CN113049682A - Damage monitoring and online maintenance system for thermosetting composite material structure - Google Patents
Damage monitoring and online maintenance system for thermosetting composite material structure Download PDFInfo
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- B29C73/00—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
- B29C73/04—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements
- B29C73/10—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements using patches sealing on the surface of the article
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- B29C73/00—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
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Abstract
Thermosetting composite materials, especially fiber reinforced thermosetting composite materials, have the advantages of small density, high specific strength and specific modulus, good impact toughness, corrosion resistance, good molding processability and the like, and thermosetting composite material parts are increasingly applied. The detection and maintenance of equipment is an important aspect of intelligent manufacturing, but the development level of the equipment is far behind the intelligent manufacturing of production equipment, and technologies related to equipment maintenance need to be vigorously developed. The invention relates to a damage monitoring and online maintenance system for a thermosetting composite material structure, which can be used for carrying out damage identification, evaluation, positioning and repair on thermosetting composite material parts in equipment such as aerospace, transportation equipment, mining machinery, offshore platforms, power generation facilities and the like, is particularly suitable for the conditions of toxic and harmful dangerous environments and the like which are not suitable for human operation, has the advantages of strong applicability, high intelligent degree, low cost and the like, can reduce the logistics supply and storage pressure, and has wide engineering application prospect.
Description
Technical Field
The invention relates to a real-time measurement, evaluation, positioning and online maintenance system for damage of thermosetting composite material structure parts in aerospace equipment, mechanical equipment, special vehicles, petroleum pipelines, chemical engineering special equipment, power generation special equipment, special equipment and other equipment, in particular to a damage monitoring and online maintenance system for a thermosetting composite material structure, and belongs to the technical field of new materials and intelligent manufacturing.
Background
The thermosetting composite material, especially the fiber reinforced thermosetting composite material, has the advantages of small density, high specific strength and specific modulus, good impact toughness, corrosion resistance, good forming and processing performance, good designability and the like, is widely applied in engineering, and has more and more parts of the thermosetting composite material (thermosetting composite material). The intelligent manufacturing is rapidly developed, and the requirements on the automation and the unmanned degree of equipment are higher and higher. However, currently, the degree of automation is still low in terms of operational monitoring and maintenance of the equipment. The overhaul of production machinery, large-scale mining equipment, special transportation equipment, offshore platforms and the like in a factory building mainly depends on a manual detection and maintenance method, so that the time is consumed, the efficiency is low, and the maintenance speed is low. In addition, there are some situations and situations where traditional human service is not appropriate, such as: space stations in space, satellites, equipment working in toxic and harmful environments and the like. Many of the components of these devices are fabricated from thermoset composites. Therefore, it is necessary to develop a damage monitoring and online maintenance technology and system suitable for a thermosetting composite material structure to improve the automation degree of equipment maintenance and provide a technical basis for intelligent maintenance for applications such as unmanned factories, unmanned power stations, unmanned ships, space stations, and the like.
Disclosure of Invention
1. The purpose of the invention is as follows:
the invention aims to provide a damage monitoring and online maintenance system for a thermosetting composite material structure, which realizes damage monitoring and automatic online maintenance of the thermosetting composite material structure, provides an automatic and efficient online maintenance system for damage identification, evaluation, positioning and repair of thermosetting composite material parts on equipment in work, and ensures safe and reliable operation of the equipment.
