CN113883406A

CN113883406A - Ultra-high pressure full-wound gas cylinder with oversized aluminum alloy inner container and manufacturing method thereof

Info

Publication number: CN113883406A
Application number: CN202111013435.6A
Authority: CN
Inventors: 王东坡; 郝强; 马世成; 汪宇羿; 许强
Original assignee: Haiying Aerospace Materials Research Institute Suzhou Co ltd
Current assignee: Haiying Aerospace Materials Research Institute Suzhou Co ltd
Priority date: 2021-08-31
Filing date: 2021-08-31
Publication date: 2022-01-04

Abstract

The application provides an ultra-high pressure full-winding gas cylinder with an oversized aluminum alloy inner container and a manufacturing method thereof. This aluminum alloy inner bag superhigh pressure is winding gas cylinder entirely includes: the aluminum alloy inner container is of an integrated seamless structure with two end closing-up forming seal heads and a bottle opening, the first seal head and the second seal head are respectively positioned at two ends of the straight cylinder section, and the first bottle opening and the second bottle opening are respectively positioned on the first seal head and the second seal head; the composite material reinforcing layer is coated on the outer side of the aluminum alloy inner container, and is formed by winding carbon fibers in a spiral and annular combined winding mode and curing resin; the outer protective layer is coated on the outer side of the composite material reinforcing layer, wherein the outer protective layer is formed by winding glass fiber in a spiral and annular combined winding mode and curing the glass fiber by resin. The length of the ultra-high pressure fully-wound gas cylinder with the oversized aluminum alloy inner container is 5-13m, the nominal outer diameter of the straight cylinder section is phi 300-phi 850mm, and the service pressure of the high-pressure gas cylinder is 30-90 Mpa.

Description

Ultra-high pressure full-wound gas cylinder with oversized aluminum alloy inner container and manufacturing method thereof

Technical Field

The application relates to the technical field of high-pressure containers, in particular to an ultra-high pressure full-winding gas cylinder with an oversized aluminum alloy liner and a manufacturing method thereof.

Background

With the rapid development and industrialization of hydrogen fuel cells and electric vehicles, research and construction of hydrogen source technology and hydrogen energy infrastructure have attracted high attention in developed countries. The safe and economic hydrogen storage and transportation technology is the key point for pushing the hydrogen energy utilization to the practicability and industrialization. The most common and direct way of storing hydrogen is to use a super-high pressure gas cylinder with 35-90MPa of pressure to store hydrogen under high pressure. The high-pressure hydrogen storage can be used at normal temperature, the hydrogen can be directly released through the adjustment of the valve, and the high-pressure hydrogen storage cylinder has the advantages of simple structure, less energy consumption for preparing compressed hydrogen, high filling speed and the like, and becomes a main mode of hydrogen energy storage and transportation at the present stage.

At present, the aluminum alloy liner carbon fiber fully-wound ultrahigh-pressure gas cylinder has numerous advantages, and the aluminum alloy liner high-pressure composite hydrogen cylinder has the following advantages:

(1) the gas cylinder has light weight, good rigidity and high strength, the thickness of the material is only 50% -70% of that of the steel cylinder under the same performance, and the density is lower, so the weight of the gas cylinder is only 35% -40% of that of the traditional steel cylinder;

(2) the fatigue failure of the metal material is usually sudden failure without obvious warning, and the combination of a reinforcement in the composite material and a matrix can effectively transfer load and prevent the expansion of cracks, so that the fracture toughness of the gas cylinder is improved;

(3) when a large number of reinforcing fibers in the composite material cause the material to be overloaded and a few fibers to be broken, the load can be quickly redistributed to the fibers which are not damaged, so that the whole gas cylinder cannot lose the bearing capacity in a short time;

(4) when the composite material gas cylinder is damaged by impact or high-speed impact, dangerous fragments cannot be generated, so that the injury to personnel is reduced or avoided;

(5) the requirement of corrosion resistance can be met without special treatment;

(6) compared with the complex process required by a seamless steel gas cylinder, the fiber winding process is more flexible, easy to change, simpler in process, easy to realize automation and far lower in energy consumption than the production process of the steel gas cylinder;

(7) the fiber winding provides a convenient and reliable technical scheme for ultrahigh pressure, and is the most effective scheme for realizing the ultrahigh pressure hydrogen storage of 90 MPa.

For example, the carbon fiber fully-wound gas cylinder with the aluminum alloy liner with the outer diameter of phi 300-phi 850mm and the length of 5-13m is mainly used as a large-volume high-pressure gas cylinder for large-scale hydrogen transportation tank vehicles, a gas station gas cylinder, a transportation ship gas cylinder and the like.

However, the carbon fiber fully-wound gas cylinder with the aluminum alloy liner with the length of more than 5m cannot be produced in China at present. Under the background, in order to further master key technologies and products of a large-scale hydrogen storage and transportation device with independent property rights, obtain a new generation of special hydrogen transportation equipment with higher transportation capacity, lighter weight and higher reliability, greatly improve the hydrogen storage and transportation capacity, and urgently need to develop an oversized aluminum alloy liner high-pressure fully-wound gas cylinder product with the characteristics of large diameter, long length, light weight, high reliability and the like.

Disclosure of Invention

The application aims to provide an ultra-large aluminum alloy inner container ultrahigh pressure fully-wound gas cylinder and a manufacturing method thereof, so as to solve or relieve the problems in the prior art.

In order to achieve the above purpose, the present application provides the following technical solutions:

the application provides a super large-size aluminum alloy inner bag superhigh pressure is winding gas cylinder entirely, include: the aluminum alloy liner, the composite material reinforcing layer and the external protective layer;the aluminum alloy inner bag is the seamless structure of integral type of both ends binding off shaping head and bottleneck, includes: the sealing device comprises a first bottle opening, a first sealing head, a straight cylinder section, a second sealing head and a second bottle opening, wherein the first sealing head and the second sealing head are respectively positioned at two ends of the straight cylinder section, and the first bottle opening and the second bottle opening are respectively positioned on the first sealing head and the second sealing head; the composite material reinforcing layer is coated on the outer side of the aluminum alloy inner container, wherein the composite material reinforcing layer is formed by winding carbon fibers in a spiral and annular combined winding mode and curing the carbon fibers with resin; the outer protective layer is coated on the outer side of the composite material reinforcing layer, wherein the outer protective layer is formed by winding glass fiber in a spiral and annular combined winding mode and curing the glass fiber by resin; the ultra-high pressure full-wound gas cylinder with the ultra-large aluminum alloy inner container has the test pressure of (0, 94.5) MPa, the test temperature of room temperature and the test medium of a mixed gas of 95% nitrogen and 5% helium, and the leak rate of a helium mass spectrum leak test by a positive pressure suction gun method under the test pressure is lower than 10^-5Pa.m³/s。

The embodiment of the application still provides a manufacturing method of super large-size aluminum alloy inner bag superhigh pressure full winding gas cylinder for make above-mentioned arbitrary super large-size aluminum alloy inner bag superhigh pressure full winding gas cylinder, include:

step S1, preparing an aluminum alloy inner container spinning pipe: performing multi-pass tension spinning forming treatment on the straight cylinder section of the seamless pipe by using an ultralong cylinder tension spinning device to obtain an aluminum alloy liner spinning pipe;

step S2, closing the end socket and spinning and forming: spinning forming of the end socket and the bottle mouth is respectively carried out on the openings at the two ends of the aluminum alloy liner spinning tube by adopting a heating closing spinning machine, so that a second spinning piece is obtained;

step S3, processing of a bottle mouth center hole and a bottle mouth excircle: respectively machining a center hole of the bottle opening and an excircle of the bottle opening on the first sealing head and the second sealing head at two ends of the second spinning part obtained in the step S2 to obtain a third spinning part;

step S4, curved surface flaw detection: performing closing quality flaw detection on the third spinning part obtained in the step S3, and checking whether a machining defect exists at the end socket position;

step S5, grinding the inner surface of the curved surface: grinding the inner surface defects of the end socket found in the step S4 by using a special end socket inner surface grinding machine tool according to the flaw detection result to obtain a third rotary pressing piece with qualified quality;

step S6, heat treatment: carrying out T6 process treatment on the third spinning piece obtained in the step S5 to obtain an aluminum alloy inner container blank;

step S7, processing bottle mouth: respectively machining the inner diameters and the outer diameters of the first bottle opening and the second bottle opening of the aluminum alloy liner blank obtained in the step S6 by using a special bottle opening machining center, and machining the inner threads and the outer threads of the bottle openings to obtain an aluminum alloy liner;

step S8, cleaning the inner container; and (4) carrying out high-pressure water spraying cleaning on the inner cavity of the aluminum alloy inner container for the oversized high-pressure gas cylinder obtained in the step S7 by adopting a special horizontal gas cylinder inner container cleaning machine, removing aluminum scraps and other processing pollutants, and drying.

