CN113492540A - Filament winding device, system for manufacturing molded body, and method for manufacturing molded body - Google Patents
Filament winding device, system for manufacturing molded body, and method for manufacturing molded body Download PDFInfo
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- CN113492540A CN113492540A CN202110270821.7A CN202110270821A CN113492540A CN 113492540 A CN113492540 A CN 113492540A CN 202110270821 A CN202110270821 A CN 202110270821A CN 113492540 A CN113492540 A CN 113492540A
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- 238000009730 filament winding Methods 0.000 title claims abstract description 24
- 238000000034 method Methods 0.000 title claims description 28
- 238000004519 manufacturing process Methods 0.000 title claims description 26
- 238000004804 winding Methods 0.000 claims abstract description 46
- 238000011144 upstream manufacturing Methods 0.000 claims abstract description 26
- 239000011162 core material Substances 0.000 claims abstract description 20
- 239000000835 fiber Substances 0.000 claims description 87
- 229920005989 resin Polymers 0.000 claims description 50
- 239000011347 resin Substances 0.000 claims description 50
- 238000001514 detection method Methods 0.000 claims description 30
- 238000000465 moulding Methods 0.000 claims description 12
- 230000008569 process Effects 0.000 claims description 9
- 239000000463 material Substances 0.000 claims description 8
- 238000013007 heat curing Methods 0.000 claims description 2
- 239000012783 reinforcing fiber Substances 0.000 description 14
- 239000011248 coating agent Substances 0.000 description 7
- 238000000576 coating method Methods 0.000 description 7
- 230000007246 mechanism Effects 0.000 description 5
- 230000002093 peripheral effect Effects 0.000 description 4
- 230000008859 change Effects 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 2
- 239000000446 fuel Substances 0.000 description 2
- 238000005470 impregnation Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 238000004806 packaging method and process Methods 0.000 description 2
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 239000004760 aramid Substances 0.000 description 1
- 229920006231 aramid fiber Polymers 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 230000008094 contradictory effect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 230000001050 lubricating effect Effects 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 239000004645 polyester resin Substances 0.000 description 1
- 229920001225 polyester resin Polymers 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
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Classifications
-
- 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
- B29C70/34—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 and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
-
- 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
- B29C70/06—Fibrous reinforcements only
- B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
- B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Textile Engineering (AREA)
- Moulding By Coating Moulds (AREA)
Abstract
A filament winding device (1) is provided with: a conveying section (20) in which a plurality of conveying rollers (22) are arranged and which conveys a prepreg (T) of tows along the circumferential surface of the conveying rollers (22); and a winding unit (30) that winds the conveyed prepreg (T) around a core material (31). In the winding part (30), the core material (31) rotates at a predetermined rotation speed. The tension of the prepreg (T) fed from each of the feed rollers (22) is controlled in the feed section (20) so as to increase stepwise from the upstream side to the downstream side.
Description
Technical Field
The present invention relates to a filament winding device, a system for manufacturing a molded body, and a method for manufacturing a molded body.
Background
Molded bodies made of fiber-reinforced resin materials are lightweight and have excellent strength, and therefore are widely used in various fields. Such shaped bodies are generally produced by: a sheet-like base material called a prepreg (preprg) in which a plurality of reinforcing fibers are impregnated with a matrix resin is laminated, and the resin is cured by heat under pressure and heat to be shaped. As the prepreg, a sheet-like prepreg and/or a finer width tow prepreg (tow-preprg) are known.
Patent document 1 describes an invention relating to a filament winding device: the filament winding device is used for manufacturing a high-pressure hydrogen tank mounted on a fuel cell vehicle by using a fiber reinforced resin material. In the fiber winding device described in patent document 1, a fiber bundle (prepreg) wound around a bobbin is conveyed along the circumferential surfaces of a plurality of conveying rollers (conveying roller and motor-driven roller), and wound around a rotating drum in a state where the width is appropriately increased by a plurality of feed rollers (also referred to as feed eye). Patent document 1 describes: a free roller is disposed downstream of the plurality of conveying rollers, and the rotation speed of the conveying rollers is controlled based on the rotation speed of the free roller. This can suppress the abrasion of the fiber bundle on the conveying roller, and can manufacture a can with stable quality.
Documents of the prior art
Patent document
Patent document 1: japanese patent laid-open publication No. 2019-55831
Problems to be solved by the invention
However, even if the prepreg is impregnated with a homogeneous fiber-reinforced resin having a uniform fiber width, variation in the thickness of the prepreg may occur due to variation in the fiber width during conveyance by the fiber winding device. When variations occur in the thickness of the strand prepreg, irregularities are likely to occur on the surface of the molded article to be molded. As a result, the strength of the molded body tends to be uneven in the circumferential direction and/or the axial direction, and the quality of the molded body tends not to be stable. Therefore, in order to stabilize the quality of the molded article, the winding amount of the tow prepreg must be increased, and the molded article is thickened to increase the weight. This is contrary to the trend of the times to reduce the weight of various components mounted on a vehicle, for example, from the viewpoint of improving the fuel consumption rate of the vehicle. Further, weight reduction of parts is required for molded bodies that are applicable not only to the transportation field of vehicles and the like but also to other various fields.
Disclosure of Invention
The invention aims to provide a filament winding device capable of forming a thin formed body with stable quality, a manufacturing system of the formed body and a manufacturing method of the formed body.