2. The technical scheme is as follows:
a damage monitoring and online maintenance system for a thermosetting composite material structure comprises a thermosetting composite material structure damage identification and positioning and evaluation subsystem, an acoustic emission sensor, a low-noise signal line, a preposed signal amplifier, a signal acquisition and analysis device, a damage identification and evaluation system and a damage positioning system; the system comprises a thermosetting composite material structure damage area scanning imaging subsystem, a three-dimensional laser scanner, a computer and a model of an area needing to be repaired; the system comprises a thermosetting composite material structure damaged area pretreatment subsystem, a damaged area pretreatment control system, a surface roughening device and a cleaning device; the system comprises a thermosetting composite material structure damage area maintenance subsystem, a photocuring 3D printing control system, a laser scanning system, a laser beam, a lifter, a lifting table, a part in forming, liquid photosensitive resin, a container, a formed part, a rubber supply pipe and an adhesive box; a post-repair treatment subsystem, a post-repair surface treatment system and a bonding line are arranged in the damaged area of the thermosetting composite material structure; the method comprises the steps of preparing a damaged thermosetting composite material part, a damaged area, a manipulator, a thermosetting composite material structure to be repaired, a repaired thermosetting composite material structure and a repaired thermosetting composite material structure;
the system comprises a thermosetting composite material structure damage identification and positioning and evaluation subsystem, a signal acquisition and analysis device, a signal acquisition and analysis subsystem, a signal processing subsystem and a signal processing subsystem, wherein the thermosetting composite material structure damage identification and positioning and evaluation subsystem consists of an acoustic emission sensor, a low-noise signal wire, a preposed signal amplifier, a signal acquisition and analysis device, a damage identification and evaluation system and a damage positioning system; the specific type of the acoustic emission sensor is determined according to the use environment, the acoustic emission sensor is arranged in a cylindrical array, namely, the acoustic emission sensor is arranged in an upper circumferential array and a lower circumferential array on the surface or the near surface of the component containing the damaged thermosetting composite material, so that a cylindrical array is formed, compared with the existing square or rhombic arrangement form, the monitoring range of the cylindrical arrangement is larger and more three-dimensional, and the acoustic emission sensor can be matched with a cylindrical coordinate system for use, so that the accurate positioning of the damage is facilitated; the acoustic emission sensor is connected with the preposed signal amplifier through a low-noise signal line or a wireless communication mode, the signal is amplified and then transmitted to the signal acquisition and analysis device, the signal acquisition and analysis device filters the signal, and the filtered waveform signal is analyzed to obtain the arrival time and amplitude of different sensor channels; the damage identification and evaluation system compares the amplitude with a preset damage threshold, damage is generated when the amplitude exceeds the threshold, and when the amplitude is 1.5 times of the threshold, the damaged area needs to be repaired; the damage positioning system calculates and judges the position of the damage according to the difference value of the arrival time of different sensor channels, the space coordinate and the sound velocity of the acoustic emission sensor;
the scanning and imaging subsystem for the damaged area of the thermosetting composite material structure consists of a three-dimensional laser scanner, a computer and a model of an area to be repaired, and mainly has the functions of scanning, imaging and modeling the damaged area; after obtaining damage position information transmitted by a damage positioning system, a three-dimensional laser scanner performs laser scanning on a damage area on a component containing a damaged thermosetting composite material, point clouds on the geometric surface of the damage area are created in a computer, a three-dimensional model of the damage area is built by interpolation of the point cloud data, Boolean operation is performed on the point clouds and a structural complete model of the thermosetting composite material stored in the computer to obtain a model of the area to be repaired, and the model of the area to be repaired is converted into a photocuring 3D printing recognizable STL format file to obtain a model (STL format) of the area to be repaired;
the system comprises a system for controlling the pretreatment of the damaged area, a surface roughening device and a cleaning device, wherein the system for pretreating the damaged area of the thermosetting composite material structure mainly has the functions of performing surface roughening treatment and cleaning dust and impurities on the damaged area to be repaired; firstly, the damaged area pretreatment control system controls the surface roughening device to brush, polish and the like the damaged area on the thermosetting composite material structure to be repaired, which is grabbed by a mechanical arm, by using a steel wire brush, sand paper and the like, so that the surface of the composite material to be bonded in the damaged area is roughened, the bonding and combination of a patch manufactured by 3D printing and the damaged area are firmer, and the bonding strength is improved; then, the damaged area pretreatment control system controls the cleaning device to blow compressed air to the damaged area, the air pressure of the compressed air is between 0.1 and 0.3MPa, and dust and impurities on the surface of the damaged area are cleaned;
