CN114778700B - Damage monitoring and online maintenance system for thermoplastic composite material structure - Google Patents
Damage monitoring and online maintenance system for thermoplastic composite material structure Download PDFInfo
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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
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
- B29C64/118—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
-
- 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
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
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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
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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
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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
- B29C73/30—Apparatus or accessories not otherwise provided for for local pressing or local heating
- B29C73/34—Apparatus or accessories not otherwise provided for for local pressing or local heating for local heating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
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- G—PHYSICS
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- 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
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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
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Abstract
The equipment is rapidly developed in light weight, and the thermoplastic composite materials are increasingly widely used. However, the degree of automation is currently low in the operation monitoring and maintenance of thermoplastic composite parts. Therefore, the invention provides a damage monitoring and online maintenance system for a thermoplastic composite structure, which belongs to the technical field of new materials and intelligent manufacturing, and comprises a thermoplastic composite structure damage identification and positioning and assessment subsystem, an acoustic emission sensor, a damage identification and assessment system, a damage positioning system, a three-dimensional laser scanner, a thermoplastic composite structure damage area pretreatment subsystem, a thermoplastic composite structure damage area maintenance subsystem and the like, wherein the damage identification and positioning is realized, and then the damage area maintenance is carried out by using a 3D printing technology, so that the problems of time consumption, low efficiency, low automation degree and the like of a traditional maintenance method can be solved, and the damage monitoring and online maintenance system can be applied to mining equipment, offshore platforms, airplanes and other equipment, and is particularly suitable for maintenance in toxic and harmful dangerous environments.
Description
Technical Field
The invention relates to a real-time measurement, evaluation, positioning and online maintenance system for damage of thermoplastic composite material structural parts in aerospace equipment, workshop mechanical equipment, vehicle transportation equipment, chemical special equipment, power generation special equipment, special equipment and other equipment, in particular to a damage monitoring and online maintenance system for a thermoplastic composite material structure, and belongs to the technical field of new material and intelligent manufacturing.
Background
Light weight is an effective way of energy conservation and emission reduction, so that light weight design and engineering application work are greatly developed for airplanes, high-speed rails, automobiles, ships, mechanical equipment and the like. The thermoplastic composite material, especially the fiber reinforced thermoplastic composite material, has the advantages of small density, high specific strength and specific modulus, good impact toughness, corrosion resistance, good molding processability, good designability, good recyclability and the like, has wide engineering application, and more thermoplastic composite material (thermoplastic composite material) parts. 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: satellites in space, equipment operating in toxic and harmful environments, and the like. In these devices, many of the components are manufactured from thermoplastic composites. Therefore, there is a need to develop damage monitoring and online maintenance techniques and systems suitable for thermoplastic composite structures to increase their automation level, providing a basis for applications such as unmanned factories, unmanned power stations, unmanned ships, etc.
Disclosure of Invention
1. The invention aims to:
the invention aims to provide a damage monitoring and online maintenance system for a thermoplastic composite material structure, which realizes damage monitoring and automatic online maintenance of the thermoplastic composite material structure, provides an automatic and efficient online maintenance system for damage identification, evaluation, positioning and repair of thermoplastic composite material parts on equipment in operation, and ensures safe and reliable operation of the equipment.
