Continuous fiber composite shell manufacturing equipment
Technical Field
The invention relates to the technical field of continuous fiber composite material manufacturing, in particular to continuous fiber composite material shell manufacturing equipment.
Background
The carbon fiber is used as a strategic material developed by the country, has the excellent characteristics of high strength, high rigidity, low specific gravity, friction and abrasion resistance, recycling and the like, is a new generation of high-performance light-weight advanced material, and has important application prospect in the fields of automobiles, ships, aerospace, rail transit, medical appliances and the like. However, the traditional carbon fiber composite structural member faces the problems of complex manufacturing process, long production period, frequent requirement of a die and difficulty in realizing the manufacturing of a complex structure. The creation of new moulds for the manufacture of single-variety small-lot structures, in particular single-piece structures, undoubtedly leads to an increase in production cycle and manufacturing costs.
Three-dimensional printing technology, which has been recently developed, is considered as one of the technologies most suitable for the fabrication of individualized structures. The prior researchers apply the method to the manufacture of continuous carbon fiber composite materials, for example, patent document with application number ZL2014103256503 discloses a continuous long fiber reinforced composite material 3D printer and a printing method thereof, in the process, a pre-customized die and a pre-treated fiber prepreg tape are not needed, so that the cost is greatly reduced, meanwhile, the direction of reinforcing fibers in manufactured parts is better and more conveniently controlled by adopting a 3D printing method, composite material parts with customized mechanical properties are easier to obtain, and the rapid manufacture of composite material parts with complex structures can be realized. For example, patent document with publication number CN107127972a discloses a continuous fiber reinforced composite material additive manufacturing nozzle and a printer, which consists of an outer nozzle and an inner nozzle, wherein the nozzle has simple structure and smaller size, and can improve the forming precision; in addition, the vertical distance between the outlet of the inner spray head and the outlet of the outer spray head is adjustable, so that the centering of the fiber composite material can be controlled, the molding quality is improved, and the additive manufacturing of the continuous fiber reinforced composite material is realized.
The method and the device mainly solve the problem of how to realize mixing and printing of the continuous carbon fiber thermoplastic material, but the mechanical property of the continuous fiber composite material in the printing direction is poor due to the process characteristics of layer-by-layer superposition of the additive manufacturing technology; in addition, the printed structural member is also influenced by the matrix performance of the thermoplastic material, and the mechanical performance of the printed structural member is still greatly different from that of the structural member manufactured by the traditional continuous carbon fiber composite material manufacturing process.
Disclosure of Invention
The invention discloses continuous fiber composite shell manufacturing equipment, which combines a three-dimensional printing technology with a fiber winding technology and a vacuum auxiliary impregnation technology to realize rapid manufacturing of a high-strength complex continuous fiber composite shell structure.
The continuous fiber composite shell manufacturing equipment comprises a frame, a movement module arranged on the frame, a thermoplastic material extrusion unit driven by the movement module, a winding mechanism, a printing platform and an impregnation module, wherein the movement module is arranged on the frame;
the printing platform comprises:
the top surface of the resin liquid tank is open and is driven by the motion module;
forming a supporting plate, sealing the top surface of the resin liquid tank, wherein a plurality of liquid through holes are distributed on the surface of the supporting plate, and the back surfaces of the liquid through holes are connected with liquid guide pipes extending into the resin liquid tank;
the impregnation module includes:
a resin supply unit that supplies resin to the resin liquid tank;
a film coating mechanism for coating the dried continuous fiber preform;
and the vacuum auxiliary unit is used for providing vacuum suction force for the resin diversion port on the continuous fiber preform.
The equipment provided by the invention realizes the individual and rapid manufacturing of the shell core mould, the continuous dry fiber bundles are wound on the surface of the core mould for molding, and finally, the continuous dry fiber impregnation is realized by means of the vacuum auxiliary impregnation module until the required structural member is obtained.