the system comprises a thermosetting composite material structure damage area maintenance subsystem, a laser scanning subsystem, a laser beam, a lifter, a lifting table, a part in forming, liquid photosensitive resin, a container, a formed part, a rubber supply pipe and a glue box, wherein the thermosetting composite material structure damage area maintenance subsystem comprises a photocuring 3D printing control system, a laser scanning system, a laser beam, a lifter, a lifting table, a part in forming, liquid photosensitive resin; the photocuring 3D printing control system performs slicing processing on a model (STL format) of a region to be repaired, and generates a motion instruction of a laser scanning system and a lifter according to the plane geometric information of each layer of slices; liquid photosensitive resin is contained in a container, laser with 355nm wavelength emitted by a laser is deflected and dynamically focused into laser beams through a laser scanning system, the laser beams scan point by point on the surface of the photosensitive resin under the control of a photocuring 3D printing control system according to section information of slices, the resin in a scanned area is subjected to photopolymerization reaction and is cured into a resin thin layer, the resin thin layer is placed on a workbench of a lifting table, after one layer of resin is cured, the lifting table is moved downwards by a layer thickness distance by the lifter control so that a new layer of resin is formed on the surface of the cured resin, the newly cured layer of resin can be firmly adhered to the previous layer of resin, the resin thin layers are overlapped and stacked to form a formed part, and the steps are repeated until 3D printing is finished, and the formed part is obtained; the adhesive agent box is internally stored with adhesives such as epoxy adhesive, phenolic adhesive, methacrylic adhesive, polyurethane adhesive and the like, each adhesive agent is arranged in one box, the boxes are arranged in a circumferential array, when a certain adhesive agent is needed, the adhesive agent box rotates, the adhesive agent is transferred to an adhesive outlet and is delivered for a glue supply pipe, the design can meet the bonding requirements of different material structures, and the adaptability and the universality of a maintenance system are improved; the photocuring 3D printing control system controls the glue supply pipe to coat the adhesive on the damaged area of the composite material, the manipulator places the formed part in the damaged area to be repaired to realize the bonding with the thermosetting composite material structure, and the repair work of the damaged area is completed after the adhesive is cured;
the system mainly has the functions of carrying out surface treatment on the repaired thermosetting composite material structure, and carrying out polishing, cleaning and paint repairing on the surface of a bonding wire and other surfaces needing paint repairing by the repaired surface treatment system so as to improve the aesthetic property of the repaired area and enable the repaired area to be closer to the original structure in appearance;
the damaged thermosetting composite material part comprises a damaged area, and when the size of the thermosetting composite material part is larger, a part comprising the damaged area can be detached by using a manipulator for maintenance; when the size of the thermosetting composite material part is smaller, the damaged thermosetting composite material part can be directly maintained;
the manipulator is controlled by a computer and mainly used for moving the thermosetting composite material structure in operations such as disassembling and installing the thermosetting composite material structure on a component in equipment, scanning a damaged area, preprocessing, maintaining and post-processing after maintenance, and the like;
the repaired thermosetting composite material structure is a thermosetting composite material structural member which is completed with repair and installation, the damaged area on the thermosetting composite material structural member is repaired well, the service function of the repaired thermosetting composite material component is the same as that of the undamaged thermosetting composite material component, and the mechanical property of the repaired thermosetting composite material component is not lower than 85% of that of the undamaged thermosetting composite material component in the aspects of tension, compression, bending, torsion and fatigue.
3. The invention relates to a damage monitoring and online maintenance system for a thermosetting composite material structure, which has the following advantages:
(1) the invention has wide application range and strong universality, and can provide maintenance service for mechanical equipment, special vehicles, special equipment for mines, special equipment for chemical industry, special equipment for aerospace, special equipment for power generation, special equipment and the like;
(2) the invention has high flexibility, high maintenance efficiency, low cost, no need of a die, no need of a blank, no requirement on the number of maintenance parts, no need of storing spare parts and greatly reduced pressure of logistics supply and material storage;
(3) the invention is beneficial to improving the intelligent degree and the safety and the reliability of equipment, is beneficial to realizing the online collection and the summarization of damage information in the service process of the equipment, and can provide data support for the optimization design and the improvement of the manufacturing process of thermosetting composite material parts.
In a word, the method can realize the damage identification, evaluation, positioning and online maintenance of the thermosetting composite material part on the equipment in work, has high automation degree, high efficiency and low cost, is particularly suitable for being used under the conditions of being unsuitable for manual operation, such as toxic and harmful dangerous environments and the like, can assist the development of intelligent manufacturing of power equipment, and has very wide engineering application prospect.
