CN114509505B - Damage monitoring and online maintenance system for thermosetting composite material structure - Google Patents
Damage monitoring and online maintenance system for thermosetting composite material structure Download PDFInfo
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- CN114509505B CN114509505B CN202210326678.3A CN202210326678A CN114509505B CN 114509505 B CN114509505 B CN 114509505B CN 202210326678 A CN202210326678 A CN 202210326678A CN 114509505 B CN114509505 B CN 114509505B
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Classifications
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/14—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object using acoustic emission techniques
-
- 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
- B29C73/00—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
- B29C73/04—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements
- B29C73/10—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements using patches sealing on the surface of the article
- B29C73/12—Apparatus therefor, e.g. for applying
-
- 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
- B29C73/00—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
- B29C73/24—Apparatus or accessories not otherwise provided for
-
- 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
- B29C73/00—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
- B29C73/24—Apparatus or accessories not otherwise provided for
- B29C73/26—Apparatus or accessories not otherwise provided for for mechanical pretreatment
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
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- G—PHYSICS
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/04—Analysing solids
- G01N29/07—Analysing solids by measuring propagation velocity or propagation time of acoustic waves
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C73/00—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
- B29C73/24—Apparatus or accessories not otherwise provided for
- B29C73/26—Apparatus or accessories not otherwise provided for for mechanical pretreatment
- B29C2073/262—Apparatus or accessories not otherwise provided for for mechanical pretreatment for polishing, roughening, buffing or sanding the area to be repaired
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/02—Indexing codes associated with the analysed material
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- G06T2207/10—Image acquisition modality
- G06T2207/10028—Range image; Depth image; 3D point clouds
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
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- Y02P10/25—Process efficiency
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Abstract
Thermosetting composite materials, especially fiber reinforced thermosetting composite materials, have the advantages of low density, high specific strength and specific modulus, good impact toughness, corrosion resistance and the like, and thermosetting composite material parts are increasingly used. However, current thermoset composite component operation monitoring and repair techniques are low in automation. The invention provides a damage monitoring and online maintenance system for a thermosetting composite material structure, which belongs to the technical field of new materials and intelligent manufacturing, and comprises a damage identification, positioning and evaluation subsystem, a damage area scanning imaging subsystem, a pretreatment subsystem, a maintenance post-treatment subsystem and the like for the thermosetting composite material structure, so that the damage monitoring and automatic online maintenance of the thermosetting composite material structure can be realized, the problems of time consumption, low efficiency and the like of the traditional maintenance method are solved, and the damage monitoring and online maintenance system has the advantages of strong applicability, high intelligent degree, low cost and the like, can reduce logistic supply and storage pressure, and has wide engineering application prospect.
Description
Technical Field
The invention relates to a real-time measurement, evaluation, positioning and online maintenance system for damage of components of a thermosetting composite material structure in aerospace equipment, mechanical equipment, special vehicles, petroleum pipelines, chemical special equipment, power generation special equipment, special equipment and other equipment, in particular to a damage monitoring and online maintenance system for the thermosetting composite material structure, and belongs to the technical field of new material and intelligent manufacturing.
Background
The thermosetting composite material, especially the fiber reinforced thermosetting composite material, has the advantages of small density, high specific strength and specific modulus, good impact toughness, corrosion resistance, good forming processability, good designability and the like, and has wide engineering application, and more parts of the thermosetting composite material (thermosetting composite material). Intelligent manufacturing develops rapidly, and demands on automation and unmanned degree of equipment are increasing. However, the degree of automation is still low in terms of operation monitoring and maintenance of the equipment at present. Maintenance of production machines, large-scale mining equipment, special transportation equipment, offshore platforms and the like in a factory building mainly depends on manual detection and maintenance methods, and is time-consuming, low in efficiency and low in maintenance speed. In addition, there are occasions and situations where it is not suitable for traditional human service, for example: space station of space, satellite, equipment operating in toxic and harmful environments, etc. Many of the components of these devices are manufactured from thermoset composite materials. Therefore, it is necessary to develop a damage monitoring and on-line maintenance technology and system suitable for the thermosetting composite material structure, so as to improve the automation degree of equipment maintenance and provide a technical basis for intelligent maintenance for applications such as unmanned factories, unmanned power stations, unmanned ships, space stations and the like.
