchronously, the speed of the main driving roller 21 for drawing the aramid fiber/PA prepreg tape 10 is kept consistent with the laying speed of the pressurizing roller 12, continuous laying and forming of the aramid fiber/PA prepreg tape 10 are achieved, the infrared temperature measuring probe 9 detects the processing temperature and feeds the processing temperature back to the computer 2, the output power of the laser 1 is adjusted in real time, and the power of the laser beam 19 is controlled, so that the processing temperature is controlled;
step four: and (4) adjusting the laying path by changing the pose of the arm at the tail end of the robot 18, and repeating the steps from the first step to the third step until the whole thermoplastic composite material member is formed.
Example 2
The method is used for automatically laying the basalt fiber and carbon fiber blending/PE prepreg tape 10 with the size of 0.4mm multiplied by 10mm by using a composite material automatic laying device, and specifically comprises the following steps:
the method comprises the following steps: the robot 18 pulls and installs the support plate 4 of the laying device, the laser welding device and the ultrasonic vibration device to the upper part of the base material 13, the basalt fiber and carbon fiber blending/PE prepreg tape 10 is conveyed to the lower part of the pressurizing roller 12 through the guide wheel 20, the main driving roller 21 and the auxiliary driving roller 22, the first air hole 25 and the fourth air hole 31 are used for air inlet, the second air hole 26 and the third air hole 29 are used for air exhaust, the first piston rod 27 and the second piston rod 30 push the pressurizing roller 12 to enable the basalt fiber and carbon fiber blending/PE prepreg tape 10 to be tightly attached to the base material 13, the pressure of the first pneumatic cylinder 11 and the pressure of the third pneumatic cylinder 28 are adjusted to enable the pressurizing roller 12 to enable the pressure of the basalt fiber and carbon fiber blending/PE prepreg tape 10 to be 0.6MPa, meanwhile, the sixth air hole 34 is used for air inlet, the fifth air hole 33 is used for air exhaust, the third piston rod 32 of the second pneumatic cylinder 17 pushes the ultrasonic vibration tool head 14 to be, the pressure of the ultrasonic vibration tool head 14 on the basalt fiber and carbon fiber blended/PE prepreg tape 10 is 0.2 MPa;
step two: the computer 2 controls the output power of the laser 1, the laser 1 releases a laser beam 19 through a laser welding head 7, the junction of the basalt fiber and carbon fiber blended/PE prepreg tape 10 and the base material 13 below the pressurizing roller 12 is heated, the basalt fiber and carbon fiber blended/PE prepreg tape 10 and the base material 13 are heated at the same time, the laser spot is a rectangular spot, the spot width is 3mm, and the temperature of a laser processing area is 150 ℃; simultaneously, the ultrasonic generator 8 is started, the transducer 16 converts the high-frequency current energy generated by the ultrasonic generator 8 into mechanical vibration energy, the mechanical vibration is amplified and converged by the amplitude transformer 15 and then transferred to the ultrasonic vibration tool head 14, the ultrasonic vibration tool head 14 ultrasonically impacts the basalt fiber and carbon fiber blended/PE prepreg tape 10 behind the pressurizing roller 12, the amplitude of the ultrasonic vibration tool head 14 is 18 mu m, and the vibration frequency of the ultrasonic vibration tool head 14 is 80 kHz;
step three: the base material 13 and the robot 18 move synchronously, the speed of the main driving roller 21 for drawing the basalt fiber and carbon fiber blending/PE prepreg tape 10 is kept consistent with the laying speed of the pressurizing roller 12, continuous laying and forming of the basalt fiber and carbon fiber blending/PE prepreg tape 10 are realized, the infrared temperature measuring probe 9 detects the processing temperature and feeds the processing temperature back to the computer 2, the output power of the laser 1 is adjusted in real time, and the power of the laser beam 19 is controlled, so that the processing temperature is controlled;
step four: and (4) adjusting the laying path by changing the pose of the arm at the tail end of the robot 18, and repeating the steps from the first step to the third step until the whole thermoplastic composite material member is formed.