Drawings
The invention will be better understood from the following description of a non-limiting preferred embodiment thereof, with reference to the accompanying drawings;
FIG. 1 is a block diagram of the subsystem configuration of the present invention;
FIG. 2 is a detailed schematic of the present invention;
the symbols in the drawings are as follows: 1-a thermosetting composite material structure damage identification and positioning and evaluation subsystem, 101-an acoustic emission sensor, 102-a low-noise signal line, 103-a preposed signal amplifier, 104-a signal acquisition and analysis device, 105-a damage identification and evaluation system and 106-a damage positioning system; 2-scanning and imaging subsystem of the damaged area of the thermosetting composite material structure, 201-three-dimensional laser scanner, 202-computer, 203-model of the area needing to be repaired; 3-a system for pretreating a damaged area of a thermosetting composite material structure, 301-a system for controlling pretreatment of the damaged area, 302-a surface texturing device and 303-a cleaning device; 4-a thermosetting composite material structure damage area maintenance subsystem, 401-a photocuring 3D printing control system, 402-a laser, 403-a laser scanning system, 404-a laser beam, 405-a lifter, 406-a lifting table, 407-a part in forming, 408-liquid photosensitive resin, 409-a container, 410-a formed part, 411-a rubber supply pipe and 412-a rubber box; 5-a post-maintenance treatment subsystem for a damaged area of a thermosetting composite material structure, 501-a post-maintenance surface treatment system and 502-a bonding line; 6-a damaged thermosetting composite material component, 7-a damaged area, 8-a manipulator, 9-a thermosetting composite material structure to be repaired, 10-a repaired thermosetting composite material structure and 11-a repaired thermosetting composite material structure.
Detailed Description
The embodiments of the invention will be described in further detail below with reference to the accompanying drawings:
as shown in fig. 1 and fig. 2, the damage monitoring and online maintenance system for a thermosetting composite material structure of the present invention comprises: the system comprises a thermosetting composite material structure damage identification and positioning and evaluation subsystem 1, an acoustic emission sensor 101, a low-noise signal line 102, a preposed signal amplifier 103, a signal acquisition and analysis device 104, a damage identification and evaluation system 105 and a damage positioning system 106; the system comprises a thermosetting composite material structure damage area scanning imaging subsystem 2, a three-dimensional laser scanner 201, a computer 202 and a model 203 of an area needing to be repaired; a system 3 for pretreating a damaged area of a thermosetting composite material structure, a control system 301 for pretreating the damaged area, a surface roughening device 302 and a cleaning device 303; a thermosetting composite material structure damage area maintenance subsystem 4, a photocuring 3D printing control system 401, a laser 402, a laser scanning system 403, a laser beam 404, a lifter 405, a lifting table 406, a molding middle part 407, liquid photosensitive resin 408, a container 409, a molded part 410, a glue supply pipe 411 and a glue box 412; a post-repair treatment subsystem 5 for a damaged area of the thermosetting composite material structure, a post-repair surface treatment system 501 and a bonding line 502; the method comprises the following steps of (1) preparing a damaged thermosetting composite material part 6, a damaged area 7, a manipulator 8, a thermosetting composite material structure 9 to be repaired, a repaired thermosetting composite material structure 10 and a repaired thermosetting composite material structure 11;
the system 1 for identifying, positioning and evaluating the structural damage of the thermosetting composite material consists of an acoustic emission sensor 101, a low-noise signal wire 102, a preposed signal amplifier 103, a signal acquisition and analysis device 104, a damage identification and evaluation system 105 and a damage positioning system 106; the specific model of the acoustic emission sensor 101 is determined according to the use environment, the acoustic emission sensor 101 is arranged in a cylindrical array, namely, the acoustic emission sensor 101 is arranged in an upper circumferential array and a lower circumferential array on the surface or the near surface of the component 6 containing the damaged thermosetting composite material, so that a cylindrical array is formed, compared with the existing square or diamond arrangement form, the cylindrical arrangement has a larger monitoring range and is more three-dimensional, and the acoustic emission sensor can be matched with a cylindrical coordinate system for use, so that the accurate positioning of the damage is facilitated; the acoustic emission sensor 101 is connected with a preposed signal amplifier 103 through a low-noise signal line 102 or a wireless communication mode, the signal is amplified and then transmitted to a signal acquisition and analysis device 104, the signal acquisition and analysis device 104 filters the signal, and the filtered waveform signal is analyzed to obtain the arrival time and the amplitude of different sensor channels; the lesion identification and assessment system 105 compares the amplitude with a pre-set lesion threshold, exceeding the threshold indicates that a lesion has been created, and when the amplitude is 1.5 times the threshold, repair of the lesion area is required; the damage positioning system 106 calculates and judges the position of the damage according to the difference value of the arrival time of different sensor channels, the space coordinate of the acoustic emission sensor and the sound velocity;