Disclosure of Invention
1. The invention aims to:
the invention aims to provide a damage monitoring and online maintenance system for a thermosetting composite material structure, which realizes damage monitoring and automatic online maintenance of the thermosetting composite material structure, provides an automatic and efficient online maintenance system for damage identification, evaluation, positioning and repair of thermosetting composite material parts on equipment in working, and ensures safe and reliable operation of the equipment.
2. The technical scheme is as follows:
a damage monitoring and online maintenance system of a thermosetting composite material structure comprises a damage identification and positioning and assessment subsystem, an acoustic emission sensor, a low-noise signal wire, a preposed signal amplifier, a signal acquisition and analysis device, a damage identification and assessment system and a damage positioning system of the thermosetting composite material structure; scanning imaging subsystem of damaged area of thermosetting composite structure, three-dimensional laser scanner, computer and model of area to be repaired; a heat-set composite structure damaged area pretreatment subsystem, a damaged area pretreatment control system, a surface roughening device and a cleaning device; the device comprises a thermosetting composite structure damaged area maintenance subsystem, a photocuring 3D printing control system, a laser scanning system, a laser beam, a lifter, a lifting table, a part in molding, liquid photosensitive resin, a container, a molded part, a rubber supply pipe and an adhesive box; a heat-set composite structure damaged area maintenance post-treatment subsystem, a maintenance post-surface treatment system and an adhesive wire; the device comprises a damaged thermosetting composite part, a damaged area, a manipulator, a thermosetting composite structure to be repaired, a repaired thermosetting composite structure and a repaired thermosetting composite structure;
the damage identification, positioning and assessment subsystem of the thermosetting composite structure consists of an acoustic emission sensor, a low-noise signal wire, a preposed signal amplifier, a signal acquisition and analysis device, a damage identification and assessment system and a damage positioning system; the specific model of the acoustic emission sensor is determined according to the use environment, the acoustic emission sensor is arranged in a cylindrical array, namely an upper circumferential array and a lower circumferential array are formed on the surface or the near surface of the damaged thermosetting composite material part, so that a cylindrical array is formed, and compared with the current square or diamond arrangement form, the acoustic emission sensor has a wider monitoring range and is more three-dimensional, and is matched with a cylindrical coordinate system for use, so that the accurate positioning of damage is realized; the acoustic emission sensor is connected with the preposed signal amplifier through a low-noise signal wire or a wireless communication mode, signals are amplified and then transmitted to the signal acquisition and analysis device, the signal acquisition and analysis device filters the signals, and the filtered waveform signals are analyzed to obtain the arrival time and the amplitude of different sensor channels; the damage identification and assessment system compares the amplitude with a preset damage threshold, the damage is generated when the amplitude exceeds the threshold, and when the amplitude is 1.5 times of the threshold, the damage area needs to be maintained; the damage positioning system calculates and judges the damage position according to the difference value of the arrival time of different sensor channels, the space coordinates of the acoustic emission sensor and the sound velocity;
the scanning imaging subsystem of the damage area of the thermosetting composite structure consists of a three-dimensional laser scanner, a computer and a model of the area to be repaired, and has the main functions of scanning imaging and modeling the damage area; after obtaining the damage position information transmitted by a damage positioning system, a three-dimensional laser scanner carries out laser scanning on a damage area on a damage-containing thermosetting composite part, creates point clouds on the geometric surface of the damage area in a computer, interpolates the point clouds to build a three-dimensional model of the damage area, carries out Boolean operation on the three-dimensional model and a complete model of a thermosetting composite structure stored in the computer to obtain a model of the area to be repaired, converts the model of the area to be repaired into a photo-curing 3D printing identifiable STL format file, and obtains the model (STL format) of the area to be repaired;