In order to achieve the above object, the present invention provides a filament winding device including: a conveying section in which a plurality of conveying rollers are arranged and which conveys a tow prepreg along the circumferential surfaces of the conveying rollers; and a winding section that winds the prepreg tows conveyed by the conveying section around a core material, wherein the core material rotates at a predetermined rotation speed in the winding section, and wherein the tension of the prepreg tows conveyed from each of the conveying rollers is controlled to increase stepwise from an upstream side to a downstream side in the conveying section.
Generally, when a large tension is applied to a tow prepreg and the tow prepreg is conveyed, when the tow prepreg is unwound from a bobbin around which the tow prepreg is wound, the tow prepreg stacked in the stacking direction tends to be in a state in which reinforcing fibers constituting the tow prepreg are embedded in each other. This makes it impossible to smoothly unwind the tow prepreg, and the fiber width is likely to vary. When the prepreg is conveyed by applying a large tension to the prepreg, the prepreg slides easily on the circumferential surface of the conveying roller, and only the conveying roller rotates. This also makes it impossible to smoothly unwind the tow prepreg, and the fiber width is likely to vary.
According to the above configuration, in the conveying section, the tension of the prepreg tows conveyed from the conveying rollers is controlled so as to become larger in stages from the upstream side to the downstream side with respect to the plurality of conveying rollers. Therefore, the tension at the time of unwinding the prepreg tow can be suppressed to be small in the upstream bobbin, while a large tension can be applied to the prepreg tow by the downstream conveying roller.
As a result, the reinforcing fibers are less likely to be embedded into each other when the prepreg is unwound, and the prepreg being conveyed is less likely to slip on the circumferential surfaces of the conveying rollers. As a result, the prepreg tows can be smoothly unwound, and the prepreg tows can be conveyed between a plurality of conveying rollers in a state where the fiber width is stable. Further, since a large tension is applied to the downstream side conveying roller, when the prepreg is conveyed along the circumferential surface of the conveying roller, the resin in the prepreg flows out, the thickness of the prepreg becomes thin, and the fiber volume fraction Vf increases. Thus, the tow prepreg is conveyed between the plurality of conveying rollers in a state where the fiber width is stable, and becomes a high fiber volume content Vf. Therefore, a thin molded body having stable quality can be molded. Further, a molded body having excellent strength can be molded while being thin.
In the above configuration, it is preferable that the torque of the plurality of conveying rollers is controlled in the conveying unit.
According to the above configuration, since the rotation of the feed rollers is controlled by the torque, even if the diameters of the plurality of feed rollers are different, the tension applied to the prepreg tows can be easily adjusted, and the feed speed of the prepreg tows can be easily adjusted.
In the above configuration, it is preferable that the plurality of conveying rollers are disposed in the conveying portion so that contact lengths of the prepreg with respect to a circumferential surface of the conveying rollers are substantially the same.
According to the above configuration, the increase widths of the torques of the plurality of conveying rollers can be made the same. Therefore, the torque of the plurality of conveying rollers can be managed by one control unit. Control can be simplified, and the apparatus configuration can be simplified. The substantially same includes not only the case where the contact lengths of the prepreg tows with respect to the circumferential surfaces of the plurality of conveying rollers are completely the same, but also the case where the error range is, for example, about ± 20%.
In the above configuration, it is preferable that the prepreg feeding apparatus further includes a detection unit that detects a tension of the prepreg fed from the most downstream side feed roller, and the feeding unit controls a tension applied to the prepreg in the most downstream side of the feed rollers based on the detected tension, and controls the tension of the prepreg fed from each of the feed rollers to be gradually increased from the upstream side to the downstream side.
According to the above configuration, the tension of the prepreg tow being conveyed by the conveying roller is controlled based on the tension applied to the prepreg tow immediately before being wound around the core material, and therefore the tension applied to the prepreg tow can be easily controlled to a target value. Since the tension applied to the tow prepreg can be controlled to a target value, the fiber volume content Vf (%) of the tow prepreg can be easily controlled to a target value.
Another aspect of the present invention provides a filament winding device including: a conveying section in which a plurality of conveying rollers are arranged and which conveys a tow prepreg along the circumferential surfaces of the conveying rollers; a winding unit that winds the tow prepreg conveyed by the conveying unit around a core material; and a detection unit that detects at least one of a fiber width and a thickness of the prepreg in the downstream side of the plurality of conveyance rollers. In the winding portion, the core material is rotated at a predetermined rotation speed. In the conveying section, tension applied to the prepreg tows on the most downstream side of the plurality of conveying rollers is controlled based on the detection value, and the tension of the prepreg tows conveyed from each of the conveying rollers is controlled so as to become larger in stages from the upstream side to the downstream side.
Another aspect of the present invention provides a manufacturing system for manufacturing a molded article made of a fiber-reinforced resin by a filament winding method. Manufacturing system the manufacturing system includes: a conveying section in which a plurality of conveying rollers are arranged and which conveys a tow prepreg along the circumferential surfaces of the conveying rollers; a winding unit that winds the tow prepreg conveyed by the conveying unit around a core material; a detecting unit that detects a fiber width of the prepreg in the downstream side of the plurality of conveying rollers; and a control unit that controls the tension of the tow prepreg conveyed from each of the conveying rollers. The control unit controls tension applied to the prepreg tows on the most downstream side of the plurality of conveying rollers based on the detected value of the fiber width obtained by the detection unit, and controls the tension of the prepreg tows conveyed from each of the conveying rollers so as to increase stepwise from the upstream side to the downstream side.