Example 3
The method is used for automatically laying the glass fiber/PP prepreg tape 10 with the size of 0.3mm multiplied by 15mm by using an automatic composite material laying device, and specifically comprises the following steps:
the method comprises the following steps: the robot 18 draws the support plate 4 of the mounting and laying device, the laser welding device and the ultrasonic vibration device to the upper part of the base material 13, the glass fiber/PP prepreg tape 10 is conveyed to the lower part of the pressurizing roller 12 through the guide wheel 20, the main driving roller 21 and the auxiliary driving roller 22, the first air hole 25 and the fourth air hole 31 are filled with air, the second air hole 26 and the third air hole 29 are filled with air, the first piston rod 27 and the second piston rod 30 push the pressurizing roller 12 to enable the glass fiber/PP prepreg tape 10 and the base material 13 to be tightly attached, the pressure of the first pneumatic cylinder 11 and the pressure of the third pneumatic cylinder 28 are adjusted to enable the pressure of the pressurizing roller 12 to the glass fiber/PP prepreg tape 10 to be 0.8MPa, at the same time, the sixth air hole 34 is filled with air, the fifth air hole 33 is exhausted, the third piston rod 32 of the second pneumatic cylinder 17 pushes the ultrasonic vibration tool head 14 to be in contact with the glass fiber/PP prepreg tape 10, and the pressure of the ultrasonic vibration tool head 14 to the glass fiber/PP prepreg tape 10 is 0.3 MPa;
step two: the computer 2 controls the output power of the laser 1, the laser 1 releases a laser beam 19 through a laser welding head 7, the junction of the glass fiber/PP prepreg tape 10 and the substrate 13 below the pressurizing roller 12 is heated, the glass fiber/PP prepreg tape 10 and the substrate 13 are heated simultaneously, the laser spot is a rectangular spot, the width of the spot is 4mm, and the temperature of a laser processing area is 180 ℃; simultaneously, the ultrasonic generator 8 is started, the transducer 16 converts the high-frequency current energy generated by the ultrasonic generator 8 into mechanical vibration energy, the mechanical vibration is amplified and converged by the amplitude transformer 15 and then transferred to the ultrasonic vibration tool head 14, the ultrasonic vibration tool head 14 ultrasonically impacts the glass fiber/PP prepreg tape 10 behind the pressurizing roller 12, the amplitude of the ultrasonic vibration tool head 14 is 16 mu m, and the vibration frequency of the ultrasonic vibration tool head 14 is 60 kHz;
step three: the base material 13 and the robot 18 move synchronously, the speed of the main driving roller 21 for drawing the glass fiber/PP prepreg tape 10 is kept consistent with the laying speed of the pressurizing roller 12, the continuous laying and forming of the glass fiber/PP prepreg tape 10 are realized, the infrared temperature measuring probe 9 detects the processing temperature and feeds the processing temperature back to the computer 2, the output power of the laser 1 is adjusted in real time, and the power of the laser beam 19 is controlled, so that the processing temperature is controlled;
step four: and (4) adjusting the laying path by changing the pose of the arm at the tail end of the robot 18, and repeating the steps from the first step to the third step until the whole thermoplastic composite material member is formed.
The interlaminar shear strength of the structural part obtained in the embodiment 3 of the invention can reach 35MPa, the performance is obviously improved compared with the prior interlaminar shear strength which can reach 28MPa, and the weight of the manufactured structural part is reduced to 75 percent compared with the traditional metal component.
Because the difference between the melting temperature and the thermal decomposition temperature of the resin material is small, the local heating in the automatic laying process is controlled within a certain range, and the condition of non-adhesion or over-melting is avoided. The temperature closed-loop control system used by the invention can ensure that the temperature of the processing area is controlled within +/-10 ℃ of the preset temperature, the interface connection condition is good, and the quality of the processed formed part is greatly improved.
The thermoplastic composite material structural part formed by the embodiment of the invention is of a multilayer structure, has the characteristics of high strength and light weight, can be applied to the integral manufacture of large-size structural parts and complex curved surface structural parts of crude oil pipelines, airplanes, automobiles, ship bodies and the like, effectively reduces the weight of equipment, reduces the assembling number of parts and saves the assembling and manufacturing cost.
All the embodiments in the present specification are described in a related manner, and the same and similar parts among the embodiments may be referred to each other, and each embodiment focuses on the differences from the other embodiments.
The above description is only for the preferred embodiment of the present invention, and is not intended to limit the scope of the present invention. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention shall fall within the protection scope of the present invention.