Step S9, checking the semi-finished product: performing spot inspection on the aluminum alloy inner container obtained in the step S8;

step S10, preprocessing the inner container: horizontally placing the aluminum alloy liner in the step S9 on a coating station of special automatic coating and drying equipment by adopting the special automatic coating and drying equipment, and coating the aluminum alloy liner with an anti-galvanic corrosion coating;

step S11, carbon fiber winding: adopting a numerical control automatic winding machine to perform carbon fiber winding processing on the aluminum alloy inner container coated with the anti-galvanic corrosion layer in the step S10 in a winding mode of combining spiral and annular directions to form a composite material reinforcing layer of the gas cylinder;

step S12, winding glass fiber: carrying out glass fiber winding processing on the gas cylinder semi-finished product of the multi-layer carbon fiber wound in the step S11 in a spiral and annular combined winding mode by using a numerical control automatic winding machine to form an external protective layer of the gas cylinder;

step S13, curing: based on a stepped temperature rise and drop curve, a box-type heating furnace with a function of supporting the gas cylinder to automatically rotate in the furnace is adopted to solidify the gas cylinder;

step S14, self-tightening and hydrostatic test: adopting a hydrostatic testing machine capable of verifying the use pressure of the gas cylinder by more than 2 times to carry out hydrostatic self-tightening and outside method hydrostatic tests on the gas cylinder one by one;

step S15, airtight test: carrying out air tightness leak detection tests on the gas cylinders one by adopting helium mass spectrum leak detection equipment;

step S16, fatigue test: performing sampling inspection verification on the fatigue performance of the gas cylinder by adopting a fatigue pressure cycle tester according to the proportion of one gas cylinder in each batch;

step S17, blasting test: and (4) performing selective inspection verification on the blasting performance of the gas cylinder by adopting a gas cylinder blasting tester according to the proportion of one piece in each batch.

Compared with the closest prior art, the technical scheme of the embodiment of the application has the following beneficial effects:

according to the technical scheme provided by the embodiment of the application, the aluminum alloy liner with the integral seamless structure and the end socket and the bottle mouth formed by closing up two ends is manufactured by adopting composite processing methods of spinning, winding, curing and the like, carbon fibers are wound on the outer side of the aluminum alloy liner in a spiral and annular combined winding mode and are cured by resin to form a composite material reinforcing layer coated on the aluminum alloy liner; and winding glass fiber in a spiral and annular combined winding mode at the outer side of the composite material reinforcing layer and curing the glass fiber by resin to form an outer protective layer for coating the composite material reinforcing layer. The whole manufacturing process has the advantages of simple preparation process, convenient operation, low energy consumption, little pollution, less loss of raw materials and great saving of raw material cost.

According to the method for manufacturing the ultra-high pressure fully-wound gas cylinder with the ultra-large aluminum alloy liner, the ultra-high pressure fully-wound gas cylinder with the ultra-large aluminum alloy liner is processed, the nominal outer diameter is phi 300-phi 850mm, and the volume of the ultra-high pressure fully-wound gas cylinder is far higher than that of the existing standard ultra-high pressure fully-wound gas cylinder with the aluminum alloy liner; the device has the characteristics of high pressure bearing capacity, high reliability, thin wall and light weight; the texture grain size of any position of the aluminum alloy liner is more than or equal to 5 grade according to the ASTME112 standard, the material texture is uniform and compact, the overall strength effect is excellent, and the high-pressure resistant characteristic is realized; the integral fatigue life of the gas cylinder reaches more than 7500 times, and the pressure bearing capacity completely meets the requirement of 20-30MPa service pressure.

Drawings

The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the application and, together with the description, serve to explain the application and are not intended to limit the application. Wherein:

fig. 1 is a schematic structural diagram of an ultra-high pressure fully-wound gas cylinder with an oversized aluminum alloy liner according to some embodiments of the application;

FIG. 2 is a schematic flow chart of a method for manufacturing an ultra-high pressure fully-wrapped gas cylinder with an oversized aluminum alloy liner according to some embodiments of the present application;

FIG. 3 is a schematic flow diagram illustrating the fabrication of an aluminum alloy liner piezotube provided in accordance with some embodiments of the present application;

fig. 4 is a schematic flow diagram of a process for grinding a screwed pipe of an aluminum alloy liner according to some embodiments of the present application;

FIG. 5 is a schematic flow diagram of a closing head spinning process provided in accordance with some embodiments of the present application;

FIG. 6 is a schematic flow diagram of a toric surface finish provided according to some embodiments of the present application;

fig. 7 is a schematic flow diagram of a heat treatment of a third spun piece provided according to some embodiments of the present application;

FIG. 8 is a schematic flow diagram of finish processing provided in accordance with some embodiments of the present application;

fig. 9 is a schematic flow diagram of liner cleaning provided in accordance with some embodiments of the present application;

figure 10 is a schematic flow diagram of liner pretreatment provided in accordance with some embodiments of the present application;

FIG. 11 is a schematic flow diagram of carbon fiber winding provided in accordance with some embodiments of the present application;

FIG. 12 is a schematic flow diagram of glass fiber winding provided in accordance with some embodiments of the present application;

fig. 13 is a schematic flow chart of step S13 provided according to some embodiments of the present application;

fig. 14 is a schematic flow chart of step S14 provided according to some embodiments of the present application;

fig. 15 is a schematic flow diagram of an aluminum alloy liner airtightness test provided in accordance with some embodiments of the present application.

Description of reference numerals:

100-aluminum alloy inner container; 200-a composite reinforcement layer; 300-outer protective layer.

Detailed Description

The present application will be described in detail below with reference to the embodiments with reference to the attached drawings. The various examples are provided by way of explanation of the application and are not limiting of the application. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present application without departing from the scope or spirit of the application. For instance, features illustrated or described as part of one embodiment, can be used with another embodiment to yield a still further embodiment. It is therefore intended that the present application cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.

Fig. 1 is a schematic structural diagram of an ultra-high pressure fully-wound gas cylinder with an oversized aluminum alloy liner according to some embodiments of the application; as shown in fig. 1, the ultra-high pressure fully-wound gas cylinder with the oversized aluminum alloy liner comprises: the aluminum alloy liner 100, the composite material reinforcing layer 200 and the outer protective layer 300; the shown aluminum alloy inner bag 100 is the seamless structure of integral type of both ends binding off shaping head and bottleneck, includes: the sealing structure comprises a first bottle opening (A bottle opening), a first sealing head (A sealing head), a straight cylinder section, a second sealing head (B sealing head) and a second bottle opening (B bottle opening), wherein the first sealing head (A sealing head) and the second sealing head (B sealing head) are respectively positioned at two ends of the straight cylinder section, and the first bottle opening (A bottle opening) and the second bottle opening (B bottle opening) are respectively positioned on the first sealing head (A sealing head) and the second sealing head (B sealing head); performing multi-pass powerful external spinning forming treatment on a straight tube section of the seamless tube by adopting a numerical control powerful external spinning machine to obtain an aluminum alloy inner container spinning tube; the composite material reinforcing layer 200 is coated on the outer side of the aluminum alloy inner container 100, wherein the composite material reinforcing layer 200 is formed by winding carbon fibers in a spiral and annular combined winding mode and curing resin; outer protective layer300 are coated on the outer side of the composite material reinforcing layer 200, wherein the outer protective layer 300 is formed by winding glass fiber in a spiral and annular combined winding mode and curing the glass fiber by resin; the ultra-high pressure full-wound gas cylinder with the ultra-large aluminum alloy inner container has the test pressure of (0, 94.5) MPa, the test temperature of room temperature and the test medium of a mixed gas of 95% nitrogen and 5% helium, and the leak rate of a helium mass spectrum leak test by a positive pressure suction gun method under the test pressure is lower than 10^-5Pa.m³/s。

In the embodiment of the application, the length of the gas cylinder is not more than 5m, the nominal outer diameter is (300, 850) mm, and the working pressure is (30, 90) MPa; the volume of the gas cylinder is (350, 6500) L; preferably, the length of the cylinder is (5, 13) m; the working pressure of the gas cylinder is 90 MPa; the volume of the gas cylinder is (1000, 3000) L; the service temperature of the gas cylinder is (-40 ℃, 85 ℃); the gas cylinder is used for containing hydrogen; the gas cylinder is used for vehicle-mounted horizontally-placed gas storage and transportation cylinders.