Another aspect of the present invention provides a method for producing a fiber-reinforced resin molded article by a filament winding method. The method for manufacturing a molded body comprises: a conveying step of conveying the tow prepreg along the circumferential surfaces of a plurality of conveying rollers; a winding step of winding the fed tow prepreg around a core material to form an intermediate body; and a molding step of molding the intermediate by heat curing the intermediate. The winding process includes: the core material is rotated at a predetermined rotation speed. The conveying process includes: controlling the tension of the tow prepreg delivered from the delivery roll in a manner that becomes greater in stages as it goes from the upstream side to the downstream side.
In the above configuration, preferably, the conveying step includes: controlling the torque of the plurality of conveying rollers.
In the above configuration, the conveying step includes: controlling tension applied to the tow prepreg on the most downstream side of the plurality of conveying rollers based on a detected value of a fiber width of the tow prepreg on the most downstream side of the plurality of conveying rollers; and controlling the tension of the prepreg tows each conveyed from the conveying rollers in such a manner as to become larger in stages from the upstream side toward the downstream side.
Effects of the invention
According to the present invention, a thin molded body having stable quality can be molded.
Drawings
Fig. 1 is a schematic view of a filament winding device according to the present embodiment.
Fig. 2 is a flowchart for explaining torque control of the feed roller in the fiber winding device.
Fig. 3 is a diagram illustrating a state in which the tow prepreg is conveyed by the conveying roller.
Fig. 4 is a graph showing the relationship between the tension applied to the tow prepreg and the fiber volume content Vf.
Fig. 5 is a flowchart illustrating a modification of the torque control of the conveying roller.
Detailed Description
Hereinafter, a filament winding apparatus (hereinafter referred to as FW apparatus) embodying the present invention will be described with reference to fig. 1.
The material of the fiber-reinforced resin constituting the molded article is not particularly limited, and the resin and the reinforcing fiber constituting the fiber-reinforced resin can be appropriately selected from conventionally known materials. Examples of the resin constituting the fiber-reinforced resin include thermosetting resins such as epoxy resins, polyester resins, and phenol resins. Examples of the reinforcing fibers constituting the fiber-reinforced resin include carbon fibers, glass fibers, and aramid fibers.
As shown in fig. 1, the FW apparatus 1 (molded body manufacturing system) of the present embodiment includes a unwinding section 10, a conveying section 20, a winding section 30, a control section 40, a detection section 50, and an input section 60.
A winding drum 11 is provided in the unwinding section 10, and a tow prepreg T in which a reinforcing fiber tow is impregnated with a resin is wound around the winding drum 11. The tow prepreg T is unwound from the bobbin 11 and conveyed in the direction indicated by the arrow a in fig. 1. That is, in fig. 1, the left side is the upstream side of the FW apparatus 1, and the right side is the downstream side of the FW apparatus 1.
The conveying unit 20 is provided with a tension roller 21, a plurality of conveying rollers 22, and a feed roller (also referred to as a feed eye) 23 from the upstream side. The tension roller 21 is a roller that applies a predetermined tension to the tow prepreg T and unwinds the tow prepreg T from the bobbin 11. The plurality of conveying rollers 22 are rollers for conveying the prepreg T along the circumferential surface of the conveying rollers 22. In the present embodiment, 5 conveying rollers 22 are provided. The feed roller 23 is a roller for applying an appropriate pressure to the tow prepreg T and feeding the tow prepreg T while maintaining the fiber width thereof.
The 5 conveying rollers 22 are disposed in a positional relationship such that the contact lengths of the prepreg T with respect to the circumferential surface of the conveying rollers 22 are substantially the same when the prepreg T is conveyed. Specifically, when 5 conveying rollers 22 are provided as the conveying rollers 22a, 22b, 22c, 22d, and 22e in this order from the upstream side, the contact length of the prepreg T with respect to the circumferential surface of the conveying roller 22a is substantially the same as the contact length of the prepreg T with respect to the circumferential surface of the conveying roller 22 b. Similarly, the contact lengths of the prepreg T with the circumferential surfaces of the conveying rollers 22c, 22d, and 22e are substantially the same.
The conveying roller 22 is provided with a torque drive unit 24. The torque drive unit 24 is controlled by a control unit 40 described later. In the present embodiment, 5 conveying rollers 22 are configured to be driven by 1 torque driving unit 24.
The winding portion 30 is provided with a mandrel 31 as a core material. The mandrel 31 is a cylindrical hollow body or a cylindrical solid body having the size of the molded body to be manufactured, and is formed, for example, with an outer diameter of 90cm and a length of 100 cm.
The control unit 40 includes a feed roller control unit 41, a feed speed control unit 42, a tension roller control unit 43, a feed roller control unit 44, and a rotation speed control unit 45.
The conveying roller control unit 41 is connected to the torque drive unit 24 of the conveying unit 20. The conveying roller control unit 41 controls the torque of the conveying roller 22 by driving the torque driving unit 24 based on a detection value of the tension applied to the prepreg T detected by the detecting unit 50 described later.
The feed speed control unit 42 is connected to the winding drum 11 of the unwinding unit 10, and controls the unwinding speed of the filament prepreg T. The tension roller control unit 43 is connected to the tension roller 21 of the conveying unit 20, and controls the tension applied to the prepreg T fed from the winding drum 11 by adjusting the torque and height of the tension roller 21. The feed roller control unit 44 is connected to the feed roller 23, and adjusts the height of the feed roller 23 to control the pressure with which the tow prepreg T is pressed by the circumferential surface of the feed roller 23. By adjusting the height of the feed roller 23, the prepreg T fed from the feed roller 22 is pressed against the circumferential surface of the feed roller 23, and the fiber width of the prepreg T can be maintained. The rotation speed control unit 45 is connected to the spindle 31 and controls the rotation speed of the spindle 31.