the scanning and imaging subsystem 2 for the damaged area of the thermosetting composite material structure consists of a three-dimensional laser scanner 201, a computer 202 and a model 203 of the area to be repaired, and has the main functions of scanning, imaging and modeling the damaged area; after obtaining the damage position information transmitted by the damage positioning system 106, the three-dimensional laser scanner 201 performs laser scanning on the damage region 7 on the thermosetting composite material part 6 containing the damage, creates point clouds on the geometric surface of the damage region in the computer 202, interpolates the point cloud data to build a three-dimensional model of the damage region, performs Boolean operation on the three-dimensional model and a complete model of a thermosetting composite material structure stored in the computer to obtain a model of a region to be repaired, converts the model of the region to be repaired into a photocuring 3D printing recognizable STL format file, and obtains a model 203(STL format) of the region to be repaired;
the system 3 for pretreating the damaged area of the thermosetting composite material structure consists of a damaged area pretreatment control system 301, a surface roughening device 302 and a cleaning device 303, and mainly has the functions of performing surface roughening treatment and dust impurity cleaning on the damaged area to be repaired; firstly, the damaged area pretreatment control system 301 controls the surface roughening device 302 to brush, polish and the like the damaged area on the thermosetting composite material structure 9 to be repaired, which is captured by the manipulator 8, by using a steel wire brush, sand paper and the like, so that the surface of the composite material to be bonded in the damaged area is roughened, the bonding and combination of a patch manufactured by 3D printing and the damaged area are firmer, and the bonding strength is improved; then, the damaged area pretreatment control system 301 controls the cleaning device 303 to blow compressed air to the damaged area, wherein the air pressure of the compressed air is between 0.1 and 0.3MPa, and dust and impurities on the surface of the damaged area are cleaned;
the system 4 for maintaining the damaged area of the thermosetting composite material structure consists of a photocuring 3D printing control system 401, a laser 402, a laser scanning system 403, a laser beam 404, a lifter 405, a lifting table 406, a molding middle part 407, liquid photosensitive resin 408, a container 409, a molded part 410, a glue supply pipe 411 and a glue box 412; the photocuring 3D printing control system 401 performs slicing processing on the model (STL format) 203 of the region to be repaired, and generates movement instructions of the laser scanning system 403 and the lifter 405 according to the planar geometric information of each layer of slices; liquid photosensitive resin 408 is placed in a container 409, laser with 355nm wavelength emitted by a laser 402 is deflected and dynamically focused into a laser beam 404 through a laser scanning system 403, the laser beam 404 is scanned point by point on the surface of the photosensitive resin under the control of a photocuring 3D printing control system 401 according to section information of slices, resin in a scanned area is subjected to photopolymerization reaction and is cured into a thin resin layer, the thin resin layer is placed on a workbench of a lifting table 406, after the curing of one layer is finished, the lifting table 405 controls the workbench to move downwards by a layer thickness distance so as to form a new layer of resin on the surface of the cured resin, the newly cured layer can be firmly adhered to the previous layer of resin, the resin sheets are overlapped and stacked to form a forming part 407, and the steps are repeated until 3D printing is finished to obtain a formed part 410; the adhesive agent box 412 is stored with adhesives such as epoxy adhesive, phenolic adhesive, methacrylic adhesive, polyurethane adhesive and the like, each adhesive agent is arranged in one box, the boxes are arranged in a circumferential array, when a certain adhesive agent needs to be used, the adhesive agent box rotates, the adhesive agent is transferred to an adhesive outlet and is supplied for the adhesive supply pipe 411, the design can meet the bonding requirements of different material structures, and the adaptability and the universality of a maintenance system are improved; the photocuring 3D printing control system 401 controls the glue supply pipe 411 to coat an adhesive on a damaged area of the composite material, the manipulator puts the molded part 410 into the damaged area to be repaired to realize bonding with a thermosetting composite material structure, and the repair work of the damaged area is completed after the adhesive is cured;
the post-repair treatment subsystem 5 for the damaged area of the thermosetting composite material structure mainly has the functions of performing surface treatment on the repaired thermosetting composite material structure 10, and performing polishing, cleaning and paint repairing on the surface of the bonding wire 502 and other surfaces needing paint repairing by the post-repair surface treatment system 501 so as to improve the attractiveness of the repaired area and enable the repaired area to be closer to the original structure in appearance;