In the embodiment of the application, the wall thickness of the straight cylinder section of the aluminum alloy liner 100 is (1, 12) mm, and the integral straightness of the straight cylinder section is not more than 0.3 mm/m; preferably, the tolerance of the wall thickness of the straight cylinder section is less than or equal to +/-0.1 mm; the local straightness at any straight line section position of the straight cylinder section is not more than 0.3mm/300 mm; the roundness of any position of the straight cylinder section is not more than 0.53 mm; the roughness of the inner surface of the straight cylinder section is less than Ra0.8 μm, and the roughness of the outer surface of the straight cylinder section is less than Ra1.6 μm.

In the embodiment of the application, the thickness of the seal head is uniformly gradually thickened from the edge to the bottle mouth; preferably, the thickness of the end socket is uniformly and gradually thickened from (5, 12) mm at the edge to (12, 25) mm at the bottle opening part; the end socket can adopt an ellipsoidal end socket or a butterfly end socket or a hemispherical end socket, and the structure of the first end socket (A end socket) is the same as that of the second end socket (B end socket); preferably, the length of the mouth is 40mm, the outer diameter of the mouth is (50, 96) mm, and the inner diameter of the mouth is (28.6, 50.8) mm.

In the embodiment of the present application, the carbon fibers of the composite reinforcement layer 200 and the glass fibers of the outer protective layer 300 are both wound by a wet process; preferably, the carbon fibers are continuous untwisted carbon fibers; the tensile strength of the carbon fiber is not less than 4900 MPa; the winding tension of carbon fiber winding is not less than 5N; the resin is thermosetting resin, and the glass transition temperature of the resin is not lower than 105 ℃; preferably, the resin is an epoxy resin or a modified epoxy resin; and (3) curing the carbon fiber and/or the glass fiber by using a box-type heating furnace within 4 hours after the carbon fiber and/or the glass fiber are wound, wherein the gas cylinder rotates automatically all the time during curing.

In the embodiment of the application, the gas cylinder needs to be subjected to self-tightening water pressure, water pressure and air tightness tests, fatigue tests and explosion tests; preferably, the self-tightening hydraulic pressure is 1.8 times of the use pressure of the gas cylinder; the fatigue times of the gas cylinder fatigue test are not less than 7500 times.

FIG. 2 is a schematic flow chart of a method for manufacturing an ultra-high pressure fully-wrapped gas cylinder with an oversized aluminum alloy liner according to some embodiments of the present application; as shown in fig. 2, the method for manufacturing the aluminum alloy liner 100 high-pressure fully-wound gas cylinder is used for manufacturing the aluminum alloy liner 100 high-pressure fully-wound gas cylinder according to any one of the embodiments, and comprises the following steps:

step S1, preparing an aluminum alloy inner container spinning pipe: carrying out multi-pass powerful external spinning forming treatment on the straight cylinder section of the seamless pipe by adopting a numerical control powerful external spinning machine to obtain an aluminum alloy inner container spinning pipe;

FIG. 3 is a schematic flow diagram illustrating the fabrication of an aluminum alloy liner piezotube provided in accordance with some embodiments of the present application; as shown in fig. 3, the process of preparing the aluminum alloy liner spinning tube comprises the following steps:

s101, spinning and forming a straight cylinder section of an aluminum alloy liner spinning pipe: carrying out 2-4 times of spinning processes on the seamless pipe by adopting an overlong cylinder tension spinning device and a tension three-spinning-wheel staggered-pitch forward spinning method to obtain an aluminum alloy liner spinning pipe;

in the embodiment of the application, the offset amount in the tension three-spinning-wheel offset forward spinning method is set to be 6-12 mm; during spinning, a floating core mould with the length of 1-2m is adopted for spinning auxiliary processing; the total deformation of the seamless pipe after spinning treatment is 55-70%; when the total deformation is more than 70%, intermediate annealing treatment should be performed. The equal-thickness straight cylinder of the aluminum alloy liner spinning pipe or the straight cylinder section with the outer circumferential end frames at two ends. In the spinning manufacturing process of the step, traction force is adopted to draw one end of the seamless pipe to extend outwards, and the traction direction of the traction force is opposite to the flowing direction of the material; the traction force is constant force, and the traction speed is adaptive to the deformation speed of the material; the axial direction of the dragged end of the seamless pipe is fixed on the traction mechanism, so that the radial freedom of the dragged end is ensured; and the positioning device is adopted to fix and support the other end of the seamless pipe in the radial direction, so that the axial freedom of the other end of the seamless pipe is ensured.

Step S102, fixed-length processing of the aluminum alloy liner spinning pipe: performing fixed-length processing on the first spinning piece obtained in the step S101 by using a sawing machine to obtain an aluminum alloy liner spinning pipe; in the embodiment of the invention, the sawing machine adopts a double-head automatic planetary sawing machine, and the saw blade adopts a special aluminum alloy saw blade.

Step S103, cleaning the aluminum alloy inner container spinning pipe: cleaning the aluminum alloy inner container spinning pipe obtained in the step S102 by using a cleaning machine;

in the embodiment of the application, the cleaning machine is a rotary spray cleaning machine or an ultrasonic cleaning machine; cleaning the aluminum alloy inner container spinning pipe by using a neutral cleaning agent heated to 30-45 ℃; and (3) removing residual water stains on the surface by using a special wiping tool or a drying device after cleaning the aluminum alloy inner container spinning tube.

Step S104, checking the aluminum alloy inner container spinning pipe: inspecting the shape and size tolerance of the aluminum alloy liner spinning tube by adopting size, shape tolerance and surface defect detection equipment, and automatically detecting whether the inner surface and the outer surface have defects;

in the embodiment of the application, the surface defect detection equipment is spinning tube laser vision automatic detection equipment; the surface defect detection equipment automatically detects whether the inner surface and the outer surface of the aluminum alloy liner spinning tube are scratched or not.

Step S105, grinding the aluminum alloy inner container spinning tube: grinding the scratch and the bruise of the inner surface and the outer surface of the aluminum alloy liner spinning tube with the surface defect detected in the step S104 by using a numerical control inner and outer circle grinding machine;

in the embodiment of the application, the numerical control inner and outer circle grinding machine has a visual rechecking function so as to grind scratches and bruises on the inner surface and the outer surface of the aluminum alloy inner container spinning tube with surface defects detected.

Fig. 4 is a schematic flow diagram of a process for grinding a screwed pipe of an aluminum alloy liner according to some embodiments of the present application; as shown in fig. 4, the grinding aluminum alloy liner spinning tube comprises:

s115, driving the aluminum alloy liner spinning pipe to rotate, driving a visual detection device of the inner circle grinding mechanism to position the inner surface defects detected in the S104, and grinding point by point according to the positioned position; during grinding, the aluminum alloy liner spinning pipe swings at the speed of 30r/min within the angle range of (-10 degrees and 10 degrees);

s125, driving the aluminum alloy inner container spinning pipe to rotate at the speed of 30r/min, driving a visual detection device of the outer circle grinding mechanism to position the outer surface defect detected in the S104, and continuously grinding according to the positioned position;

step S106, carrying out full-automatic flaw detection on the straight cylinder section of the aluminum alloy liner spinning pipe obtained in the step S105 by adopting a special ultrasonic automatic flaw detector, and detecting whether a processing defect exists;

in the embodiment of the application, the special ultrasonic automatic flaw detector performs full-automatic flaw detection on the straight cylinder section of the aluminum alloy liner spinning tube, and detects whether the straight cylinder section of the aluminum alloy liner spinning tube has peeling, wrinkles and cracks.