The detection unit 50 is configured as a contact tension detection sensor provided to the feed roller 23. The tension detection sensor detects the tension applied to the prepreg T on the downstream side of the feed roller 23, obtains the detected value as a detected value, converts the detected value into an electric signal (tension detection signal ST), and outputs the electric signal to the feed roller control unit 41 of the control unit 40 at predetermined time intervals.
The input unit 60 is configured to: as the initial setting at the time of driving the FW apparatus 1, the feed speed of the bobbin 11, the torque or height of the tension roller 21, the height of the feed roller 23, the target value of the tension applied to the prepreg T in the tow on the downstream side of the feed roller 23, the rotation speed of the mandrel 31, and the like can be input to the control section 40. From these input values, the torque signal SR is output from the conveying roller control unit 41 to the torque driving unit 24 of the conveying unit 20 based on the map stored in the control unit 40, and the torque of the conveying roller 22 is set to an initial value.
Next, tension control for the tow prepreg T in the FW apparatus 1 will be described.
In the FW apparatus 1, the torques of the plurality of conveyance rollers 22 are controlled based on the detected value of the tension applied to the prepreg T detected by the tension detection sensor of the detection unit 50. By controlling the torque of the plurality of conveying rollers 22, the tension applied to the prepreg T fed from the conveying roller 22e on the most downstream side among the plurality of conveying rollers 22 is set to a predetermined value, and the tension of the prepreg T fed from each of the conveying rollers 22 is set to be gradually increased from the upstream side to the downstream side.
Before the prepreg T is conveyed in the FW apparatus 1, the FW apparatus 1 is initially set from the input unit 60 based on the fiber width of the prepreg T wound around the bobbin 11, the resin content Rc, the number of reinforcing fibers in the fiber bundle, the material of the reinforcing fibers, the material of the resin applied, and the like. Specifically, the feed speed of the bobbin 11, the torque and height of the tension roller 21, the height of the feed roller 23, a target value of the tension applied to the tow prepreg T on the downstream side of the feed roller 23, the rotation speed of the mandrel 31, and the like are input from the input unit 60. The fiber width of the tow prepreg T is input from the input unit 60. Each input value input from the input unit 60 is sent to the control unit 40.
The input value of the feed speed of the spool 11 is output from the feed speed control unit 42 to the spool 11 as an initial value. Accordingly, the winding drum 11 rotates at a predetermined rotation speed, and the filament prepreg T is unwound at a predetermined unwinding speed. The input value of the torque and height of the tension roller 21 is output from the tension roller control unit 43 to the tension roller 21 as an initial value, and a predetermined tension is applied to the prepreg T fed from the bobbin 11. The input value of the height of the feed roller 23 is output from the feed roller control unit 44 to the feed roller 23 as an initial value, and the fed prepreg T is pressed against the circumferential surface of the feed roller 23 and applied with a predetermined pressure. The input value of the rotation speed of the spindle 31 is output as an initial value from the rotation speed control unit 45 to the spindle 31, and the spindle 31 rotates at a predetermined rotation speed. The target value of the tension applied to the prepreg T on the downstream side of the feed roller 23, which is input from the input unit 60, is stored in the control unit 40 as an initial value of the tension applied to the prepreg T fed from the feed roller 23.
The control unit 40 outputs a torque signal SR for setting the torque of the conveying roller 22 from the conveying roller control unit 41 to the torque drive unit 24 based on the map stored in the control unit 40. The torque of the conveying roller 22 is set to an initial value by the torque signal SR here.
In the FW apparatus 1, 1 torque driving unit 24 is provided for 5 transport rollers 22, and 5 transport rollers 22 are driven by the 1 torque driving unit 24. The torque signal SR output from the conveying roller control section 41 drives the torque drive section 24 so that the tension applied to the prepreg T conveyed from each conveying roller 22 increases in stages with the same increase width. Specifically, when the tension of the tow prepreg T conveyed from the most downstream conveying roller 22e is set to X (kgf), the torque driving unit 24 is driven so that a tension of X/5(kgf) is applied to the tow prepreg T conveyed from the most upstream conveying roller 22a, a tension of 2X/5(kgf) is applied to the tow prepreg T conveyed from the downstream conveying roller 22b, and a tension of 3X/5(kgf) is applied to the tow prepreg T conveyed from the downstream conveying roller 22 c. In the FW apparatus 1, since the 5 conveying rollers 22 are arranged in a positional relationship such that the contact lengths of the prepreg T with respect to the circumferential surface of the conveying rollers 22 when conveying the prepreg T are substantially the same, the 1-torque driving unit 24 can control the torques of all the conveying rollers 22 to be increased by the same increase width.
As shown in the flowchart of fig. 2, the tension detection sensor of the detection unit 50 is configured to detect the value of the tension applied to the prepreg T at predetermined time intervals. In step S11, the detected value of the tension is converted into a tension detection signal ST and input to the conveying roller control unit 41 of the control unit 40.
In step S12, the conveying roller control unit 41 determines whether or not the detected value of the tension has a fluctuation width equal to or larger than a predetermined value with respect to the target value of the tension. When it is determined that the fluctuation range is not greater than the predetermined fluctuation range, the torque signal SR is not output from the conveying roller control unit 41 to the torque drive unit 24. If it is determined that the fluctuation range is greater than or equal to the predetermined fluctuation range, the process proceeds to step S13.