the damaged thermosetting composite material part 6 comprises a damaged area 7, and when the size of the thermosetting composite material part is larger, a manipulator 8 can be used for disassembling the part comprising the damaged area 7 for maintenance; when the size of the thermosetting composite material part is small, the damaged thermosetting composite material part 6 can be directly maintained;
the manipulator 8 is controlled by the computer 202 and mainly used for moving the thermosetting composite material structure in operations such as disassembling and installing the thermosetting composite material structure on a component in equipment, scanning a damaged area, preprocessing, maintaining and post-processing after maintenance, and the like, and the inner sides of partial claws at the end part of the manipulator 8 are provided with hill-shaped array protrusions made of rubber materials, so that the grabbing friction force can be improved, the composite material structure is prevented from falling off, and the design can also prevent the surface of the composite material structure from being scratched because the hardness of the composite material structure is far lower than that of steel;
the repaired thermosetting composite material structure 11 is a thermosetting composite material structural member which is completed with repair and installation, the damaged area 7 on the thermosetting composite material structure is repaired, the service function of the repaired thermosetting composite material part is the same as that of the undamaged thermosetting composite material part, and the mechanical property of the undamaged thermosetting composite material part is not lower than 85% of that of the undamaged thermosetting composite material part in the aspects of tension, compression, bending, torsion and fatigue.
The present invention has been described in terms of specific embodiments, but is not limited to the above embodiments, and all technical solutions obtained by using similar structures and alternative materials according to the idea of the present invention fall within the protection scope of the present invention.
Claims (6)
1. A damage monitoring and online maintenance system for a thermosetting composite material structure is characterized by comprising a thermosetting composite material structure damage identification and positioning and evaluation subsystem, an acoustic emission sensor, a low-noise signal line, a preposed signal amplifier, a signal acquisition and analysis device, a damage identification and evaluation system and a damage positioning system; the system comprises a thermosetting composite material structure damage area scanning imaging subsystem, a three-dimensional laser scanner, a computer and a model of an area needing to be repaired; the system comprises a thermosetting composite material structure damaged area pretreatment subsystem, a damaged area pretreatment control system, a surface roughening device and a cleaning device; the system comprises a thermosetting composite material structure damage area maintenance subsystem, a photocuring 3D printing control system, a laser scanning system, a laser beam, a lifter, a lifting table, a part in forming, liquid photosensitive resin, a container, a formed part, a rubber supply pipe and an adhesive box; a post-repair treatment subsystem, a post-repair surface treatment system and a bonding line are arranged in the damaged area of the thermosetting composite material structure; the method comprises the steps of preparing a damaged thermosetting composite material part, a damaged area, a manipulator, a thermosetting composite material structure to be repaired, a repaired thermosetting composite material structure and a repaired thermosetting composite material structure;
the system comprises a thermosetting composite material structure damage identification and positioning and evaluation subsystem, a signal acquisition and analysis device, a signal acquisition and analysis subsystem, a signal processing subsystem and a signal processing subsystem, wherein the thermosetting composite material structure damage identification and positioning and evaluation subsystem consists of an acoustic emission sensor, a low-noise signal wire, a preposed signal amplifier, a signal acquisition and analysis device, a damage identification and evaluation system and a damage positioning system; the specific type of the acoustic emission sensor is determined according to the use environment, the acoustic emission sensor is arranged in a cylindrical array, namely, the acoustic emission sensor is arranged in an upper circumferential array and a lower circumferential array on the surface or the near surface of the component containing the damaged thermosetting composite material, so that a cylindrical array is formed, compared with the existing square or rhombic arrangement form, the monitoring range of the cylindrical arrangement is larger and more three-dimensional, and the acoustic emission sensor can be matched with a cylindrical coordinate system for use, so that the accurate positioning of the damage is facilitated; the acoustic emission sensor is connected with the preposed signal amplifier through a low-noise signal line or a wireless communication mode, the signal is amplified and then transmitted to the signal acquisition and analysis device, the signal acquisition and analysis device filters the signal, and the filtered waveform signal is analyzed to obtain the arrival time and amplitude of different sensor channels; the damage identification and evaluation system compares the amplitude with a preset damage threshold, damage is generated when the amplitude exceeds the threshold, and when the amplitude is 1.5 times of the threshold, the damaged area needs to be repaired; the damage positioning system calculates and judges the position of the damage according to the difference value of the arrival time of different sensor channels, the space coordinate and the sound velocity of the acoustic emission sensor;