Step S2, closing the end socket and spinning and forming: spin forming the end sockets and the bottle openings at two ends of the aluminum alloy liner spin-pressing pipe by using a heating closing-up spinning machine to obtain a second spin-pressing part (spin-formed part B), wherein the second spin-pressing part (spin-formed part B) comprises a straight cylinder section and an end socket A and an end socket B at two ends of the straight cylinder section;

FIG. 5 is a schematic flow diagram of a closing head spinning process provided in accordance with some embodiments of the present application; as shown in fig. 5, the flow of spinning formation of the closing end includes:

step S201, clamping: clamping the aluminum alloy inner container spinning pipe by adopting a split type hollow main shaft;

step S202, heating: heating the spinning part of the spinning pipe of the aluminum alloy inner container to be contracted to 180-390 ℃;

in the embodiment of the application, oxygen and propane/LNG natural gas are used for combustion flame spraying heating when the spinning part to be closed of the aluminum alloy inner container spinning tube is heated;

step S203, forming and spinning of the end socket and the bottle mouth: performing multi-pass necking spinning on the aluminum alloy liner spinning tube heated in the step S202 by adopting a unilateral X straight line, a unilateral Z straight line and a rotary three-way interpolation type necking spinning machine; wherein, in the spinning process, the closing spinning band has 8 times of reverse spinning and is used for thickening the bottle mouth part; the thickness of the end socket of the prepared second spinning part (spinning forming part B) is uniformly and gradually thickened from 8mm at the edge to 25mm at the bottle opening part;

step S204, repeating the operations of the steps S201, S202 and S203 on the other end of the spinning pipe of the aluminum alloy liner to obtain a second spinning part (spinning formed part B); the second spinning part (spinning forming part B) comprises a straight cylinder section, and a first seal head (A seal head) and a second seal head (B seal head) at two ends of the straight cylinder section;

and S205, processing a center hole and an outer circle of the on-position bottle mouth of the second spinning piece (spinning forming piece B) in the step S204.

In the embodiment of the application, multi-axis automatic machining is adopted for machining the center hole and the outer circle of the on-site bottle mouth.

Step S3, processing of a central hole and an excircle of a bottle mouth: respectively machining a center hole of a bottle opening and an excircle of a first seal head (A seal head) and a second seal head (B seal head) at two ends of the second spinning part (spinning formed part B) obtained in the step S2 to obtain a third spinning part (spinning formed part C);

step S4, curved surface flaw detection: performing closing quality flaw detection on the third spinning part (spinning formed part C) obtained in the step S3, and checking whether machining defects such as orange peel and folding exist at the end socket position;

step S5, grinding the inner surface of the curved surface: grinding the defects of the inner surface of the end socket found in the step S4 by using a special end socket inner surface grinding machine tool according to the flaw detection result to obtain a third spinning part (spinning formed part C) with qualified quality;

FIG. 6 is a schematic flow diagram of a toric surface finish provided according to some embodiments of the present application; as shown in fig. 6, the process of thinning the curved inner surface includes:

step S501, clamping a third spinning part (spinning formed part C) by using a special clamping tool;

in the embodiment of the application, the clamping tool of the third spinning part (spinning formed part C) is a split hollow clamping tool;

s502, automatically observing and judging the defect condition of the inner surface of the end socket by adopting an automatic endoscope system arranged on a special end socket inner surface grinding machine tool, recording the corresponding position, and combining artificial confirmation;

and S503, grinding the defects of the inner surface of the end socket found in the step S4 by using an inner surface grinding mechanism of the end socket of the special end socket inner surface grinding machine tool to obtain a third spinning part (spinning formed part C) with qualified quality.

In the embodiment of the application, the grinding of the inner profile of the end socket is a numerical control automatic grinding mechanism which can be programmed and executed independently.

Step S6, heat treatment: performing T6 process treatment on the third spinning part (spinning formed part C) obtained in the step S5 to obtain an aluminum alloy inner container blank for the high-pressure gas cylinder;

fig. 7 is a schematic flow diagram of a heat treatment of a third spun piece provided according to some embodiments of the present application; as shown in fig. 7, the flow of the heat treatment of the third spinning member includes:

step S601, quenching: 3-5 special split heat treatment tools are used for clamping the third spinning part prepared in the step S5 at equal intervals to prevent the third spinning part from deforming during heat treatment; placing a plurality of third spinning parts on a three-dimensional heat treatment tool frame through a split special heat treatment tool, so that a plurality of inner containers can be conveniently subjected to heat treatment at one time;

step S602, placing the three-dimensional heat treatment tool frame assembled in the step S601 on a roller way of a horizontal continuous quenching and aging furnace, sending the three-dimensional heat treatment tool frame into a quenching chamber for quenching treatment, heating the third spinning part in the quenching chamber to the temperature of 525-; during quenching, ensuring that the time for the aluminum alloy liner for the oversized high-pressure gas cylinder to be in contact with water mist is not more than 5 s;

step S603, aging treatment: transferring the three-dimensional heat treatment frame provided with the third spinning part after quenching to an aging furnace through a roller way for aging treatment, and finally preserving heat for 6-10 hours in an environment with the temperature of 160-200 ℃ to prepare the aluminum alloy liner blank.

In the embodiment of the application, the quenching furnace and the aging furnace are horizontal type and pass-through type continuous treatment furnaces;

in the embodiment of the application, the quenching adopts water mist spray quenching.

Step S7, processing bottle mouth: respectively machining the inner diameter and the outer diameter of the first bottle opening (A bottle opening) and the second bottle opening (B bottle opening) of the aluminum alloy liner blank for the high-pressure gas cylinder obtained in the step S6 by using a special bottle opening machining center, and machining internal threads and external threads of the bottle openings to obtain an aluminum alloy liner 100 for the high-pressure gas cylinder;

FIG. 8 is a schematic flow diagram of finish processing provided in accordance with some embodiments of the present application; as shown in fig. 8, the process of bottle mouth processing includes:

s701, clamping an aluminum alloy inner container blank by adopting a split type hollow clamping tool;

step S702, processing a bottle mouth: and (4) processing the external diameter and the internal diameter of the bottle mouth and the internal thread of the bottle mouth of the aluminum alloy inner container blank obtained in the step (S6) by using a special bottle mouth processing center to obtain the aluminum alloy inner container 100 for the high-pressure gas bottle, wherein the lengths, the external diameters and the internal diameters of the first bottle mouth (A bottle mouth) and the second bottle mouth (B bottle mouth) are respectively 40mm, 50mm and 28 mm.

Step S8, inner container cleaning: and (4) performing high-pressure water spraying cleaning on the inner cavity of the aluminum alloy inner container 100 for the high-pressure gas cylinder obtained in the step S7 by using a special vertical gas cylinder inner container cleaning machine to remove aluminum scraps and other processing pollutants.

Fig. 9 is a schematic flow diagram of liner cleaning provided in accordance with some embodiments of the present application; as shown in fig. 9, the cleaning of the aluminum alloy liner comprises:

step S801, horizontally placing the aluminum alloy liner on a turnover frame of a special automatic turnover gas cylinder liner cleaning machine, enabling a spraying mechanism of the special horizontal gas cylinder liner cleaning machine to enter the aluminum alloy liner, and fixing the aluminum alloy liner;

s802, cleaning the inner cavity of the aluminum alloy inner container by adopting a high-pressure water spraying or ultrasonic cleaning mode to remove processing pollutants;

step S803, after the cleaning is finished, starting the turnover frame to incline to 45 degrees for pouring water;

and step S804, drying the inner container by adopting an inward extending type steam dryer.

Step S9, checking the semi-finished product: performing sampling inspection on the aluminum alloy inner container obtained in the step S8, measuring the texture grain sizes of any six positions of the aluminum alloy inner container subjected to sampling inspection, and measuring the tensile strength, yield strength and elongation of the straight cylinder section of the aluminum alloy inner container subjected to sampling inspection; wherein the tensile strength of the straight cylinder section of the aluminum alloy liner is not less than 345MPa, the yield strength is not less than 310MPa, and the elongation is less than 16%;

step S10, preprocessing the inner container: horizontally placing the aluminum alloy inner container 100 in the step S9 on a coating station of special automatic coating and drying equipment by adopting special automatic coating and drying equipment, and coating the aluminum alloy inner container with an anti-galvanic corrosion layer;

figure 10 is a schematic flow diagram of liner pretreatment provided in accordance with some embodiments of the present application; as shown in fig. 10, the liner pretreatment includes:

step S1001, preparing glue solution according to the weight ratio of the resin to the curing agent being 1: 0.85;

in the embodiment of the application, the galvanic corrosion prevention layer adopts the mixed liquid of epoxy resin and curing agent.