the heat-set composite structure damage area pretreatment subsystem consists of a damage area pretreatment control system, a surface roughening device and a cleaning device, and has the main functions of carrying out surface roughening treatment and dust impurity cleaning on a damage area to be repaired; firstly, a damaged area pretreatment control system controls a surface roughening device to brush and polish a damaged area on a thermosetting composite structure to be repaired, which is grabbed by a manipulator, by using a steel wire brush and sand paper, so that the surface of the composite material to be adhered in the damaged area is roughened, the adhesive bonding between a patch manufactured by 3D printing and the damaged area is firmer, and the adhesive bonding strength is improved; then, the damage area pretreatment control system controls the cleaning device to blow compressed air to the damage area, the air pressure of the compressed air is between 0.1 and 0.3MPa, and dust and impurities on the surface of the damage area are cleaned;
the thermosetting composite structure damaged area maintenance subsystem consists of a photocuring 3D printing control system, a laser scanning system, a laser beam, a lifter, a lifting table, a part in molding, liquid photosensitive resin, a container, a molded part, a rubber supply pipe and an adhesive box; slicing the model (STL format) of the area to be repaired by the photocuring 3D printing control system, and generating movement instructions of the laser scanning system and the lifter according to plane geometric information of each layer of slicing; the container is filled with liquid photosensitive resin, 355nm wavelength laser emitted by a laser is deflected and dynamically focused into a laser beam through a laser scanning system, the laser beam is scanned point by point on the surface of the photosensitive resin according to section information of a slice under the control of a photocuring 3D printing control system, the resin in a scanned area is subjected to photopolymerization reaction to be solidified into a resin thin layer, the resin thin layer is arranged on a workbench of a lifting table, after one layer of resin thin layer is solidified, the workbench is controlled by the lifting table to move downwards by a layer thickness distance, so that a new layer of resin is formed on the surface of the solidified resin, the newly solidified layer is firmly adhered to a previous resin layer, the resin thin layer is stacked and piled to form a part in forming, and the process is repeated until 3D printing is finished, and the formed part is obtained; the adhesive boxes are stored with epoxy adhesive, phenolic adhesive, methacrylic acid adhesive and polyurethane adhesive, each adhesive is arranged in one box, the boxes are arranged in a circumferential array, when one adhesive is needed, the adhesive boxes rotate to transfer the adhesive to the adhesive outlet, the adhesive is supplied to a rubber pipe, the bonding requirements of different material structures are met, and the adaptability and the universality of a maintenance system are improved; the photo-curing 3D printing control system controls the rubber supply pipe to smear the adhesive on the damaged area of the composite material, the mechanical arm places the formed part in the damaged area to be repaired, the adhesion with the thermosetting composite material structure is realized, and the repair work of the damaged area is completed after the adhesive is cured;
the repair post-treatment subsystem of the damaged area of the thermosetting composite structure has the main functions of carrying out surface treatment on the repaired thermosetting composite structure, and carrying out polishing, cleaning and paint repairing operations on the surface of an adhesive line and other surfaces needing paint repairing by the surface treatment system after repair so as to improve the aesthetic property of a repair area and enable the repair area to be more similar to the original structure in appearance;
the damage-containing thermosetting composite material part comprises a damage area, and when the thermosetting composite material part is large in size, the part comprising the damage area can be detached by using a manipulator for maintenance; when the size of the thermosetting composite material part is smaller, the thermosetting composite material part containing damage can be directly maintained;
the manipulator is controlled by a computer and mainly has the functions of disassembling and installing a thermosetting composite material structure on a part in equipment and moving the thermosetting composite material structure in the operations of scanning, preprocessing, maintaining and post-maintaining damaged areas, wherein a hilly array bulge made of rubber materials is arranged on the inner side of a part of claws at the end part of the manipulator, so that the grabbing friction force is improved, the composite material structure is prevented from falling off, and the hardness of the composite material structure is far lower than that of steel;
the thermosetting composite structure with the maintained structure is a thermosetting composite structural member with the maintained and installed structure, a damaged area on the thermosetting composite structural member is maintained, the service function of the thermosetting composite structural member after maintenance is the same as that of an undamaged thermosetting composite structural member, and the service function of the thermosetting composite structural member after maintenance is not lower than 85% of that of the undamaged thermosetting composite structural member in terms of mechanical properties of tension, compression, bending, shearing and fatigue.