2. The technical scheme is as follows:
a damage monitoring and online maintenance system for a thermoplastic composite structure comprises a thermoplastic composite structure damage identification and positioning and assessment subsystem, an acoustic emission sensor, a low-noise signal wire, a preamplifier, a signal acquisition and analysis device, a damage identification and assessment system and a damage positioning system; scanning imaging subsystem of damaged area of thermoplastic composite structure, three-dimensional laser scanner, computer, and model of area to be repaired; the device comprises a thermoplastic composite structure damaged area pretreatment subsystem, a damaged area pretreatment control system, a decontamination device and a heating device; the thermoplastic composite structure damage area maintenance subsystem, the fused deposition 3D printing control system, a feed box, a spray head control module, a rolling roller, a material wire, a spray head and fused deposition materials; a post-maintenance treatment subsystem for the damaged area of the thermoplastic composite structure, a post-maintenance residual stress eliminating system and a post-maintenance surface treatment system; the device comprises a damaged thermoplastic composite part, a damaged area, a manipulator, a thermoplastic composite structure to be repaired, a thermoplastic composite structure in repair and a thermoplastic composite structure after repair;
the damage identification, positioning and evaluation subsystem of the thermoplastic composite structure consists of an acoustic emission sensor, a low-noise signal wire, a preamplifier, a signal acquisition and analysis device, a damage identification and evaluation 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 thermoplastic composite material part containing the damage, so that a cylindrical shape is formed, and compared with the current square and diamond arrangement forms, the acoustic emission sensor has the advantages that the monitoring range of the cylindrical arrangement is larger, is more three-dimensional, is matched with a cylindrical coordinate system for use, and realizes the accurate positioning of the damage; the acoustic emission sensor is connected with the pre-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 thermoplastic composite structure damaged area scanning imaging subsystem consists of a three-dimensional laser scanner, a computer and a model of an area to be repaired, and has the main functions of scanning imaging and modeling the damaged area; after obtaining the damage position information transmitted by a damage positioning system, a three-dimensional laser scanner carries out laser scanning on a damage region on a thermoplastic composite material part containing the damage, creates point clouds on the geometric surface of the damage region in a computer, interpolates the point clouds to build a three-dimensional model of the damage region, carries out Boolean operation on the three-dimensional model and a thermoplastic composite material structural complete model 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 3D printing identifiable STL format file, and obtains a model (STL format) of the region to be repaired;
the thermoplastic composite structure damage area pretreatment subsystem consists of a damage area pretreatment control system, a decontamination device and a heating device, and has the main functions of cleaning and preheating the damage area to be repaired; firstly, a damage area pretreatment control system controls a decontamination device to brush and wipe a damage area on a thermoplastic composite structure to be repaired, which is grasped by a manipulator, by using a steel wire brush, so that the surface of the composite material in the damage area is roughened, and a fused deposition material is attached to the surface of the damage area during 3D printing maintenance and is tightly combined with the composite structure; then, the damage area pretreatment control system controls the decontamination device to compress 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; finally, lesion area pretreatment controlThe system control heating device adopts an infrared heating mode to preheat the composite material in the damaged area, so as to facilitate engineering application and improve the bonding strength of the 3D printed molten material and the composite material in the damaged area, and the preheating temperature (T p Units: the value at degrees celsius is the glass transition temperature (T) of the thermoplastic matrix polymer material in the composite material g Units: temperature of melting point (T) m Units: average value in degrees centigrade plus 10 degrees centigrade, i.e. T p ＝(T g +T m )/2+10；
The thermoplastic composite structure damaged area maintenance subsystem consists of a fused deposition 3D printing control system, a feed box, a spray head control module, a rolling roller, material wires, a spray head and fused deposition materials; slicing the model (STL format) of the area to be repaired by the fused deposition 3D printing control system, and generating a numerical control motion instruction of the spray head control module according to the plane geometric information of each layer of slice; the short glass fiber reinforced nylon composite material, the continuous glass fiber reinforced nylon composite material, the short carbon fiber reinforced nylon composite material, the continuous carbon fiber reinforced nylon composite material, the short glass fiber reinforced polypropylene composite material, the continuous glass fiber reinforced polypropylene composite material, the short carbon fiber reinforced polypropylene composite material and the continuous carbon fiber reinforced polypropylene composite material are deposited in a melting mode to form 3D consumable materials, the shape is a wire shape, the shape is a disc-shaped coiled material, the disc-shaped coiled materials are circumferentially arrayed, the