Step S1002, recording the serial number of the aluminum alloy liner 100, measuring the weight of the aluminum alloy liner 100 by using an electronic balance, winding a tool by using the same thread, sleeving tetrafluoro gaskets on the thread positions of the winding tool, screwing the tetrafluoro gaskets to bottle mouths at two ends of the aluminum alloy liner 100, and fixing the aluminum alloy liner 100 on a coating device;

step S1003, automatically coating glue solution by adopting an automatic coating rolling brush until the glue solution is uniformly coated on the aluminum alloy inner container 100;

and step S1004, curing the aluminum alloy inner container in a rotary curing mode according to the curing temperature of 160 ℃ and the curing time of 3 h.

In the embodiment of the application, the drying temperature of the aluminum alloy inner container 100 coated with the anti-galvanic corrosion layer is 140-.

Step S11, carbon fiber winding: performing carbon fiber winding processing on the aluminum alloy inner container 100 coated with the anti-galvanic corrosion layer in the step S10 by using a numerical control automatic winding machine;

FIG. 11 is a schematic flow diagram of carbon fiber winding provided in accordance with some embodiments of the present application; as shown in fig. 11, the flow of carbon fiber winding includes:

step S1101, mounting a bottle mouth outer sleeve at a bottle mouth, and checking the smooth degree of the transition between the bottle mouth outer sleeve and a seal head curved surface section;

step S1102, leading out the carbon fiber yarn from a creel, sequentially passing through a steering wheel, a glue dipping tank and a winding nozzle, and binding the yarn on the winding nozzle to finish yarn threading;

step S1103, mixing epoxy resin and a curing agent according to a certain proportion, pouring the prepared glue solution into a glue dipping tank, opening a heating button of the glue dipping tank, and setting the glue dipping tank to a specified temperature;

step S1104, mounting two end winding fixing tools for the weighed aluminum alloy inner container 100 for the high-pressure gas cylinder and fixing the tools on an overlong winding machine;

and S1105, selecting a winding procedure, unwinding the yarn at the yarn winding nozzle, manually winding the yarn on the inner container, ensuring that the yarn and the inner container do not slip, rotating the gas cylinder until the yarn soaked with the resin is pulled to the inner container, and starting and finishing carbon fiber winding.

Step S12, winding glass fiber: carrying out glass fiber winding processing on the semi-finished product of the gas cylinder with the layers of carbon fibers wound in the step S11 by adopting a numerical control automatic winding machine;

FIG. 12 is a schematic flow diagram of glass fiber winding provided in accordance with some embodiments of the present application; as shown in fig. 12, the glass fiber winding process includes:

step S1201, mounting two end winding fixing tools on the semi-finished product of the carbon fiber wound gas cylinder obtained in the step S11, and fixing the semi-finished product on a winding machine;

step S1202, pasting two labels with the same number on two sides of the middle part of the gas cylinder;

step S1203, leading out the glass fiber yarns from a creel, sequentially passing through a steering wheel, a glue dipping tank and a wire winding nozzle, and binding the yarns on the wire winding nozzle to finish threading;

step S1204, mixing epoxy resin and curing agent proportionally, pouring the prepared glue solution into a glue dipping tank, opening a heating button of the glue dipping tank, and setting to a specified temperature;

step S1205, selecting a winding program, unwinding the yarn at the yarn winding nozzle, manually winding the yarn on the aluminum alloy inner container, ensuring that the yarn and the aluminum alloy inner container do not slip, rotating the gas cylinder until the yarn soaked with resin is pulled onto the inner container, and starting and finishing glass fiber winding according to set tension; wherein, the thickness of the single layer is 0.464mm, the circumferential winding angle is +/-89 degrees, and the longitudinal winding angle is +/-5 degrees.

Step S13, curing: a box-type heating furnace with the function of supporting the gas cylinder to automatically rotate in the furnace is adopted for curing the gas cylinder, and a stepped temperature rise and fall curve is adopted for curing;

fig. 13 is a schematic flow chart of step S13 provided according to some embodiments of the present application; as shown in fig. 13, step S13 includes:

step S1301, placing a winding gas cylinder on a box type heating furnace support frame, and fixing a rotary joint of the box type heating furnace and a winding tool through a positioning pin;

step S1302, calling the equipment into a program model, selecting a programmed curing program according to the set heating temperature and the set heat preservation time, and then opening a starting key for curing;

and step S1303, after the solidification is finished, opening a box type heating furnace to cool down, opening an equipment door after the temperature is reduced to a specified value, and moving the solidified gas cylinder to the next procedure.

Preferably, the solidified gas cylinder is transferred by a special lifting device capable of lifting two-end winding tools.

Step S14, self-tightening and hydrostatic test: adopting a hydrostatic testing machine capable of verifying the use pressure of the gas cylinder by more than 2 times to carry out hydrostatic self-tightening and outside method hydrostatic tests of the gas cylinder one by one;

fig. 14 is a schematic flow chart of step S14 provided according to some embodiments of the present application; as shown in fig. 14, step S14 includes:

step S1401, after filling water into a tested gas bottle, connecting the tested gas bottle with a hydrostatic testing machine through a hydrostatic joint, wherein the connecting pipeline is free of gas;

step S1402, carrying out self-tightening water pressure on the tested gas bottle at room temperature, wherein the self-tightening water pressure is 1.8 times of the use pressure, the boosting speed does not exceed 0.5MPa/S in the boosting process, the pressure is maintained for 5min under the self-tightening water pressure after the pressure is reached, and then the pressure is released;

step S1403, carrying out hydrostatic test on the tested gas cylinder at room temperature, wherein the pressure is 1.5 times of the use pressure, the boosting rate does not exceed 0.5MPa/S in the boosting process, the pressure is maintained for 30S after the pressure reaches, and then the pressure is released; wherein the volume residual deformation rate of the tested gas cylinder is not more than 5%.

Step S15, airtight test: carrying out air tightness leakage detection tests on the air cylinders one by adopting an integrated air tightness testing machine with an explosion-proof function;

FIG. 15 is a schematic flow diagram of an aluminum alloy liner airtightness test provided in accordance with some embodiments of the present application; as shown in fig. 15, step S15 includes:

s1501, placing a tested gas cylinder in an airtight experiment chamber and installing the airtight experiment chamber on a fixed airtight experiment table, wherein the airtight experiment chamber is built by pouring integral concrete and attaching an 18mm steel plate;

step S1502, a positive pressure suction gun method helium mass spectrum leak detection test is carried out, the test pressure is (0, 94.5) MPa, the test temperature is room temperature, the test medium is a mixed gas of 95% nitrogen and 5% helium, pressure maintaining is carried out under the test pressure, a helium mass spectrum leak detector suction gun fixed on an automatic axial moving track type robot is adopted, bottle openings at two ends and valves are respectively detected, the leak rate is lower than 10^-5Pa.m³/s。

Preferably, in step S1502, the distance between the suction gun and the measured position is controlled by a manipulator, and is not greater than 2mm, and the moving speed of the suction gun is not greater than 20 mm/S.

in the embodiment of the application, in the fatigue test process, the test pressure is (0, 94.5) MPa, the test temperature is room temperature, the test medium is oil or water, the pressure cycle is carried out for at least 7500 times from 0MPa to 94.5MPa, and the bottle body of the tested gas bottle does not leak or explode.

Step S17, blasting test: and (4) performing sampling inspection verification on the blasting performance of the gas cylinders by adopting a gas cylinder blasting tester according to the proportion of one piece in each batch.

In the embodiment of the application, during the burst test, the air pressure of the tested air bottle is increased to 211.5MPa by adopting an aqueous medium, and after the pressure is maintained for 5s, the pressurization is continued until the tested air bottle is damaged.

In the embodiment of the application, a composite processing method such as spinning, winding and curing is adopted to manufacture the aluminum alloy liner 100 with the integrated seamless structure and the end socket and the bottle mouth formed by closing up two ends, carbon fibers are wound on the outer side of the aluminum alloy liner 100 in a spiral and annular combined winding mode and are cured by resin to form the composite material reinforcing layer 200 covering the aluminum alloy liner 100; on the outside of the composite reinforcement layer 200, glass fiber is wound in a combined spiral and hoop winding manner and cured with resin to form an outer protective layer 300 covering the composite reinforcement layer 200. The whole manufacturing process has the advantages of simple preparation process, convenient operation, low energy consumption, little pollution, less loss of raw materials and great saving of raw material cost.