3. The invention relates to a damage monitoring and online maintenance system for a thermosetting composite material structure, which has the following advantages:
(1) The invention has wide application range and strong universality, and can provide maintenance service for equipment such as mechanical equipment, special vehicles, special equipment for mines, special equipment for chemical industry, special equipment for aerospace, special equipment for power generation, special equipment and the like;
(2) The invention has high flexibility, high maintenance efficiency, low cost, no need of dies, no need of blanks, no need of maintenance parts, no need of storing spare parts, and greatly reduced pressure of logistical replenishment and material storage;
(3) The invention is beneficial to improving the intelligent degree and the safety and reliability of equipment, is beneficial to realizing the online collection and the summarization of damage information in the equipment service process, and can provide data support for the optimization design and the manufacturing process improvement of the thermosetting composite material parts.
In a word, the invention can realize the damage identification, evaluation, positioning and online maintenance of the thermosetting composite material component on the equipment in working, has high degree of automation, high efficiency and low cost, is particularly suitable for being used under the condition of unsuitable manual operation such as toxic and harmful dangerous environment, can assist the development of intelligent manufacturing of equipment, and has very wide engineering application prospect.
Drawings
The invention will be better understood from the following description of non-limiting preferred embodiments, taken in conjunction with the accompanying drawings;
FIG. 1 is a block diagram of the subsystem architecture of the present invention;
FIG. 2 is a detailed schematic of the composition of the present invention;
the symbols in the drawings are as follows: the system comprises a 1-thermosetting composite structure damage identification and positioning and assessment subsystem, a 101-acoustic emission sensor, a 102-low noise signal wire, a 103-pre-signal amplifier, a 104-signal acquisition and analysis device, a 105-damage identification and assessment system and a 106-damage positioning system; 2-scanning imaging subsystem of the damaged area of the thermosetting composite structure, 201-three-dimensional laser scanner, 202-computer and 203-model of the area to be repaired; 3-a pretreatment subsystem of a damaged area of a thermosetting composite structure, 301-a pretreatment control system of the damaged area, 302-a surface roughening device and 303-a cleaning device; the method comprises the steps of (1) a 4-thermosetting composite structure damaged area maintenance subsystem, 401-a photo-curing 3D printing control system, 402-a laser, 403-a laser scanning system, 404-a laser beam, 405-a lifter, 406-a lifting table, 407-a part in molding, 408-a liquid photosensitive resin, 409-a container, 410-a molded part, 411-a rubber supply pipe and 412-an adhesive box; 5-a repair post-treatment subsystem of a damaged area of the thermosetting composite structure, 501-a repair post-surface treatment system and 502-bonding wires; 6-a damaged thermosetting composite part, 7-a damaged area, 8-a manipulator, 9-a thermosetting composite structure to be repaired, 10-a thermosetting composite structure after repair and 11-a thermosetting composite structure after repair.
Detailed Description
Embodiments of the invention are described in further detail below with reference to the attached drawing figures:
as shown in fig. 1 and 2, the damage monitoring and on-line maintenance system of the thermosetting composite material structure of the present invention comprises: the damage identification, positioning and evaluation subsystem 1 of the thermosetting composite structure, an acoustic emission sensor 101, a low-noise signal line 102, a preposed signal amplifier 103, a signal acquisition and analysis device 104, a damage identification and evaluation system 105 and a damage positioning system 106; the method comprises the steps of scanning an imaging subsystem 2 of a damaged area of a thermosetting composite structure, a three-dimensional laser scanner 201, a computer 202 and a model 203 of an area to be repaired; a damage area pretreatment subsystem 3, a damage area pretreatment control system 301, a surface texturing device 302 and a cleaning device 303 of the thermosetting composite structure; a thermosetting composite structure damaged area maintenance subsystem 4, a photocuring 3D printing control system 401, a laser 402, a laser scanning system 403, a laser beam 404, a lifter 405, a lifting table 406, a part under molding 407, a liquid photosensitive resin 408, a container 409, a molded part 410, a rubber supply pipe 411 and an adhesive box 412; a heat-set composite structure damaged area maintenance post-treatment subsystem 5, a maintenance post-surface treatment system 501 and an adhesive line 502; the device comprises a damaged thermosetting composite part 6, a damaged area 7, a manipulator 8, a thermosetting composite structure 9 to be repaired, a repaired thermosetting composite structure 10 and a repaired thermosetting composite structure 11;