In step S13, it is determined whether the detected value of the tension is smaller than a target value of the tension. When it is determined that the detected value of the tension is smaller than the target value of the tension, the conveying roller control unit 41 calculates a target value of the increase width of the torque of the conveying roller 22. Then, in step S14, the torque signal SR is transmitted from the conveying roller control unit 41 to the torque drive unit 24, and the torque drive unit 24 is driven so that the torque of the conveying roller 22 reaches the target increase width.
On the other hand, when it is determined that the detected value of the tension is larger than the target value of the tension, the conveying roller control unit 41 calculates a target value of the decrease width of the torque of the conveying roller 22. Then, in step S15, the torque signal SR is transmitted from the conveying roller control unit 41 to the torque driving unit 24, and the torque driving unit 24 is driven so that the torque of the conveying roller 22 reaches the target lowering width.
In this way, in the FW apparatus 1, the tension applied to the tow prepreg T is detected at predetermined time intervals, and the torque of the conveying roller 22 is controlled based on the detected value. Thereby, the tension applied to the tow prepreg T conveyed from the feed roller 23 is controlled so as to approach a target value, and the tension applied to the tow prepreg T conveyed from the 5 conveying rollers 22 is controlled so as to become larger in stages with the same magnitude from the upstream side to the downstream side.
Next, a method for producing a molded article made of a fiber-reinforced resin using the FW apparatus 1 will be described together with its operation.
The method for manufacturing the formed body comprises the following steps: a fiber opening step of opening fiber bundles of reinforcing fibers in a so-called dry state before resin impregnation; a resin coating step of impregnating the opened reinforcing fibers with a resin to obtain a tow prepreg T; a filament winding step of conveying a tow prepreg T by an FW apparatus 1 and winding the tow prepreg T around a mandrel 31 to obtain an intermediate body; a winding step of winding a packaging tape around the peripheral surface of the intermediate body; and a molding step of heating the intermediate body around which the packaging tape is wound to obtain a molded body. The fiber opening step, the resin coating step, the winding step, and the molding step can be performed by conventionally known methods.
For example, the fiber opening step may be a method of rubbing a dry fiber bundle traveling with a constant tension with a roller, a method of applying an air flow in a state where the fiber bundle is bent, or the like. By performing the opening step, the undulation of the fiber bundle can be suppressed, so-called fiber unevenness can be reduced, and the thickness can be reduced. In addition, the fiber width is constant over the entire length, and the amount of resin applied in the resin application step can be stabilized.
Examples of the resin application step include a method of immersing the opened fiber bundle in a resin tank while conveying the fiber bundle along a conveying roller, a method of conveying the fiber bundle along the circumferential surface of a lubricating roller to which a predetermined amount of resin is supplied, and the like. By passing through the resin coating step, a certain amount of resin can be coated on the opened fiber bundle. The prepreg T subjected to the resin coating step has a predetermined fiber width, and the resin content Rc (wt%) is stable over the entire length of the prepreg T. The tow prepreg T is wound up on a bobbin 11 and supplied to a fiber winding step.
In the filament winding step, the FW apparatus 1 is used. First, the input unit 60 performs initial setting of the FW apparatus 1. The tow prepreg T is unwound at a predetermined unwinding speed while a predetermined tension is applied from the bobbin 11. Further, the sheet is conveyed to the feed roller 23 along the circumferential surface of the conveying roller 22 while the tension is increased in stages. The feed roll 23 feeds the tow prepreg T to the mandrel 31 while maintaining the fiber width thereof, and winds the tow prepreg T around the mandrel 31.
In the filament winding step, the control as described above is performed based on the detected value of the tension applied to the tow prepreg T detected by the detecting section 50 in the FW apparatus 1. Therefore, when the prepreg T is unwound, the reinforcing fibers are less likely to be embedded into each other, and the prepreg T being conveyed is less likely to slip on the circumferential surface of each conveying roller 22. As a result, the tow prepreg T is conveyed between the plurality of conveying rollers 22 in a state where the fiber width is stable.
As shown in fig. 3, when the prepreg T is conveyed along the circumferential surface of the conveying roller 22, the prepreg T is pressed by the circumferential surface of the conveying roller 22 and becomes flat. In the prepreg T pressed by the circumferential surface of the conveying roller 22, the impregnated resin R bleeds out in the width direction due to the pressure, and as a result, the fiber volume content Vf of the prepreg T increases. By increasing the tension in stages, a large tension is applied to the tow prepreg T conveyed from the conveying roller 22e on the most downstream side. The resin in the tow prepreg T is more likely to bleed out with a larger applied tension, and the fiber volume content Vf increases with a smaller thickness.
Fig. 4 shows a graph showing the relationship between the tension applied to the tow prepreg T and the fiber volume content Vf. As shown in fig. 4, in the range of the tension of 1.5kgf, the value of the fiber volume content Vf tends to increase as the tension applied to the tow prepreg T increases. In this way, in the filament winding step, the fiber width is kept constant and the fiber volume content Vf is increased by conveying the tow prepreg T while applying tension in stages, so that the quality of the tow prepreg T is stabilized.
The winding step is performed by winding a known wrapping tape around the peripheral surface of the intermediate body formed by winding the tow prepreg T around the mandrel 31. Since a moderate pressure can be applied to the peripheral surface of the intermediate body through the winding step, the generation of voids in the resin can be suppressed, and the generation of irregularities in the subsequent molding step can be suppressed.