the scanning and imaging subsystem for the damaged area of the thermosetting composite material structure consists of a three-dimensional laser scanner, a computer and a model of an area to be repaired, and mainly has the functions of scanning, imaging and modeling the damaged area; after obtaining damage position information transmitted by a damage positioning system, a three-dimensional laser scanner performs laser scanning on a damage area on a component containing a damaged thermosetting composite material, point clouds on the geometric surface of the damage area are created in a computer, a three-dimensional model of the damage area is built by interpolation of the point cloud data, Boolean operation is performed on the point clouds and a structural complete model of the thermosetting composite material stored in the computer to obtain a model of the area to be repaired, and the model of the area to be repaired is converted into a photocuring 3D printing recognizable STL format file to obtain a model (STL format) of the area to be repaired;
the system comprises a system for controlling the pretreatment of the damaged area, a surface roughening device and a cleaning device, wherein the system for pretreating the damaged area of the thermosetting composite material structure mainly has the functions of performing surface roughening treatment and cleaning dust and impurities on the damaged area to be repaired; firstly, the damaged area pretreatment control system controls the surface roughening device to brush, polish and the like the damaged area on the thermosetting composite material structure to be repaired, which is grabbed by a mechanical arm, by using a steel wire brush, sand paper and the like, so that the surface of the composite material to be bonded in the damaged area is roughened, the bonding and combination of a patch manufactured by 3D printing and the damaged area are firmer, and the bonding strength is improved; then, the damaged area pretreatment control system controls the cleaning device to blow compressed air to the damaged area, the air pressure of the compressed air is between 0.1 and 0.3MPa, and dust and impurities on the surface of the damaged area are cleaned;
the system comprises a thermosetting composite material structure damage area maintenance subsystem, a laser scanning subsystem, a laser beam, a lifter, a lifting table, a part in forming, liquid photosensitive resin, a container, a formed part, a rubber supply pipe and a glue box, wherein the thermosetting composite material structure damage area maintenance subsystem comprises a photocuring 3D printing control system, a laser scanning system, a laser beam, a lifter, a lifting table, a part in forming, liquid photosensitive resin; the photocuring 3D printing control system performs slicing processing on a model (STL format) of a region to be repaired, and generates a motion instruction of a laser scanning system and a lifter according to the plane geometric information of each layer of slices; liquid photosensitive resin is contained in a container, laser with 355nm wavelength emitted by a laser is deflected and dynamically focused into laser beams through a laser scanning system, the laser beams scan point by point on the surface of the photosensitive resin under the control of a photocuring 3D printing control system according to section information of slices, the resin in a scanned area is subjected to photopolymerization reaction and is cured into a resin thin layer, the resin thin layer is placed on a workbench of a lifting table, after one layer of resin is cured, the lifting table is moved downwards by a layer thickness distance by the lifter control so that a new layer of resin is formed on the surface of the cured resin, the newly cured layer of resin can be firmly adhered to the previous layer of resin, the resin thin layers are overlapped and stacked to form a formed part, and the steps are repeated until 3D printing is finished, and the formed part is obtained; the adhesive agent box is internally stored with adhesives such as epoxy adhesive, phenolic adhesive, methacrylic adhesive, polyurethane adhesive and the like, each adhesive agent is arranged in one box, the boxes are arranged in a circumferential array, when a certain adhesive agent is needed, the adhesive agent box rotates, the adhesive agent is transferred to an adhesive outlet and is delivered for a glue supply pipe, the design can meet the bonding requirements of different material structures, and the adaptability and the universality of a maintenance system are improved; and the photocuring 3D printing control system controls the glue supply pipe to coat the adhesive on the damaged area of the composite material, the manipulator places the formed part in the damaged area to be repaired to realize the bonding with the thermosetting composite material structure, and the repair work of the damaged area is completed after the adhesive is cured.