the damage identification, positioning and evaluation subsystem 1 of the thermosetting composite structure consists of an acoustic emission sensor 101, a low-noise signal wire 102, a pre-signal amplifier 103, a signal acquisition and analysis device 104, a damage identification and evaluation system 105 and a damage positioning system 106; the specific model of the acoustic emission sensor 101 is determined according to the use environment, the acoustic emission sensor 101 is arranged in a cylindrical array, namely an upper circumferential array and a lower circumferential array are formed on the surface or the near surface of the damaged thermosetting composite material part 6, so that a cylindrical array is formed, and compared with the current square or diamond arrangement form, the acoustic emission sensor 101 has a larger monitoring range and is more three-dimensional, and is matched with a cylindrical coordinate system for use, so that the accurate positioning of damage is realized; the acoustic emission sensor 101 is connected with the pre-signal amplifier 103 through a low-noise signal line 102 or a wireless communication mode, signals are amplified and then transmitted to the signal acquisition and analysis device 104, the signal acquisition and analysis device 104 filters the signals, and the filtered waveform signals are analyzed to obtain the arrival time and the amplitude of different sensor channels; the lesion recognition and assessment system 105 compares the amplitude with a pre-set lesion threshold value, exceeding the threshold value indicates that a lesion has occurred, and when the amplitude is 1.5 times the threshold value, repair of the lesion area is required; the damage positioning system 106 calculates and judges the damage position according to the difference value of the arrival time of different sensor channels, the space coordinates of the acoustic emission sensor and the sound velocity;
the scanning imaging subsystem 2 of the damage area of the thermosetting composite structure consists of a three-dimensional laser scanner 201, a computer 202 and a model 203 of the area to be repaired, and has the main functions of scanning imaging and modeling the damage area; after obtaining the damage position information transmitted by the damage positioning system 106, the three-dimensional laser scanner 201 performs laser scanning on the damage region 7 on the damaged thermosetting composite material component 6, creates a point cloud on the geometric surface of the damage region in the computer 202, interpolates the point cloud data to build a three-dimensional model of the damage region, performs boolean operation on the three-dimensional model and a complete model of the thermosetting composite material structure stored in the computer to obtain a model of the region to be repaired, converts the model of the region to be repaired into a light-cured 3D printing identifiable STL format file, and obtains a model 203 (STL format) of the region to be repaired;
the damage area pretreatment subsystem 3 of the thermosetting composite structure consists of a damage area pretreatment control system 301, a surface roughening device 302 and a cleaning device 303, and has the main functions of carrying out surface roughening treatment and dust impurity cleaning on a damage area to be repaired; firstly, a damaged area pretreatment control system 301 controls a surface roughening device 302 to brush and polish a damaged area on a thermosetting composite structure 9 to be repaired, which is grabbed by a manipulator 8, by using a steel wire brush and sand paper, so that the surface of the composite material to be adhered in the damaged area is roughened, the adhesion and the combination of a patch manufactured by 3D printing and the damaged area are firmer, and the adhesion strength is improved; then, the damaged area pretreatment control system 301 controls the cleaning device 303 to blow compressed air to the damaged area, the air pressure of the compressed air is between 0.1 and 0.3MPa, and dust and impurities on the surface of the damaged area are cleaned;