According to the method for manufacturing the 100 high-pressure fully-wound gas cylinder with the aluminum alloy inner container, the processed 100 high-pressure fully-wound gas cylinder with the aluminum alloy inner container has the nominal outer diameter of phi 300-phi 850mm and the volume far higher than that of the 100 high-pressure fully-wound gas cylinder with the existing standard aluminum alloy inner container; the grain size of the texture at any position of the aluminum alloy inner container 100 is more than or equal to 5 grade according to the ASTME112 standard, the texture of the material is uniform and compact, the overall strength effect is excellent, and the high-pressure resistant characteristic is realized; the integral fatigue life of the gas cylinder reaches more than 7500 times, and the pressure bearing capacity completely meets the requirement of 30-90MPa service pressure.

Example 1

In the embodiment of the application, the aluminum alloy liner 100 for the high-pressure gas cylinder with the diameter of 580mm, the length of 5.7m and the wall thickness of 12mm is manufactured by the method for manufacturing the ultra-high pressure fully-wound gas cylinder with the oversized aluminum alloy liner, wherein the rated pressure of the high-pressure gas cylinder is required to be 90Mpa, and the method comprises the following specific steps:

step S1, preparing an aluminum alloy inner container spinning tube, comprising the following steps:

step S101, spinning and forming a straight cylinder section of the spinning pipe of the aluminum alloy liner, and carrying out length-length spinning by adopting an ultralong cylinder tension spinning device and a tension three-spinning wheel staggered pitch forward spinning method1600mmThe seamless pipe is spun for 4 times, and the offset in the tension three-spinning-wheel offset forward spinning method is set to be 6 mm; during spinning, a floating core mould with the length of 2m is adopted for spinning auxiliary processing; and obtaining a first spinning piece which is a straight cylinder with equal thickness or a straight cylinder section with two ends provided with outer annular end frames. In the spinning manufacturing process of the step, traction force is adopted to draw one end of the seamless pipe to extend outwards, and the traction direction of the traction force is opposite to the flowing direction of the material; the traction force is constant force, and the traction speed is adaptive to the deformation speed of the material; the axial direction of the dragged end of the seamless pipe is fixed on the traction mechanism, so that the radial freedom of the dragged end is ensured; and the positioning device is adopted to fix and support the other end of the seamless pipe in the radial direction, so that the axial freedom of the other end of the seamless pipe is ensured. The first spinning member has the following dimensions: has a total length of6500mm, the thickness of the straight cylinder section is 12mm, and the thickness of the step sections at two ends is18mm。

Step S102, fixed-length processing of the aluminum alloy liner spinning pipe: performing fixed-length processing on the first spinning and pressing piece (spinning and pressing piece A) obtained in the step S101 by adopting a double-column automatic planetary sawing machine to obtain an aluminum alloy liner spinning pipe, wherein the length of the straight section of the aluminum alloy liner spinning pipe is 6200 mm;

step S103, cleaning the aluminum alloy inner container spinning pipe: adding a neutral cleaning agent at 40 ℃ into a rotary spray cleaning machine or an ultrasonic cleaning machine to clean the aluminum alloy liner spinning pipe obtained in the step S102; and after cleaning, removing residual water stains on the surface by using an automatic wiping machine or a drying device.

S104, adopting automatic laser visual detection equipment for the spinning tube, fixing the spinning tube of the aluminum alloy liner obtained in the step S103 on a lathe bed through an automatic clamping device, and carrying out quality detection on the spinning tube;

in the embodiment of the present application, the flow of step S104 is specifically as follows:

s114, programming and rotating the aluminum alloy liner spinning tube, and driving a laser detection mechanism to automatically detect whether the dimensions such as the diameter, the roundness, the straightness, the end face verticality and the like of the aluminum alloy liner spinning tube and the form and position tolerance meet the design requirements;

step S124, programming to rotate the aluminum alloy liner spinning tube, and driving the inner surface visual recognition device to automatically detect whether the inner surface has surface defects such as scratches, peeling, folds, surface cracks and the like with the depth of more than 0.03 mm;

and 134, programming to rotate the aluminum alloy liner spinning pipe, driving the outer surface visual identification device, and automatically detecting whether the inner surface has surface defects such as scratches, peeling, wrinkles, surface cracks and the like with the depth of more than 0.03 mm.

Step S105, grinding the aluminum alloy inner container spinning tube: fixing the aluminum alloy liner spinning tube with the surface defects detected in the step S104 on a numerical control inner and outer circle grinding machine through an automatic clamping device, and grinding the inner and outer surfaces of the cleaned aluminum alloy liner spinning tube detected in the step S104 by scratching and bruising;

in the embodiment of the present application, the flow of step S105 is specifically as follows:

step S115, driving the aluminum alloy liner spinning tube to rotate, firstly driving a visual detection device of the inner circle grinding mechanism to position the inner surface defect detected in the step S104, and grinding point by point according to the positioned position, wherein the aluminum alloy liner spinning tube swings in an angle range of-10 degrees to +10 degrees at a speed of 30r/min during grinding;

and S125, driving the aluminum alloy inner container spinning pipe to rotate at the speed of 30r/min, driving a visual detection device of the outer circle grinding mechanism to position the outer surface defect detected in the S104, and continuously grinding according to the positioned position.

And S106, carrying out full-automatic flaw detection on the aluminum alloy inner container spinning tube obtained in the step S104 by using an ultrasonic automatic flaw detector, and detecting whether the barrel has machining defects such as orange peel and folding.

Step S2, spinning and forming of the end socket and the bottle mouth: respectively carrying out spin forming on the end socket and the bottle mouth at the openings at the two ends of the aluminum alloy liner spin-pressing pipe by using a heating closing-up spinning machine to obtain a second spin-pressing part (spin-formed part B); the second spinning part (spinning forming part B) comprises a straight cylinder section, and a first seal head (A seal head) and a second seal head (B seal head) at two ends of the straight cylinder section;

specifically, step S2 includes:

step S202, heating: carrying out flame spraying and heating on a spinning part to be closed of the spinning pipe of the aluminum alloy liner to 310 ℃ by adopting oxygen and propane/LNG natural gas combustion;

step S203, forming and spinning of the end socket and the bottle mouth: performing closing-up spinning on the aluminum alloy liner spinning tube heated in the step S202 by adopting a single-side X straight line, a single-side Z straight line and a rotary three-way interpolation type closing-up spinning machine;

in the spinning process, the closing spinning band has 8 times of reverse spinning and is used for thickening the bottle mouth part; the thickness of the end socket of the prepared second spinning part (spinning forming part B) is uniformly and gradually thickened from 12mm of the edge to 25mm of the bottle opening part.

Step S204, repeating the operations of the steps S201, S202 and S203 on the other end of the spinning pipe of the aluminum alloy liner to obtain a second spinning part (spinning formed part B); the second spinning part (spinning forming part B) comprises a straight cylinder section, a first seal head (A seal head) and a second seal head (B seal head) which are arranged at two ends of the straight cylinder section.

Step S3, processing of a central hole and an excircle of a bottle mouth: clamping a second spinning part (spinning formed part B) by adopting a split type hollow clamping tool, and respectively machining a center hole and an excircle of a bottle mouth of a first seal head (A seal head) and a second seal head (B seal head) at two ends of the second spinning part (spinning formed part B) obtained in the step S2 by adopting a special bottle mouth machining center to obtain a third spinning part (spinning formed part C); preparing for subsequent heat treatment;

specifically, step S5 includes:

step S501, clamping a third spinning part (spinning formed part C) by adopting a split type hollow clamping tool;

s502, automatically observing and judging the defect condition of the inner surface of the seal head by adopting a visual recognition system of a special seal head inner surface grinding machine tool, recording the corresponding position, and combining artificial confirmation;

and S503, grinding the defects of the inner surface of the end socket found in the step S5 by using a numerical control automatic grinding mechanism of a special end socket inner surface grinding machine tool to obtain a third spinning part (spinning formed part C) with qualified quality, wherein the numerical control automatic grinding mechanism can be programmed and independently executed in the grinding process.