The working process of the equipment is as follows:
manufacturing a core, namely printing the core mold on a printing platform by adopting a thermoplastic material extruding mechanism according to a structure designed in advance;
winding, namely starting a winding mechanism to wind dry continuous fibers on the printed core mold according to a designed path after the core mold is printed, so as to obtain a preform;
after the fiber winding is finished, covering the vacuum film on the continuous fiber preform by a film covering mechanism, and connecting a hose on a resin supply unit with a resin liquid tank of a printing platform; the tail end of the suction pipe of the vacuum auxiliary unit is aligned with a resin diversion opening arranged on the preform under the control of the lifting mechanism and the motion unit, and the resin diversion opening is an upper end outlet of the resin runner; starting an oil pump of the resin supply unit, and pumping the resin liquid to a resin liquid tank; starting a vacuum pump of the vacuum auxiliary unit, gradually uploading resin liquid from the bottom to the top of the continuous fiber preform under the assistance of the vacuum pump, realizing the impregnation of the whole structure, and closing the vacuum pump and an oil pump of the resin supply unit.
And after the resin is cured, removing the structural member from the printing platform, resetting each module, and ending the whole working process.
In order to ensure that the thermoplastic material extrusion unit, the winding mechanism and the impregnating module work without interference, preferably, the moving module comprises an XY axis moving unit arranged above the printing platform, and the XY axis moving unit is provided with two power output ends for respectively driving the thermoplastic material extrusion unit and the winding mechanism.
The vacuum auxiliary unit is provided with a lifting mechanism, a vacuum pump and a vacuum hose, and preferably, the vacuum hose of the vacuum auxiliary unit and the thermoplastic material extrusion unit are arranged on the power output end of the same XY axis movement unit.
In order to allow quick core making and winding, it is preferred that the movement module comprises:
a Z-axis movement unit;
the mounting frame is fixed on the power output end of the Z-axis movement unit;
the turnover mechanism comprises a turnover motor and a turnover frame, wherein the turnover motor is fixedly arranged on a motor seat on the installation frame, one end of the turnover frame is connected with a turnover motor shaft, and the other end of the turnover frame is rotatably arranged on the installation frame;
and the rotating motor is arranged on the roll-over stand, and the resin liquid tank is arranged on the rotating shaft.
The structure can drive the structural member to turn over and rotate, so that the structure can be wound rapidly.
In order to facilitate opening and sealing of the resin liquid tank, preferably, the forming support plate is in threaded engagement with the top surface opening of the resin liquid tank.
In order to be suitable for structural members with different shapes, the passing liquid Kong Zina on the forming supporting plate is preferably distributed outwards in an annular manner. The annular arrangement is suitable for impregnating shell structural members with different diameters.
In order to further improve the application range, it is preferable that the diameters of the liquid passing holes on the same ring are different. The liquid through holes on the same ring can be suitable for impregnating shell structural members with different thicknesses.
In order to realize automatic vacuum film coverage, preferably, the film covering mechanism comprises a vacuum film feeding unit and a six-degree-of-freedom manipulator. The vacuum film is covered on the wound dry continuous fiber preform by means of the rotation of the manipulator and the printing platform.
In order to ensure the impregnation effect and achieve the full impregnation of the dry continuous fiber preform, it is further preferable that the vacuum film is internally provided with a diversion net and a release cloth in sequence, and the vacuum film is a special composite film.
The invention has the beneficial effects that:
(1) According to the continuous fiber composite shell manufacturing equipment, a three-dimensional printing technology is combined with a continuous fiber winding technology and a vacuum auxiliary impregnation technology, so that the continuous fiber composite shell is manufactured rapidly;
(2) The invention solves the problems that the traditional carbon fiber composite structural member faces the manufacturing process is complex, the production period is long, the die is often needed, and the manufacturing of complex structures is difficult to realize, and simultaneously can solve the problem that the strength of the structural member manufactured by the traditional continuous fiber composite three-dimensional printing technology is not high.
Drawings
Fig. 1 is a schematic view of the overall structure of the continuous fiber composite casing manufacturing apparatus of example 1.
Fig. 2 is a schematic diagram of the structure of fig. 1 with a portion of the structure removed.
Fig. 3 is a schematic structural view of the printing platform of fig. 1.