the repair subsystem 4 of the damaged area of the thermosetting composite structure consists of a photocuring 3D printing control system 401, a laser 402, a laser scanning system 403, a laser beam 404, a lifter 405, a lifting table 406, a part 407 in molding, liquid photosensitive resin 408, a container 409, a molded part 410, a rubber supply pipe 411 and an adhesive box 412; the photocuring 3D printing control system 401 performs slicing processing on a model (STL format) 203 of an area to be repaired, and generates movement instructions of the laser scanning system 403 and the lifter 405 according to plane geometric information of slicing of each layer; the container 409 holds liquid photosensitive resin 408, 355nm wavelength laser emitted by the laser 402 is deflected and dynamically focused into a laser beam 404 by the laser scanning system 403, the laser beam 404 is scanned point by point on the surface of the photosensitive resin according to the section information of the slice under the control of the photocuring 3D printing control system 401, the resin in the scanned area is subjected to photopolymerization reaction to be solidified into a resin thin layer, the resin thin layer is placed on a workbench of the lifting table 406, after one layer of the resin thin layer is solidified, the lifting table 405 is controlled by the lifter 405 to move down by a layer thickness distance so that a new layer of resin is formed on the surface of the solidified resin, the newly solidified layer is firmly adhered to the previous layer of resin layer, the resin thin layer is stacked and piled to form a part 407 in the formation, and the process is repeated until the 3D printing is finished, and the formed part 410 is obtained; the adhesive boxes 412 are stored with epoxy adhesive, phenolic adhesive, methacrylic acid adhesive and polyurethane adhesive, each adhesive is arranged in one box, the boxes are arranged in a circumferential array, when one adhesive is needed, the adhesive boxes rotate to transfer the adhesive to the adhesive outlet, the adhesive is supplied to the rubber pipe 411, the bonding requirements of different material structures are met, and the adaptability and the universality of a maintenance system are improved; the photo-curing 3D printing control system 401 controls the rubber supply pipe 411 to smear the adhesive on the damaged area of the composite material, the formed part 410 is placed in the damaged area to be repaired by the mechanical arm, the bonding with the thermosetting composite material structure is realized, and the repair work of the damaged area is completed after the curing of the adhesive is finished;
the main function of the repair post-treatment subsystem 5 of the damaged area of the thermosetting composite structure is to perform surface treatment on the repaired thermosetting composite structure 10, and the surface of the bonding wire 502 and other surfaces needing paint repair are polished, cleaned and paint repaired by the repair post-treatment system 501 so as to improve the aesthetic property of the repair area and enable the repair area to be more similar to the original structure in appearance;
the damage-containing thermosetting composite material part 6 comprises a damage area 7, and when the thermosetting composite material part is large in size, the part comprising the damage area 7 can be detached for maintenance by using a manipulator 8; when the size of the thermosetting composite material part is smaller, the damaged thermosetting composite material part 6 can be directly maintained;
the manipulator 8 is controlled by the computer 202, and has the main functions of disassembling and installing the thermosetting composite material structure on parts in equipment and moving the thermosetting composite material structure in the operations of scanning a damaged area, preprocessing, maintaining and post-maintaining, wherein a hilly array bulge made of rubber materials is arranged on the inner side of a part of claws at the end part of the manipulator 8, so that the grabbing friction force is improved, the composite material structure is prevented from falling off, and the hardness of the composite material structure is far lower than that of steel;
the repair-completed thermosetting composite structure 11 is a thermosetting composite structural member which has been repaired and installed, the damaged area 7 of the thermosetting composite structural member has been repaired, the service function of the thermosetting composite structural member after repair is the same as that of the undamaged thermosetting composite structural member, and the mechanical properties of the thermosetting composite structural member after repair are not lower than 85% of those of the undamaged thermosetting composite structural member in terms of tensile, compression, bending, shearing and fatigue.
The invention has been described in terms of specific embodiments envisaged, but is not limited to the examples described above, all the solutions obtained by adopting similar structures and material substitution methods, which are in line with the idea of the invention, are within the scope of protection of the invention.