requirement of materials with different types of structures is met, and the adaptability and the universality of a maintenance system are improved; when a certain thermoplastic composite material is needed, the feeding box rotates to transfer the material to the discharging hole, the driving roller in the rolling roller rotates anticlockwise, the driven roller rotates clockwise, so that the material wire of the composite material is pulled out and conveyed into the spray head, the electrically driven wire driving wheel arranged in the spray head extrudes the material wire to a heating channel with a heater, and the material wire is extruded from the nozzle when heated to a molten state, so that a molten deposition material is formed; along with the movement of the spray head, the fused deposition material falls in the preheated composite material damaged area, scans and stacks the fused deposition thermoplastic composite material wire material layer by layer in the damaged area until the 3D printing of the model of the area to be repaired is completed in the damaged area, and then the fused deposition material is solidified and molded to complete the repair work of the damaged area;
the post-maintenance treatment subsystem for the damaged area of the thermoplastic composite structure consists of a post-maintenance residual stress eliminating system and a post-maintenance surface treatment system; the residual stress eliminating system performs ultrasonic impact or hot air blowing operation on a maintenance area of the thermoplastic composite material structure which is subjected to 3D printing maintenance, so as to eliminate internal residual stress; then, polishing, cleaning and paint repairing operations are carried out on the surface of the maintained area by a surface treatment system after maintenance;
the thermoplastic composite material part with the damage comprises a damage area, and when the thermoplastic composite material part is large in size, the part with the damage area is detached by using a manipulator for maintenance; when the thermoplastic composite material part is smaller in size, directly repairing the damaged thermoplastic composite material part;
the manipulator is controlled by a computer and mainly has the functions of disassembling and installing a thermoplastic composite material structure on a part in equipment and moving the thermoplastic composite material structure in the operations of scanning, preprocessing, maintaining and post-maintaining a damaged area, wherein hilly array protrusions made of rubber materials are arranged on the inner sides of claws at the end parts 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 repaired thermoplastic composite structure is a thermoplastic composite structural member which is completed in maintenance and installation, the damaged area on the thermoplastic composite structural member is repaired, the service function of the repaired thermoplastic composite structural member is the same as that of an undamaged thermoplastic composite structural member, and the mechanical properties of the repaired thermoplastic composite structural member in terms of tension, compression, bending, shearing and fatigue are not lower than 85% of that of the undamaged thermoplastic composite structural member.
3. The invention relates to a damage monitoring and online maintenance system for a thermoplastic 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, transportation equipment, 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 service process of equipment, and provides data support for the optimal design of thermoplastic composite material parts.
In a word, the invention can realize the damage identification, evaluation, positioning and online maintenance of the thermoplastic composite material part in the operation equipment, has high automation degree, high efficiency and low cost, is particularly suitable for being used under the condition of unsuitable human operation such as toxic and harmful dangerous environment, can assist the development of intelligent manufacturing, 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 a subsystem of the present invention;
FIG. 2 is a schematic diagram of the composition of the present invention;
the symbols in fig. 1 and 2 are as follows: the device comprises a 1-thermoplastic composite structure damage identification and positioning and assessment subsystem, a 101-acoustic emission sensor, a 102-low noise signal line, a 103-preamplifier, 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 thermoplastic composite structure damaged area, 201-three-dimensional laser scanner, 202-computer, 203-model of area to be repaired; 3-a thermoplastic composite structure damaged area pretreatment subsystem, 301-a damaged area pretreatment control system, 302-a decontamination device and 303-a heating device; 4-thermoplastic composite structure damaged area maintenance subsystem, 401-fused deposition 3D printing control system, 402-feed box, 403-spray head control module, 404-rolling roller, 405-material wire, 406-spray head, 407-fused deposition material; a 5-thermoplastic composite structure damaged area maintenance post-treatment subsystem, a 501-residual stress relief system after maintenance and a 502-surface treatment system after maintenance; 6-a thermoplastic composite part containing damage, 7-a damage area, 8-a manipulator, 9-a thermoplastic composite structure to be repaired, 10-a thermoplastic composite structure in repair and 11-a thermoplastic 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 online maintenance system of the thermoplastic composite structure of the present invention comprises: the thermoplastic composite structure damage identification, positioning and assessment subsystem 1, an acoustic emission sensor 101, a low-noise signal line 102, a preamplifier 103, a signal acquisition and analysis device 104, a damage identification and assessment system 105 and a damage positioning system 106; the