Step S6, heat treatment: carrying out T6 process treatment on the third spinning part (spinning formed part C) obtained in the step S5 by adopting a horizontal type through continuous treatment furnace to obtain an aluminum alloy inner container blank for the high-pressure gas cylinder;

specifically, step S6 includes:

specifically, step S7 includes:

s701, clamping an aluminum alloy inner container blank for the high-pressure gas cylinder by adopting a split type hollow clamping tool;

step S702, processing a bottle mouth: and (4) carrying out high-speed processing on the outside diameter and the inside diameter of the bottle mouth, the inside and the outside threads of the bottle mouth of the aluminum alloy liner blank for the high-pressure gas bottle obtained in the step (S6) by adopting a special bottle mouth processing center to obtain the aluminum alloy liner 100 for the high-pressure gas bottle, wherein the lengths, the outside diameters and the inside diameters of the first bottle mouth (A bottle mouth) and the second bottle mouth (B bottle mouth) are respectively 40mm, 50mm and 28 mm.

Step S8, inner container cleaning: performing high-pressure water spraying cleaning on the inner cavity of the aluminum alloy inner container 100 for the high-pressure gas cylinder obtained in the step S7 by using a special vertical gas cylinder inner container cleaning machine to remove aluminum scraps and other processing pollutants;

specifically, step S8 includes:

Step S9, checking the semi-finished product: the aluminum alloy inner container 100 for the high-pressure gas cylinder obtained in step S8 is inspected, and a part of items are subjected to spot inspection at a spot inspection rate of 1 piece per batch (usually, the number of pieces per batch is not more than 200 pieces). The texture grain sizes of any six positions of the aluminum alloy inner container 100 for the high-pressure gas cylinder to be inspected are measured, and the texture grain sizes of the six positions are respectively 6-grade, 7-grade, 6-grade and 5-grade according to the ASTM E112 standard, and the tensile strength of the straight cylinder section of the aluminum alloy inner container 100 for the high-pressure gas cylinder to be inspected is measured. And respectively measuring the yield strength and the elongation, wherein the tensile strength of the straight cylinder section is 345MPa, the yield strength is 310MPa, and the elongation is 16%, and the products produced in the batch are qualified, so that the finished product of the aluminum alloy liner 100 for the high-pressure gas cylinder is obtained.

Step S10, preprocessing the inner container: horizontally placing the aluminum alloy inner container 100 on a coating station of special automatic coating and drying equipment, and coating the aluminum alloy inner container with an anti-galvanic corrosion layer;

specifically, step S10 includes:

step S1002, recording the serial number of the liner, measuring the weight of the liner by using an electronic balance, sleeving tetrafluoro gaskets on the thread positions of a winding tool by using the winding tool with the same threads, screwing the tetrafluoro gaskets to bottle mouths at two ends of the liner by hands, and fixing the liner on a coating device;

step S1003, automatically coating glue solution by adopting an automatic coating rolling brush until the glue solution is uniformly coated on the inner container;

step S1004, adopting a rotary curing mode, according to the curing temperature: 160 ℃, curing time: and curing the inner container for 3 hours.

Step S11, carbon fiber winding: adopting a numerical control automatic winding machine to perform carbon fiber winding processing on the aluminum alloy inner container 100 coated with the anti-galvanic corrosion layer in the step S10

Specifically, step S11 includes:

specifically, step S12 includes:

step S1201, mounting two end winding fixing tools on the semi-finished product of the carbon fiber wound gas cylinder obtained in the step S11 and fixing the semi-finished product on a winding machine;

step S1202, two labels with the same number are pasted on two sides of the middle part of the gas cylinder;

step S1203, leading out the glass fiber yarns from a creel, sequentially passing through a steering wheel, a glue dipping tank and a winding nozzle, and binding the yarns on the winding nozzle to finish yarn threading;

step S1204, according to epoxy resin: curing agent 1:0.85 (weight ratio) of mixed epoxy resin and curing agent, pouring the prepared glue solution into a glue dipping tank, wherein the glue content is 40 percent, opening a heating button of the glue dipping tank, and setting the temperature to a specified temperature;

step S1205, selecting a winding program, unwinding the yarn at the yarn winding nozzle, manually winding the yarn on the inner container, ensuring that the yarn and the inner container do not slip, rotating the air bottle until the yarn soaked with resin is pulled on the inner container, setting the tension to be 5N, completing the winding of 1 layer of circular glass fiber, wherein the thickness of the wound single layer is 0.464mm, and the circular winding angle is +/-89 degrees.

specifically, step S13 includes:

step S1301, a special lifting device capable of lifting winding tools at two ends is adopted to place a winding gas cylinder on a box type heating furnace supporting frame, and a rotary joint of the box type heating furnace is fixed with the winding tools through a positioning pin;

step S1302, calling the equipment into a program model, setting preheating and heating to 80 ℃, preserving heat for 1 hour, then heating to 120 ℃, preserving heat for 3 hours, and opening a starting key for curing after a programmed curing program is selected;

and step S1303, when the heat is preserved, automatically opening the box type heating furnace to cool down to 40 ℃, opening the equipment door, and moving the solidified gas cylinder to the next procedure.

S14, self tightening, hydrostatic test: adopting a hydrostatic testing machine capable of verifying the use pressure of the gas cylinder by more than 2 times to carry out hydrostatic self-tightening and outside method hydrostatic tests of the gas cylinder one by one;

specifically, step S14 includes:

and step S1401, connecting the tested bottle with a hydrostatic testing machine through a hydrostatic joint after the tested bottle is filled with water. No gas should be present in the pipeline;

step S1402, carrying out self-tightening water pressure on the tested bottle, wherein the self-tightening pressure is 1.8 times of the use pressure, namely 162MPa, the boosting speed is not more than 0.5MPa/S in the boosting process, the pressure is maintained for 5min under the self-tightening pressure after the bottle is pressurized, and then the pressure is released, the test temperature is room temperature, and the test medium is water;

step S1403, carrying out a hydrostatic test on the tested bottle, wherein the pressure is 1.5 times of the use pressure, namely 135MPa, the boosting rate is not more than 0.5MPa/S in the boosting process, the pressure is maintained for 30S after the pressure is reached, then the pressure is relieved, the test temperature is room temperature, the test medium is water, and the volume residual deformation rate is not more than 5%.

Step S15, airtight test: performing air tightness leak detection tests of the gas cylinders one by adopting a helium mass spectrometer leak detector;

specifically, step S15 includes:

step S1502, a positive pressure suction gun method helium mass spectrum leak detection test is carried out, the test pressure is (0, 94.5) MPa, the test temperature is room temperature, the test medium is a mixed gas of 95% nitrogen and 5% helium, pressure maintaining is carried out under the test pressure, a helium mass spectrum leak detector suction gun fixed on an automatic axial moving track type robot is adopted, bottle openings at two ends and valves are respectively detected, the leak rate is lower than 10^-5Pa.m³And s. The distance between the suction gun and the measured position is controlled by a mechanical hand and is not more than 2mm, and the moving speed of the suction gun is not more than 20 mm/s.

the test pressure is 0MPa to 94.5MPa, the test temperature is room temperature, and the test medium oil or water is subjected to pressure cycle for at least 7500 times from 0MPa to 94.5 MPa; the bottle should not leak or burst.

Step S17, blasting test: and (4) performing sampling inspection verification on the blasting performance of the gas cylinders by adopting a gas cylinder blasting tester according to the proportion of one piece in each batch. During the test, the gas cylinder is pressurized to 211.5MPa by adopting an aqueous medium, and is qualified without being damaged after the pressure is maintained for 5 s. Pressurization thereafter continues until failure.

Through inspection, the texture grain size of any position of the aluminum alloy inner container 100 for the high-pressure gas cylinder prepared in the embodiment is more than or equal to 5 grades according to the standard grade of ASTM E112, the tensile strength of the straight cylinder section is 345MPa, the yield strength is 310MPa, and the elongation is 16%; the testing limit pressure of the high-pressure gas cylinder obtained after the inner container is wound is 275Mpa, and the requirement of the rated pressure of 90Mpa is met.