In the molding step, the resin is thermally cured by heating the intermediate in a mold or in a heating furnace, for example. In this case, the intermediate body is thermally cured with pressure applied from the outer peripheral surface thereof by thermal shrinkage of the wrapping tape, so that generation of voids in the resin can be suppressed, and generation of irregularities on the surface can be suppressed.
Next, the effects of the above embodiment will be described.
(1) A plurality of conveying rollers 22 are disposed in the conveying section 20 of the FW device 1, and the tension of the prepreg T conveyed from the conveying rollers 22 is controlled in the conveying section 20 so as to increase stepwise from the upstream side to the downstream side.
Therefore, a large tension can be applied to the tow prepreg T conveyed from the most downstream side. The thickness of the tow prepreg T is reduced, and the fiber volume content Vf is increased. This enables molding of a thin molded article having excellent strength.
(2) The tension of the tow prepreg T conveyed from the conveying roller 22 is controlled to become larger in stages as it goes from the upstream side to the downstream side.
Therefore, the rapid application of a large tension to the conveyed tow prepreg T can be suppressed. When the prepreg T is unwound from the winding drum 11, the reinforcing fibers constituting the prepreg T are prevented from being embedded into each other, and the prepreg T can be smoothly unwound. This can suppress variation in fiber width and prevent variation in fiber width over the entire length of the tow prepreg T.
(3) Since the rapid application of a large tension to the transported prepreg T can be suppressed, the prepreg T is less likely to slip on the circumferential surface of the transport roller 22. The filament bundle prepreg T can be smoothly unwound, and variation in the fiber width of the filament bundle prepreg T can be suppressed. The quality of the molded article is stable.
(4) In the conveying section 20 of the FW apparatus 1, the tension applied to the prepreg T fed by the feed roller 22 is adjusted by controlling the torque of the feed roller 22.
Therefore, even if the plurality of conveying rollers 22 have different diameters, the tension applied to the prepreg T can be easily adjusted, and the conveying speed of the prepreg T can be easily adjusted.
(5) In the conveying section 20 of the FW apparatus 1, a plurality of conveying rollers 22 are arranged so that the contact lengths of the prepreg tows T with respect to the circumferential surface of the conveying rollers 22 are substantially the same.
Therefore, even if there are a plurality of conveying rollers 22, the rise widths of their torques can be made the same. This enables the torque of the plurality of conveying rollers 22 to be managed by 1 torque driving unit 24. The tension of the prepreg T can be controlled by the 1 torque signal SR from the conveying roller control unit 41 from the plurality of conveying rollers 22. The control of the tension applied to the tow prepreg T can be simplified, and the configuration of the FW apparatus 1 can be simplified.
(6) A detection unit 50 for detecting tension applied to the prepreg T is provided downstream of the most downstream conveying roller 22e and immediately before the mandrel 31 of the winding unit 30. Then, the tension of the tow prepreg T in the conveying section 20 is controlled based on the detected value of the tension detected by the detecting section 50.
Therefore, the tension can be brought close to the target value, and the prepreg T can be wound around the mandrel 31 in a state in which the fiber volume content Vf is well controlled. The quality of the molded article can be improved.
(7) In the conveying section 20, based on the detected value of the tension applied to the prepreg T, the tension applied to the downstream-most prepreg T of the plurality of conveying rollers 22 is controlled, and the tension of the prepreg T conveyed from each of the conveying rollers 22 is controlled so as to increase stepwise from the upstream side to the downstream side.
Therefore, the tension applied to the tow prepreg T can be easily controlled to a desired state, and the fiber volume content Vf can be made close to a target value.
(8) The method for producing a molded body using the FW apparatus 1 includes a fiber opening step and a resin coating step before the fiber winding step. In the opening step, a bundle of reinforcing fibers in a so-called dry state before resin impregnation is opened.
Therefore, the tow prepreg T supplied to the FW apparatus 1 is suppressed in undulation of the fiber tow, so-called fiber unevenness is reduced, and the thickness thereof is reduced. Further, since the fiber width is constant over the entire length, the amount of resin applied in the resin application step can be stabilized.
(9) In the resin coating step, the fiber bundles of the reinforcing fibers opened in the opening step are impregnated with a resin.
Therefore, a certain amount of resin can be applied, and the resin content Rc (wt%) is stable over the entire length of the prepreg T.
(10) The prepreg T is fed through the opening step and the resin application step while controlling the tension by the FW apparatus 1, the fiber width and the resin content Rc being stable.
Therefore, the high-quality tow prepreg T can be wound around the mandrel 31 while keeping its state. In addition, the occurrence of irregularities in the state of being wound around the mandrel 31 can be suppressed. A molded article having excellent quality can be obtained.
(11) Since a large tension can be applied to the tow prepreg T, the fiber volume content Vf of the tow prepreg T can be increased, and variation in the thickness of the tow prepreg T can be suppressed.
Therefore, the number of layers of the tow prepreg T for molding the molded body can be reduced, and the occurrence of gaps between the layers of the multilayer tow prepreg T can be suppressed. This can suppress the generation of voids due to the gaps in the winding step and the molding step. A molded body having good quality can be produced.
The above embodiment can be modified as follows. The above embodiment and the following modifications can be combined and applied within a range not technically contradictory to the technology.