Claims (5)
1. The damage monitoring and online maintenance system for the thermosetting composite material structure is characterized by comprising a damage identification and positioning and assessment subsystem, an acoustic emission sensor, a low-noise signal wire, a preposed signal amplifier, a signal acquisition and analysis device, a damage identification and assessment system and a damage positioning system for the thermosetting composite material structure; scanning imaging subsystem of damaged area of thermosetting composite structure, three-dimensional laser scanner, computer and model of area to be repaired; a heat-set composite structure damaged area pretreatment subsystem, a damaged area pretreatment control system, a surface roughening device and a cleaning device; the device comprises a thermosetting composite structure damaged area maintenance subsystem, a photocuring 3D printing control system, a laser scanning system, a laser beam, a lifter, a lifting table, a part in molding, liquid photosensitive resin, a container, a molded part, a rubber supply pipe and an adhesive box; a heat-set composite structure damaged area maintenance post-treatment subsystem, a maintenance post-surface treatment system and an adhesive wire; the device comprises a damaged thermosetting composite part, a damaged area, a manipulator, a thermosetting composite structure to be repaired, a repaired thermosetting composite structure and a repaired thermosetting composite structure;
the damage identification, positioning and assessment subsystem of the thermosetting composite structure consists of an acoustic emission sensor, a low-noise signal wire, a preposed signal amplifier, a signal acquisition and analysis device, a damage identification and assessment system and a damage positioning system; the specific model of the acoustic emission sensor is determined according to the use environment, the acoustic emission sensor is arranged in a cylindrical array, namely an upper circumferential array and a lower circumferential array are formed on the surface or the near surface of the damaged thermosetting composite material part, so that a cylindrical array is formed, and compared with the current square or diamond arrangement form, the acoustic emission sensor has a wider monitoring range and is more three-dimensional, and is matched with a cylindrical coordinate system for use, so that the accurate positioning of damage is realized; the acoustic emission sensor is connected with the preposed signal amplifier through a low-noise signal wire or a wireless communication mode, signals are amplified and then transmitted to the signal acquisition and analysis device, the signal acquisition and analysis device filters the signals, and the filtered waveform signals are analyzed to obtain the arrival time and the amplitude of different sensor channels; the damage identification and assessment system compares the amplitude with a preset damage threshold, the damage is generated when the amplitude exceeds the threshold, and when the amplitude is 1.5 times of the threshold, the damage area needs to be maintained; the damage positioning system calculates and judges the damage position according to the difference value of the arrival time of different sensor channels, the space coordinates of the acoustic emission sensor and the sound velocity;
the scanning imaging subsystem of the damage area of the thermosetting composite structure consists of a three-dimensional laser scanner, a computer and a model of the area to be repaired, and has the main functions of scanning imaging and modeling the damage area; after obtaining the damage position information transmitted by a damage positioning system, a three-dimensional laser scanner carries out laser scanning on a damage area on a damage-containing thermosetting composite part, creates point clouds on the geometric surface of the damage area in a computer, interpolates the point clouds to build a three-dimensional model of the damage area, carries out Boolean operation on the three-dimensional model and a complete model of a thermosetting composite structure stored in the computer to obtain a model of the area to be repaired, converts the model of the area to be repaired into a photo-curing 3D printing identifiable STL format file, and obtains the model of the area to be repaired;
the heat-set composite structure damage area pretreatment subsystem consists of a damage area pretreatment control system, a surface roughening device and a cleaning device, and has the main functions of carrying out surface roughening treatment and dust impurity cleaning on a damage area to be repaired; firstly, a damaged area pretreatment control system controls a surface roughening device to brush and polish a damaged area on a thermosetting composite structure to be repaired, which is grabbed by a manipulator, by using a steel wire brush and sand paper, so that the surface of the composite material to be adhered in the damaged area is roughened, the adhesive bonding between a patch manufactured by 3D printing and the damaged area is firmer, and the adhesive bonding strength is improved; then, the damage area pretreatment control system controls the cleaning device to blow compressed air to the damage area, the air pressure of the compressed air is between 0.1 and 0.3MPa, and dust and impurities on the surface of the damage area are cleaned;
the thermosetting composite structure damaged area maintenance subsystem consists of a photocuring 3D printing control system, a laser scanning system, a laser beam, a lifter, a lifting table, a part in molding, liquid photosensitive resin, a container, a molded part, a rubber supply pipe and an adhesive box; slicing the model of the area to be repaired by the photocuring 3D printing control system, and generating movement instructions of the laser scanning system and the lifter according to plane geometric information of slicing of each layer; the container is filled with liquid photosensitive resin, 355nm wavelength laser emitted by a laser is deflected and dynamically focused into a laser beam through a laser scanning system, the laser beam is scanned point by point on the surface of the photosensitive resin according to section information of a slice under the control of a photocuring 3D printing control system, the resin in a scanned area is subjected to photopolymerization reaction to be solidified into a resin thin layer, the resin thin layer is arranged on a workbench of a lifting table, after one layer of resin thin layer is solidified, the workbench is controlled by the lifting table to move downwards by a layer thickness distance, so that a new layer of resin is formed on the surface of the solidified resin, the newly solidified layer is firmly adhered to a previous resin layer, the resin thin layer is stacked and piled to form a part in forming, and the process is repeated until 3D printing is finished, and the formed part is obtained; the adhesive boxes are internally provided with epoxy adhesives, phenolic adhesives, methacrylic adhesives and polyurethane adhesives, each adhesive is arranged in one box, the boxes are arranged in a circumferential array, when one adhesive is needed, the adhesive boxes rotate to transfer the adhesive to the adhesive outlet, the adhesive is supplied to a rubber pipe for adhesive feeding, the bonding requirements of different material structures are met, and the adaptability and the universality of a maintenance system are improved; the photo-curing 3D printing control system controls the rubber supply pipe to smear the adhesive on the damaged area of the composite material, the mechanical arm places the formed part in the damaged area to be repaired, the bonding with the thermosetting composite material structure is realized, and the repair work of the damaged area is completed after the curing of the adhesive is finished.