2. The system for damage monitoring and on-line repair of thermoset composite structures according to claim 1, wherein: the system realizes damage monitoring and automatic online maintenance of the thermosetting composite material structure, and provides an automatic and efficient online maintenance system for identifying, evaluating, positioning and repairing the damage of the thermosetting composite material parts on the equipment in work.
3. The system for damage monitoring and on-line repair of thermoset composite structures according to claim 1, wherein: the post-repair treatment subsystem for the damaged area of the thermosetting composite material structure mainly has the functions of performing surface treatment on the repaired thermosetting composite material structure, and performing polishing, cleaning and paint repair on the surface of a bonding wire and other surfaces needing paint repair by the post-repair surface treatment system so as to improve the attractiveness of the repaired area and enable the repaired area to be closer to the original structure in appearance.
4. The system for damage monitoring and on-line repair of thermoset composite structures according to claim 1, wherein: the damaged thermosetting composite material part comprises a damaged area, and when the size of the thermosetting composite material part is larger, a part comprising the damaged area can be detached by using a manipulator for maintenance; when the size of the thermosetting composite material part is small, the damaged thermosetting composite material part can be directly repaired.
5. The system for damage monitoring and on-line repair of thermoset composite structures according to claim 1, wherein: the manipulator is controlled by a computer and mainly used for moving the thermosetting composite material structure in operations such as disassembling and installing the thermosetting composite material structure on a component in equipment, scanning a damaged area, preprocessing, maintaining and post-processing after maintenance, and the like.
6. The system for damage monitoring and on-line repair of thermoset composite structures according to claim 1, wherein: the repaired thermosetting composite material structure is a thermosetting composite material structural member which is completed with repair and installation, the damaged area on the thermosetting composite material structural member is repaired well, the service function of the repaired thermosetting composite material component is the same as that of the undamaged thermosetting composite material component, and the mechanical property of the repaired thermosetting composite material component is not lower than 85% of that of the undamaged thermosetting composite material component in the aspects of tension, compression, bending, torsion and fatigue.
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN114055814A (en) * | 2021-11-12 | 2022-02-18 | 航天特种材料及工艺技术研究所 | Repairing method of structure-function integrated composite material product |
| CN116714288A (en) * | 2023-08-10 | 2023-09-08 | 中国人民解放军空军工程大学 | Rapid repairing method for filling damaged preformed body of aircraft composite material broken hole |
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| AU2473501A (en) * | 2000-01-03 | 2001-07-16 | Board Of Regents Of The University Of Nebraska, The | Hybrid transient-parametric method and system to distinguish and analyze sourcesof acoustic emission for nondestructive inspection and structural health monito ring |
| CN101701880B (en) * | 2009-08-05 | 2011-06-29 | 南京航空航天大学 | Embedded health monitoring system for active and passive structure of aeroplane |
| US20150185128A1 (en) * | 2013-12-26 | 2015-07-02 | The Boeing Company | Detection and Assessment of Damage to Composite Structure |
| CN108318357A (en) * | 2018-01-11 | 2018-07-24 | 浙江大学 | Damage monitoring device and method for composites gas cylinder fatigue test |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN114055814A (en) * | 2021-11-12 | 2022-02-18 | 航天特种材料及工艺技术研究所 | Repairing method of structure-function integrated composite material product |
| CN114055814B (en) * | 2021-11-12 | 2023-04-14 | 航天特种材料及工艺技术研究所 | Repairing method of structure-function integrated composite material product |
| CN116714288A (en) * | 2023-08-10 | 2023-09-08 | 中国人民解放军空军工程大学 | Rapid repairing method for filling damaged preformed body of aircraft composite material broken hole |
| CN116714288B (en) * | 2023-08-10 | 2023-10-31 | 中国人民解放军空军工程大学 | Rapid repairing method for filling damaged preformed body of aircraft composite material broken hole |
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Application publication date: 20210629 |