It can be seen from the above embodiments that the high-pressure gas cylinder manufactured by the method for manufacturing the high-pressure fully-wound gas cylinder with the aluminum alloy liner 100 provided by the embodiment of the application has a nominal outer diameter of phi 300-phi 850mm, and the volume of the high-pressure gas cylinder is far higher than that of the existing standard aluminum alloy liner 100; the wall thickness of the straight cylinder section is 1-10mm, and the straight cylinder section has the characteristics of thin wall thickness and light weight; the tensile strength of the straight cylinder section is more than or equal to 345MPa, the yield strength is more than or equal to 310MPa, and the elongation is more than or equal to 15 percent; the grain size of the tissue at any position of the straight cylinder section is more than or equal to 5 grades according to the standard of ASTME112, the tissue of the material in the straight cylinder section is uniform and compact, the whole strength effect is excellent, the straight cylinder section has the characteristic of high pressure resistance, the energy consumption is low, the pollution is small, the loss of raw materials in the whole manufacturing process is less, and the raw material cost is saved.

The above description is only a preferred embodiment of the present application and is not intended to limit the present application, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, improvement and the like made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. The utility model provides an ultra-large-size aluminum alloy inner bag superhigh pressure is winding gas cylinder entirely, its characterized in that includes: the aluminum alloy liner, the composite material reinforcing layer and the external protective layer;

the aluminum alloy inner bag is the seamless structure of integral type of both ends binding off shaping head and bottleneck, includes: the sealing device comprises a first bottle opening, a first sealing head, a straight cylinder section, a second sealing head and a second bottle opening, wherein the first sealing head and the second sealing head are respectively positioned at two ends of the straight cylinder section, and the first bottle opening and the second bottle opening are respectively positioned on the first sealing head and the second sealing head; performing multi-pass tension spinning forming treatment on a straight cylinder section of the seamless pipe by adopting an ultralong cylinder tension spinning device to obtain an aluminum alloy liner spinning pipe;

the composite material reinforcing layer is coated on the outer side of the aluminum alloy inner container, wherein the composite material reinforcing layer is formed by winding carbon fibers in a spiral and annular combined winding mode and curing the carbon fibers with resin;

the outer protective layer is coated on the outer side of the composite material reinforcing layer, wherein the outer protective layer is formed by winding glass fiber in a spiral and annular combined winding mode and curing the glass fiber by resin;

the ultra-high pressure full-winding gas cylinder with the ultra-large aluminum alloy inner container is tested under the test pressure of (0, 94.5) MPaThe test temperature is room temperature, the test medium is a mixed gas of 95% nitrogen and 5% helium, and the leak rate of the helium mass spectrum leak test by the positive pressure suction gun method under the test pressure is lower than 10^-5Pa.m³/s。

2. The aluminum alloy liner ultrahigh-pressure fully-wound gas cylinder according to claim 1, characterized in that the length of the gas cylinder is not more than 5-13m, the nominal outer diameter is (300, 850) mm, and the working pressure is (30, 90) MPa; the volume of the gas cylinder is (350, 6500) L;

preferably, the length of the gas cylinder is (5, 13) m;

preferably, the working pressure of the gas cylinder is 90 MPa;

preferably, the volume of the gas cylinder is (1000, 3000) L;

preferably, the service temperature of the gas cylinder is (-40 ℃, 85 ℃);

preferably, the gas cylinder is used for containing hydrogen;

preferably, the gas cylinder is used for vehicle-mounted horizontally-placed storage and transportation gas cylinders;

preferably, the wall thickness of a straight cylinder section of the aluminum alloy inner container is (1, 10) mm, and the integral straightness of the straight cylinder section is not more than 0.3 mm/m;

preferably, the tolerance of the wall thickness of the straight cylinder section is less than or equal to +/-0.1 mm;

preferably, the local straightness at any straight section position of the straight cylinder section is not more than 0.3mm/300 mm;

preferably, the roundness of any position of the straight cylinder section is not more than 0.3 mm;

preferably, the roughness of the inner surface of the straight cylinder section is less than Ra0.8 μm, and the roughness of the outer surface of the straight cylinder section is less than Ra1.6 μm.

3. The ultrahigh-pressure fully-wound gas cylinder with the aluminum alloy inner container as recited in claim 1, wherein the thickness of the seal head is uniformly increased gradually from the edge to the opening of the cylinder;

preferably, the thickness of the seal head is uniformly and gradually thickened from (5, 12) mm at the edge to (12, 25) mm at the bottle mouth part;

preferably, the end socket can adopt an ellipsoidal end socket, a butterfly end socket or a hemispherical end socket, and the structure of the first end socket is the same as that of the second end socket;

preferably, the length of the bottle mouth is 40mm, the outer diameter of the bottle mouth is (50, 96) mm, and the inner diameter of the bottle mouth is (28.6, 50.8) mm.

4. The ultrahigh-pressure fully-wound gas cylinder with the aluminum alloy liner as claimed in claim 1, wherein the carbon fibers of the composite material reinforcing layer and the glass fibers of the outer protective layer are wound by a wet method;

preferably, the carbon fibers are continuous untwisted carbon fibers;

preferably, the tensile strength of the carbon fiber is not less than 4900 MPa; the winding tension of the carbon fiber winding is not less than 5N;

preferably, the resin is a thermosetting resin, and the glass transition temperature of the resin is not lower than 105 ℃;

preferably, the resin is epoxy resin or modified epoxy resin;

preferably, the carbon fibers and/or the glass fibers are cured by a box-type heating furnace within 4 hours after being wound, and the gas cylinder is rotated automatically all the time during curing.

5. The ultra-high pressure fully-wound gas cylinder with the ultra-large aluminum alloy inner container according to claim 1, characterized in that the gas cylinder needs to be subjected to self-tightening water pressure, water pressure and air tightness tests, fatigue and explosion tests;

preferably, the water pressure of the self-tightening water is 1.8 times of the using pressure of the gas cylinder;

preferably, the fatigue times of the gas cylinder fatigue test are not less than 7500 times.

6. A manufacturing method of an ultra-high pressure fully-wound gas cylinder with an ultra-large aluminum alloy liner is used for manufacturing the ultra-high pressure fully-wound gas cylinder with the ultra-large aluminum alloy liner as claimed in any one of claims 1 to 5, and is characterized by comprising the following steps:

step S7, processing bottle mouth: respectively machining the inner diameters and the outer diameters of the first bottle opening and the second bottle opening of the aluminum alloy liner blank obtained in the step S6 by using a special bottle opening machining center, and machining internal threads and external threads of the bottle openings to obtain an aluminum alloy liner;

step S10, preprocessing the inner container: horizontally placing the aluminum alloy liner in the step S9 on a coating station of special automatic coating and drying equipment by adopting the special automatic coating and drying equipment, and coating the aluminum alloy liner with an anti-galvanic corrosion layer;

s1501, placing a tested gas bottle in an airtight test box, immersing the gas bottle in water, and connecting a test pipeline;

step S1502, carrying out a water immersion method airtight test, wherein the test pressure is (0, 26) MPa, the test temperature is room temperature, the test medium is compressed air, maintaining the pressure for 1min under the test pressure, and observing whether bubbles appear in the pressure maintaining process through a high-definition camera;

7. The manufacturing method of the ultra-high pressure fully-wound gas cylinder with the ultra-large aluminum alloy liner according to claim 6, characterized in that in step S1: the cleaning of the aluminum alloy inner container spinning tube is completed by a heated (30 ℃, 45 ℃) neutral cleaning agent;

preferably, after the aluminum alloy inner container spinning tube is cleaned, a special wiping tool or a drying device is adopted to remove residual water stains on the surface.

8. The manufacturing method of the ultra-high pressure fully-wound gas cylinder with the ultra-large aluminum alloy liner according to claim 6, wherein the step S5 comprises the following steps:

s501, clamping a third spinning part by using a special clamping tool;

step S503, grinding the defects of the inner surface of the end socket found in the step S4 by using an inner surface grinding mechanism of the end socket of a special end socket inner surface grinding machine tool to obtain a third rotary pressing piece with qualified quality;

preferably, the clamping tool of the third spinning part is a split hollow clamping tool;

preferably, the grinding of the inner molded surface of the end socket is a programmable and independently executed numerical control automatic grinding mechanism.

9. The manufacturing method of the ultra-high pressure fully-wound gas cylinder with the ultra-large aluminum alloy liner according to claim 6, wherein the step S8 comprises the following steps:

10. The manufacturing method of the large-scale aluminum alloy inner container ultrahigh pressure fully-wound gas cylinder with one end sealed according to claim 6, wherein the step S11 comprises the following steps:

step S1104, mounting two end winding fixing tools for the weighed aluminum alloy inner container of the high-pressure gas cylinder and fixing the aluminum alloy inner container on an overlong winding machine;