Claims (4)
1. The laying method of the thermoplastic composite material automatic laying device is characterized in that the thermoplastic composite material automatic laying device comprises a laying device, the laying device is fixed on a support plate (4), a laser welding head (7) of a laser welding device is fixed on one side of the laying device, an ultrasonic vibration device is fixed on the other side of the laying device, and the support plate (4) is connected with an arm of a robot (18) through a flange (3);
the laying device consists of a belt reel (5), a tensioning device (6), a thermoplastic prepreg tape (10), a first pneumatic cylinder (11), a pressurizing roller (12), a guide wheel (20), a main driving roller (21), an auxiliary driving roller (22) and a third pneumatic cylinder (28), wherein the thermoplastic prepreg tape (10) is wound on the belt reel (5), and the tensioning device (6) is arranged in the center of the belt reel (5); the guide wheel (20) is fixed below the thermoplastic prepreg tape (10) led out from the tape reel (5) and is contacted with the thermoplastic prepreg tape (10); a main driving roller (21) and an auxiliary driving roller (22) which are parallel to each other are positioned below the guide wheel (20), and the thermoplastic prepreg tape (10) passes through the middle of the main driving roller (21) and the auxiliary driving roller (22) and is contacted with the main driving roller (21) and the auxiliary driving roller (22); the pressure roller (12) is positioned below the main driving roller (21) and the auxiliary driving roller (22), and the thermoplastic prepreg tape (10) is conveyed along the pressure roller (12) to the position below the pressure roller (12) to be contacted with the base material (13); one side of the pressurizing roller (12) is connected with a first air cylinder (11), and the first air cylinder (11) is provided with a first piston rod (27), a first air hole (25) positioned above the first piston rod (27) and a second air hole (26) positioned below the first piston rod (27); the other side of the pressurizing roller (12) is connected with a third pneumatic cylinder (28), and a second piston rod (30), a third air hole (29) positioned below the second piston rod (30) and a fourth air hole (31) positioned above the second piston rod (30) are arranged on the third pneumatic cylinder (28);
the laser welding device is composed of a laser (1), a computer (2), a laser welding head (7) and an infrared temperature measuring probe (9), wherein an input line of the laser (1) is connected with the computer (2), an output line of the laser (1) is connected with the laser welding head (7), the infrared temperature measuring probe (9) is installed on the laser welding head (7), the infrared temperature measuring probe (9) is connected with the computer (2), and a laser beam (19) emitted by the laser welding head (7) obliquely irradiates the junction of a thermoplastic prepreg tape (10) and a base material (13) below a pressurizing roller (12);
the ultrasonic vibration device comprises an ultrasonic generator (8), an ultrasonic vibration tool head (14), an amplitude transformer (15), a transducer (16), a second pneumatic cylinder (17), a sliding block (23) and a guide rail (24), wherein the ultrasonic vibration tool head (14), the amplitude transformer (15) and the transducer (16) are sequentially connected to form a vibration working unit, the transducer (16) is connected with the ultrasonic generator (8) through a signal transmission line, the second pneumatic cylinder (17) is connected with the transducer (16) through a third piston rod (32), one end of the sliding block (23) is fixed on the transducer (16), the other end of the sliding block (23) is clamped on the guide rail (24), the vibration working unit linearly moves along the axial direction of the guide rail (24) through the sliding block (23), a fifth air hole (33) positioned below the third piston rod (32) and a sixth air hole (34) positioned above the third piston rod (32) are arranged on the second pneumatic cylinder (17), the guide rail (24) and the second pneumatic cylinder (17) are fixed on the support plate (4);
the thermoplastic prepreg tape (10) is a composition of a thermoplastic resin and fibers;
the thermoplastic resin is one of polypropylene, polyethylene or polyamide;
the fiber is one or a combination of more than two of carbon fiber, glass fiber, aramid fiber or basalt fiber;
the first air hole (25), the fourth air hole (31) and the sixth air hole (34) are air inlet holes; the second air hole (26) and the third air hole (29) and the fifth air hole (33) are exhaust holes;
the laying method of the thermoplastic composite material automatic laying device comprises the following steps:
the method comprises the following steps: a robot (18) pulls a support plate (4) of the mounting and laying device, the laser welding device and the ultrasonic vibration device to the upper side of a base material (13), a thermoplastic prepreg tape (10) is conveyed to the lower side of a pressurizing roller (12) through a guide wheel (20), a main driving roller (21) and an auxiliary driving roller (22), a first air hole (25) and a fourth air hole (31) are used for air intake, a second air hole (26) and a third air hole (29) are used for air exhaust, a first piston rod (27) of a first air cylinder (11) and a second piston rod (30) of a third air cylinder (28) push the pressurizing roller (12), so that the thermoplastic prepreg tape (10) and the base material (13) are tightly attached, and the pressure is kept stable; meanwhile, the sixth air hole (34) is used for air intake, the fifth air hole (33) is used for air exhaust, and the third piston rod (32) of the second pneumatic cylinder (17) pushes the ultrasonic vibration tool head (14) to be in contact with the thermoplastic prepreg tape (10) and keeps the pressure stable;
step two: the computer (2) controls the output power of the laser (1), the laser (1) releases a laser beam (19) through a laser welding head (7), the junction of the thermoplastic prepreg tape (10) below the pressurizing roller (12) and the base material (13) is heated, the ultrasonic generator (8) is started at the same time, the transducer (16) converts high-frequency current energy generated by the ultrasonic generator (8) into mechanical vibration energy, the mechanical vibration is amplified and converged through an amplitude transformer (15), and then the mechanical vibration is transferred to the ultrasonic vibration tool head (14), so that the ultrasonic impact of the ultrasonic vibration tool head (14) on the thermoplastic prepreg tape (10) behind the pressurizing roller (12) is realized;
step three: the base material (13) and the robot (18) move synchronously, the speed of the main driving roller (21) for drawing the thermoplastic prepreg tape (10) is kept consistent with the laying speed of the pressurizing roller (12), continuous laying and forming of the thermoplastic prepreg tape (10) are realized, the infrared temperature measuring probe (9) detects the processing temperature and feeds the processing temperature back to the computer (2), the output power of the laser (1) is adjusted in real time, and the power of the laser beam (19) is controlled, so that the processing temperature is controlled;
step four: and (3) adjusting the laying path by changing the pose of the tail end arm of the robot (18), and repeating the steps from the first step to the third step until the molding of the whole thermoplastic composite material member is finished.
2. The laying method of the thermoplastic composite automatic laying device according to the claim 1, characterized in that in the first step, when laying the thermoplastic prepreg tape (10), the pressure of the pressurizing roller (12) on the thermoplastic prepreg tape (10) is 0.6MPa to 1.0MPa, and the pressure of the ultrasonic vibration tool head (14) on the thermoplastic prepreg tape (10) is 0.2MPa to 0.5 MPa.
3. The laying method of the thermoplastic composite material automatic laying device according to the claim 1, characterized in that in the second step, the laser spot is a rectangular spot with a width of 3 mm-5 mm, and the thermoplastic prepreg tape (10) and the base material (13) are heated at the same time, and the temperature of the laser processing area is 150 ℃ to 270 ℃.
4. The laying method of the thermoplastic composite material automatic laying device according to the claim 1, characterized in that in the second step, the amplitude of the ultrasonic vibration tool head (14) is 16-20 μm, and the vibration frequency is 40-80 kHz; and after the infrared temperature measuring probe (9) collects the radiation signals of the processing area, the radiation signals are transmitted to the computer (2) through serial port communication.
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| CN109822938B (en) * | 2019-02-20 | 2021-09-21 | 长春理工大学 | Laser hot-pressing laying forming device for thermoplastic composite material plate |
| CN111361179A (en) * | 2020-03-30 | 2020-07-03 | 西安交通大学 | Thermoplastic composite material forming process suitable for complex large curvature |
| US11819942B2 (en) | 2020-12-10 | 2023-11-21 | Magna International Inc. | Method and apparatus for applying an active joining force during laser welding of overlapping workpieces |
| CN113289837A (en) * | 2021-05-27 | 2021-08-24 | 燕山大学 | Vibration-assisted powder coating roll forming device and method |
| CN113459501B (en) * | 2021-06-16 | 2022-03-18 | 华中科技大学 | Complex bearing part forming device based on fused deposition technology |
| WO2022271633A1 (en) * | 2021-06-21 | 2022-12-29 | University Of Washington | Closed loop composite welding and bonding system using radio-frequency and pressure |
| CN114474720B (en) * | 2022-01-17 | 2022-10-04 | 浙江大学 | Irradiation angle-adjustable laser-assisted continuous fiber composite in-situ additive manufacturing device |
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