Although 5 conveying rollers 22 are provided in the conveying unit 20, the number thereof is not particularly limited. The number can be set to an appropriate number according to the magnitude of the tension applied to the tow prepreg T, the rise width of the tension, the diameter of the conveying roller 22, and the like.
The plurality of conveying rollers 22 may all have the same diameter, may have different diameters mixed, or may all have different diameters.
The configuration of the tension roller 21 is not particularly limited. A roller for adjusting the tension of the tow prepreg T may be used together with a known movable dancer roller.
The tension roller 21 and the feed roller 23 may be omitted. When the feed roller 23 is omitted, the tension detection sensor of the detection unit 50 may be provided on the most downstream feed roller 22 e.
The torque driving unit 24 may not be one, and may be provided separately from each of the conveying rollers 22.
The plurality of conveying rollers 22 may not be arranged so that the contact length of the prepreg T with the circumferential surface of the roller is substantially the same.
The configuration of the control unit 40 is not limited to the above embodiment. For example, the feed speed control unit 42 and the tension roller control unit 43 may not be provided.
The rise widths of the torques may not be substantially the same, and the rise widths of the tensions of the prepreg tows T conveyed from the conveying rollers 22 may not be substantially the same. The range of the increase is not particularly limited as long as the increase is stepwise from the upstream side to the downstream side. The torque increase width and the tension increase width can be appropriately set within a range in which the fiber width does not fluctuate due to slippage of the prepreg T on the circumferential surface of the conveying roller 22.
In the above embodiment, the tension applied to the prepreg T is detected by the detecting unit 50, and based on the detected value, the tension applied to the prepreg T on the most downstream side of the plurality of conveying rollers 22 is controlled in the conveying unit 20, and the tension of the prepreg T conveyed from each of the conveying rollers 22 is controlled so as to become larger in stages from the upstream side to the downstream side. However, the object to be detected by the detecting unit 50 is not limited to the tension. The fiber width of the tow prepreg T may be set, and the thickness of the tow prepreg T may be set. The control method is not limited to the above embodiment.
For example, the case where the detecting portion 50 is configured by a width detecting sensor for detecting the fiber width of the prepreg T on the downstream side of the feed roller 23 has been described. The width detection sensor includes a light projecting section and a light receiving section. The width detection sensor converts a change in the amount of light reaching the light receiving portion into an electrical signal and outputs the electrical signal when the light projected from the light projection portion is blocked by the filament prepreg T. For example, when the prepreg T passes through the width detection sensor, the width detection sensor detects the positions of both edges in the width direction of the prepreg T from the change in the amount of light reaching the light receiving unit, and acquires the value of the fiber width of the prepreg T from the detected value. The value of the fiber width is converted into an electric signal and outputted to the transport roller control unit 41 of the control unit 40 at predetermined time intervals.
As a control method in this case, a flowchart shown in fig. 5 is considered. First, the input value of the fiber width of the prepreg T input from the input unit 60 is stored in the control unit 40 as an initial value of the fiber width of the prepreg T.
The detection unit 50 is configured to: the fiber width value of the tow prepreg T passing through the detection section 50 is detected at predetermined intervals. In step S21, the detected value of the fiber width is converted into a width detection signal and input to the conveyance roller control unit 41 of the control unit 40.
In step S22, the conveying roller control unit 41 determines whether or not the detected value of the fiber width has a fluctuation range equal to or larger than a predetermined value with respect to the initial value of the fiber width. When it is determined that the fluctuation range is not greater than the predetermined fluctuation range, the torque signal SR is not output from the conveying roller control unit 41 to the torque drive unit 24. If it is determined that the fluctuation range is greater than or equal to the predetermined fluctuation range, the process proceeds to step S23.
In step S23, it is determined whether the detected value of the fiber width is smaller than the initial value of the fiber width. When it is determined that the detected value of the fiber width is smaller than the initial value of the fiber width, the conveying roller control unit 41 calculates a target value of the increase width of the torque of the conveying roller 22. Then, in step S24, the torque signal SR is transmitted from the conveying roller control unit 41 to the torque drive unit 24, and the torque drive unit 24 is driven so that the torque of the conveying roller 22 increases to the target value.
On the other hand, when it is determined that the detected value of the fiber width is larger than the initial value of the fiber width, the conveying roller control unit 41 calculates a target value of the decrease width of the torque of the conveying roller 22. Then, in step S25, the torque signal SR is transmitted from the conveying roller control unit 41 to the torque driving unit 24, and the torque driving unit 24 is driven so that the torque of the conveying roller 22 is reduced to the target value.
By detecting the fiber width of the prepreg T at predetermined intervals and controlling the torque of the conveying roller 22 based on the detected value, it is possible to suppress variation in the fiber width of the prepreg T during conveyance by the conveying roller 22.
The winding portion 30 may be provided with a temperature adjustment mechanism on the mandrel 31 as a core. Examples of the temperature adjustment mechanism include a structure in which a heat source such as an IH heater is disposed inside the spindle 31, and a structure in which a high-temperature fluid as a heat source is circulated inside the spindle 31. In this case, the temperature control unit may be provided in the control unit 40, and the temperature of the mandrel 31 may be controlled by connecting the temperature control unit to the temperature adjustment mechanism of the mandrel 31. As the initial setting for driving the FW apparatus 1, the temperature of the spindle 31 may be inputted from the input unit 61. The input value of the temperature of the spindle 31 is output from the temperature adjustment unit to the temperature adjustment mechanism as an initial value, and the heat source is set to a predetermined temperature.