Fig. 4 is a schematic structural view of the resin liquid tank of example 1.
Fig. 5 is a schematic view of the structure of the molded pallet of embodiment 1.
Fig. 6 is a schematic diagram of the core making operation of example 1.
Fig. 7 is a schematic view of the winding operation of example 1.
Fig. 8 is a schematic diagram of the impregnation procedure of example 1.
Fig. 9 is a schematic view showing the structure of the upper surface of the molded pallet of example 2.
The reference numerals in the drawings are as follows: 1. the system comprises a carrier platform, 2a six degree of freedom manipulator, 3 a vacuum pump, 4 a thermoplastic extrusion unit, 5.Y a shaft motion unit, 6 a vacuum assist unit, 7.Z a shaft motion unit, 8 a wire wrapping mechanism, 9.X a shaft motion unit, 10 a resin supply unit, 11 a continuous fiber, 12 a preform, 46 a hanging plate, 101 a print platform, 102 a mounting bracket, 103 a vacuum film supply unit, 104 a roll-over stand, 105 a rotating motor, 106 a reversing motor, 301 a vacuum hose, 401 a thermoplastic extrusion mechanism, 402 a thermoplastic supply unit, 403 a thermoplastic conduit, 601 a vacuum hose guide, 602 a lifting mechanism, 603 a drive motor, 801 a lifting mechanism, 802 a continuous fiber wire feeder, 803 a pallet, 804 a drive motor, 1001 a resin liquid conduit, 1002 a resin liquid tank oil pump, 1003 a resin liquid, 1011 a molding, 1012 a resin liquid tank, 4011 an extruder 4012 a print head, 3 a fan, 4021 a thermoplastic material, 1012 a thermoplastic material, 10111 a resin liquid bracket, 10121, a heat sink, a screw hole 10113, a threaded hole 10113.
Detailed Description
The invention is described in detail below with reference to the attached drawings:
example 1
As shown in fig. 1 and 2, the continuous fiber composite housing manufacturing apparatus of the present embodiment includes: the device comprises a carrying platform 1, a six-degree-of-freedom manipulator 2, a vacuum pump 3, a thermoplastic material extrusion unit 4, a Y-axis movement unit 5, a vacuum auxiliary unit 6, a Z-axis movement unit 7, a winding mechanism 8 and an X-axis movement unit 9.
The X-axis movement unit 9 and the Y-axis movement unit 5 form a translational movement unit, two movement output ends are arranged, one of the two movement output ends is provided with the thermoplastic material extrusion unit 4 and the vacuum auxiliary unit 6 through the hanging plate 46, and the vacuum auxiliary unit 6 realizes up-and-down lifting movement through the upgrading mechanism 602; one is provided with a wire winding mechanism 8 through a lifting mechanism 801, and the wire winding mechanism 8 adopts a wire feeding mechanism 802 to realize the function; the vacuum auxiliary unit 6 is provided with a vacuum hose guide 601.
As shown in fig. 3, the loading platform 1 includes: a printing platform 101, a mounting frame 102, a tilting mechanism and a rotary motor 105. The turnover mechanism comprises a turnover motor 106 and a turnover frame 104, wherein the turnover motor 106 is fixedly arranged on a motor base on the installation frame 102, one end of the turnover frame 104 is connected with a turnover motor shaft, and the other end of the turnover frame is rotatably arranged on the installation frame 102. A rotary motor 105 is mounted on the roll-over stand 104; the printing platform 101 is mounted on the rotation shaft of the rotary motor 105.
The printing platform 101 includes: a resin liquid tank 1012 mounted on the rotation shaft of the rotary motor 105, and a molding pallet 1011 fixedly attached to the resin liquid tank 1012.
As shown in fig. 4, a schematic structure of a resin tank is provided with a resin tank connection port 10121 connected to a resin supply unit, an internal thread 10122 for mounting a molding pallet, and a resin liquid discharge port 10123 for discharging a resin liquid.