2. The damage monitoring and online maintenance system for a thermoset composite material structure of claim 1, wherein: the repair post-treatment subsystem for the damaged area of the thermosetting composite structure has the main functions of carrying out surface treatment on the repaired thermosetting composite structure, and carrying out polishing, cleaning and paint repair operations on the surface of an adhesive line and other surfaces needing paint repair by the surface treatment system after repair so as to improve the aesthetic property of a repair area and enable the repair area to be more similar to the original structure in appearance.
3. The damage monitoring and online maintenance system for a thermoset composite material structure of claim 1, wherein: the damage-containing thermosetting composite material part comprises a damage area, and when the size of the thermosetting composite material part is large, the part comprising the damage area is detached by using a manipulator for maintenance; when the size of the thermosetting composite material part is smaller, the thermosetting composite material part containing damage is directly maintained.
4. The damage monitoring and online maintenance system for a thermoset composite material structure of claim 1, wherein: the manipulator is controlled by a computer, and has the main effects of disassembling and installing a thermosetting composite material structure on a part in equipment and moving the thermosetting composite material structure in the operations of scanning, preprocessing, maintaining and post-maintaining damaged areas, wherein the inner side of part of claws at the end part of the manipulator is provided with hillock-shaped array bulges made of rubber materials, the grabbing friction force is improved, the composite material structure is prevented from falling off, and the hardness of the composite material structure is far lower than that of steel.
5. The damage monitoring and online maintenance system for a thermoset composite material structure of claim 1, wherein: the thermosetting composite structure with the maintained structure is a thermosetting composite structural member with the maintained and installed structure, a damaged area on the thermosetting composite structural member is maintained, the service function of the thermosetting composite structural member after maintenance is the same as that of an undamaged thermosetting composite structural member, and the service function of the thermosetting composite structural member after maintenance is not lower than 85% of that of the undamaged thermosetting composite structural member in terms of mechanical properties of tension, compression, bending, shearing and fatigue.
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| CN116714288B (en) * | 2023-08-10 | 2023-10-31 | 中国人民解放军空军工程大学 | Rapid repairing method for filling damaged preformed body of aircraft composite material broken hole |
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| CN101701880A (en) * | 2009-08-05 | 2010-05-05 | 南京航空航天大学 | Embedded health monitoring system for active and passive structure of aeroplane |
| CN108318357A (en) * | 2018-01-11 | 2018-07-24 | 浙江大学 | Damage monitoring device and method for composites gas cylinder fatigue test |
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| WO2001050122A1 (en) * | 2000-01-03 | 2001-07-12 | The Board Of Regents Of The University Of Nebraska | Hybrid transient-parametric method and system to distinguish and analyze sources of acoustic emission for nondestructive inspection and structural health monitoring |
| US20150185128A1 (en) * | 2013-12-26 | 2015-07-02 | The Boeing Company | Detection and Assessment of Damage to Composite Structure |
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| CN101701880A (en) * | 2009-08-05 | 2010-05-05 | 南京航空航天大学 | Embedded health monitoring system for active and passive structure of aeroplane |
| CN108318357A (en) * | 2018-01-11 | 2018-07-24 | 浙江大学 | Damage monitoring device and method for composites gas cylinder fatigue test |
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| Zhang Yiben等.Direct injection molding and mechanical properties of high strength steel/composite hybrids.Composite Structures.2019,全文. * |
| 傅天航 ; 刘松平 ; 刘菲菲 ; 高军鹏 ; .复合材料桨叶无损检测技术研究进展.工程塑料应用.2020,(第10期),全文. * |
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