By mounting the temperature adjustment mechanism on the mandrel 31 in this way, the temperature change of the mandrel 31 during the molding process is suppressed, and the outer dimension of the mandrel 31 can be stabilized. This can improve the quality of the molded article.
The method of producing the molded article is not limited to the case of adjusting the prepreg T by the opening step and the resin coating step. The adjustment may be performed on a commercially available prepreg T wound around a bobbin. When the fiber width and the resin content Rc of the prepreg T can be appropriately controlled, the state of the prepreg T can be maintained during the conveyance by the FW device 1.
Description of the reference numerals
T: tow prepreg
1: fiber winding device
10: unwinding part
11: winding reel
20: conveying part
21: tension roller
22. 22a, 22b, 22c, 22d, 22 e: conveying roller
23: feed roll
30: winding part
31: mandrel (core material)
40: control unit
41: conveying roller control unit
50: detection part
Claims (9)
1. A filament winding device is provided with:
a conveying section in which a plurality of conveying rollers are arranged and which conveys a tow prepreg along the circumferential surfaces of the conveying rollers; and
a winding section that winds the tow prepreg conveyed by the conveying section around a core material,
the core material is rotated at a predetermined rotation speed in the winding portion,
in the conveying section, the tension of the prepreg tows conveyed from the conveying rollers is controlled to be gradually increased from the upstream side to the downstream side.
2. The filament winding device according to claim 1,
the torque of the plurality of conveying rollers is controlled in the conveying section.
3. The filament winding device according to claim 1 or 2,
in the conveying section, the plurality of conveying rollers are arranged so that contact lengths of the prepreg with respect to a circumferential surface of the conveying rollers are substantially the same.
4. The filament winding device according to any one of claims 1 to 3,
a detection unit that detects the tension of the prepreg material fed from the feed roller on the most downstream side,
in the conveying section, tension applied to the prepreg tows on the most downstream side of the plurality of conveying rollers is controlled based on the detected value of the tension, and the tension of the prepreg tows conveyed from each of the conveying rollers is controlled so as to become larger in stages from the upstream side to the downstream side.
5. A filament winding device is provided with:
a conveying section in which a plurality of conveying rollers are arranged and which conveys a tow prepreg along the circumferential surfaces of the conveying rollers;
a winding unit that winds the tow prepreg conveyed by the conveying unit around a core material; and
a detection unit that detects at least one of a fiber width and a thickness of the prepreg in the downstream side of the plurality of transport rollers,
the core material is rotated at a predetermined rotation speed in the winding portion,
in the conveying section, tension applied to the prepreg tows on the most downstream side of the plurality of conveying rollers is controlled based on the detection value, and the tension of the prepreg tows conveyed from each of the conveying rollers is controlled so as to become larger in stages from the upstream side to the downstream side.
6. A manufacturing system for manufacturing a molded body made of fiber-reinforced resin by a filament winding method, the manufacturing system comprising:
a conveying section in which a plurality of conveying rollers are arranged and which conveys a tow prepreg along the circumferential surfaces of the conveying rollers;
a winding unit that winds the tow prepreg conveyed by the conveying unit around a core material;
a detecting unit that detects a fiber width of the prepreg in the downstream side of the plurality of conveying rollers; and
a control unit that controls the tension of the tow prepreg fed from each of the feed rollers,
the control unit controls tension applied to the prepreg tows on the most downstream side of the plurality of conveying rollers based on the detected value of the fiber width obtained by the detection unit, and controls the tension of the prepreg tows conveyed from each of the conveying rollers so as to increase stepwise from the upstream side to the downstream side.
7. A method for manufacturing a molded article by a filament winding method, the method comprising:
a conveying step of conveying the tow prepreg along the circumferential surfaces of a plurality of conveying rollers;
a winding step of winding the fed tow prepreg around a core material to form an intermediate body; and
a molding step of molding the intermediate by heat curing the intermediate,
the winding process includes: the core material is rotated at a predetermined rotational speed,
the conveying process includes: controlling the tension of the tow prepreg delivered from the delivery roll in a manner that becomes greater in stages as it goes from the upstream side to the downstream side.
8. The method for producing a shaped body according to claim 7, wherein,
the conveying process includes: controlling the torque of the plurality of conveying rollers.
9. The method for producing a shaped body according to claim 7 or claim 8, wherein,
the conveying process includes:
controlling tension applied to the tow prepreg on the most downstream side of the plurality of conveying rollers based on a detected value of a fiber width of the tow prepreg on the most downstream side of the plurality of conveying rollers; and
the tension of the prepreg tows each fed from the feed roller is controlled to become larger in stages from the upstream side toward the downstream side.
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| JP2020-047436 | 2020-03-18 | ||
| JP2020047436 | 2020-03-18 | ||
| JP2021005950A JP7355768B2 (en) | 2020-03-18 | 2021-01-18 | filament winding device |
| JP2021-005950 | 2021-01-18 |
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| CN113492540A true CN113492540A (en) | 2021-10-12 |
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| CN202110270821.7A Active CN113492540B (en) | 2020-03-18 | 2021-03-12 | Filament winding device, system for manufacturing molded body, and method for manufacturing molded body |
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| CN117584478B (en) * | 2024-01-18 | 2024-04-02 | 江西元通新材料有限公司 | Multi-layer winding equipment for glass fiber tube processing |
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Also Published As
| Publication number | Publication date |
|---|---|
| CN113492540B (en) | 2023-12-29 |
| JP7355768B2 (en) | 2023-10-03 |
| JP2021151770A (en) | 2021-09-30 |
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