As shown in fig. 5, in order to ensure rapid impregnation and drying of the resin, the forming pallet is provided with a plurality of liquid passing holes annularly distributed from inside to outside, and the liquid passing holes are communicated with the resin in the resin tank 1012 through a hose 10112.
The working procedure of this embodiment is as follows:
each module is reset, the wire feeding mechanism 802 is lifted to the highest position under the drive of the lifting mechanism 801, and the whole wire feeding mechanism is moved to the rightmost side of the X axis under the drive of the X axis and the ball screw; similarly, the guide sleeve 601 of the vacuum hose 301 of the vacuum auxiliary unit 6 is driven by the lifting mechanism 602 to move to the highest position, and is driven by the other ball screw on the X axis to move to the leftmost side on the X axis together with the thermoplastic material extrusion mechanism 401; the six-degree-of-freedom manipulator 2 end effector moves to the leftmost side together with the manipulator; disconnecting the impregnating module resin supply unit 10 from the resin tank 1012; the printing platform of the core making module is driven by the Z-axis movement unit 7 to move to the uppermost end;
performing core making, as shown in fig. 6, printing a core mold on the carrying platform 1 according to a pre-designed structure by adopting a thermoplastic material extrusion mechanism 401; the specific process is that thermoplastic material 4021 enters an extruder 4011 through a thermoplastic material conduit 403, a core mold designed in advance is printed on a forming supporting plate 1011 through a printing nozzle 4012, and a cooling fan 4013 accelerates the cooling of the melted thermoplastic material. The preset resin runner is aligned with the liquid through holes on the forming supporting plate 1011, and the core dies with different structures can be printed on the forming supporting plate 1011 according to the different shapes of the structural members 12, and the preset resin runner can be adjusted according to the needs.
After the core mold is printed, as shown in fig. 7, the thermoplastic material extruding mechanism 401 is moved to the leftmost side of the X axis, the winding mechanism 8 is started, the continuous fibers 11 enter the continuous fiber feeding mechanism 802 through the continuous fiber guide 803, the continuous fibers are wound on the core mold printed in advance according to a designed path by combining the rotation and turning movement of the forming support plate 1011 under the driving of the driving motor 804 by the driving mechanism 801, and the fiber layer on the preform 12 is communicated with the resin runner.
After the fiber winding is completed, as shown in fig. 8, the winding mechanism 8 is moved to the rightmost side of the X-axis, the six-degree-of-freedom robot 2 covers the vacuum film on the continuous fiber preform 12 from the vacuum film supply unit 103, and connects the resin liquid conduit 1001 on the resin liquid tank oil pump 1002 in the resin supply unit 10 with the resin liquid tank 1012 of the printing platform 101; the tail end 601 of the vacuum hose 301 of the vacuum auxiliary unit 6 is aligned with a resin diversion opening arranged on the preform 12 under the control of a driving motor 603 driving a lifting mechanism 602 and an X-axis motion unit; starting the oil pump 1002 of the resin supply unit 10 to pump the resin liquid 1003 to the resin liquid tank 1012; starting a vacuum pump 3 of the vacuum auxiliary unit 6, gradually uploading resin liquid 1003 from a liquid passing hole to a resin runner inlet at the bottom of the continuous fiber preform 12 to the top under the assistance of the vacuum pump 3, realizing the impregnation of the whole structure, and closing the vacuum pump 3 and an oil pump 1002 of the resin supply unit 10 to finish the impregnation process;
after the resin is cured, the structural member 12 is removed from the printing platform 101, and the modules are reset, and the whole working process is finished.
Example 2
In this embodiment, the configuration is the same as that of embodiment 1 except that the configuration of the molded pallet 1011 is different.
As shown in fig. 9, the through holes on the forming support plate 1011 are distributed in multiple rings, and the sizes of the through holes in the same ring are different, so that the forming support plate can be suitable for structural members with various sizes and thicknesses, and the application range of the equipment is improved.
The foregoing description is only of the preferred embodiments of the present invention, and is not intended to limit the scope of the invention, but rather is intended to cover all equivalent structures as modifications within the scope of the invention, either directly or indirectly, as may be contemplated by the present invention.