thermoplastic composite structure damage area scanning imaging subsystem 2, the three-dimensional laser scanner 201, the computer 202 and the model 203 of the area to be repaired; a thermoplastic composite structure damaged area pretreatment subsystem 3, a damaged area pretreatment control system 301, a decontamination device 302 and a heating device 303; a thermoplastic composite structure damaged area maintenance subsystem 4, a fused deposition 3D printing control system 401, a feed box 402, a spray head control module 403, a rolling roller 404, a material wire 405, a spray head 406 and a fused deposition material 407; a thermoplastic composite structure damaged area post-repair treatment subsystem 5, a post-repair residual stress relief system 501, and a post-repair surface treatment system 502; the device comprises a damaged thermoplastic composite part 6, a damaged area 7, a manipulator 8, a thermoplastic composite structure 9 to be repaired, a thermoplastic composite structure 10 in repair and a thermoplastic composite structure 11 after repair;
the thermoplastic composite structure damage identification, positioning and assessment subsystem 1 consists of an acoustic emission sensor 101, a low-noise signal line 102, a preamplifier 103, a signal acquisition and analysis device 104, a damage identification and assessment 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 thermoplastic composite material part 6 containing the damage, so that a cylindrical shape is formed, and compared with the current square and 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 the damage is realized; the acoustic emission sensor 101 is connected with the pre-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 thermoplastic composite structure damaged area scanning imaging subsystem 2 consists of a three-dimensional laser scanner 201, a computer 202 and a model 203 of an area to be repaired, and has the main functions of scanning imaging and modeling the damaged area; after obtaining the damage position information transmitted by the damage positioning system 106, the three-dimensional laser scanner 201 performs laser scanning on the damage region 7 on the thermoplastic composite material part 6 containing the damage, 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 thermoplastic composite material structural complete model 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 3D printing identifiable STL format file, and obtains a model 203 (STL format) of the region to be repaired;
the thermoplastic composite structure damage area pretreatment subsystem 3 consists of a damage area pretreatment control system 301, a decontamination device 302 and a heating device 303, and has the main functions of cleaning and preheating the damage area to be repaired; firstly, the damaged area pretreatment control system 301 controls the decontamination device 302 to brush the damaged area on the thermoplastic composite structure 9 to be repaired, which is grasped by the manipulator 8, by using a steel wire brush, so as to make the composite material of the damaged areaRoughening the material surface to enable the fused deposition material 407 to adhere to the surface of the damaged area during the 3D printing maintenance and tightly combine with the composite material structure; then, the damage area pretreatment control system 301 controls the decontamination device 302 to compress 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; finally, the damaged area pretreatment control system 301 controls the heating device 303 to preheat the composite material in the damaged area by adopting an infrared heating manner, so as to facilitate engineering application and improve the bonding strength between the 3D printed molten material and the composite material in the damaged area, and the preheating temperature (T p Units: the value at degrees celsius is the glass transition temperature (T) of the thermoplastic matrix polymer material in the composite material g Units: temperature of melting point (T) m Units: average value in degrees centigrade plus 10 degrees centigrade, i.e. T p ＝(T g +T m )/2+10；
The thermoplastic composite structure damaged area maintenance subsystem 4 consists of a fused deposition 3D printing control system 401, a feed box 402, a spray head control module 403, a rolling roller 404, a material wire 405, a spray head 406 and a fused deposition material 407; the fused deposition 3D printing control system 401 performs slicing processing on a model (STL format) 203 of an area to be repaired, and generates a numerical control motion instruction of a spray head control module 403 according to plane geometric information of each layer of slices; the feeding box 402 is internally provided with a short glass fiber reinforced nylon composite material, a continuous glass fiber reinforced nylon composite material, a short carbon fiber reinforced nylon composite material, a continuous carbon fiber reinforced nylon composite material, a short glass fiber reinforced polypropylene composite material, a continuous glass fiber reinforced polypropylene composite material, a short carbon fiber reinforced polypropylene composite material and a continuous carbon fiber reinforced polypropylene composite material which are fused deposition 3D consumable materials, the shape is a wire shape, the shape is a disc-shaped coiled material, the disc-shaped coiled materials are circumferentially arrayed, the material requirements of different types of structures are met, and the adaptability and the universality of a maintenance system are improved; when a certain thermoplastic composite material is needed, the feed box 402 rotates to transfer the material to a discharge hole, the driving roller in the rolling roller 404 rotates anticlockwise, and the driven roller rotates clockwise, so that the material wire 405 of the composite material is pulled out and conveyed into the spray head 406, and the electrically driven wire driving wheel arranged in the spray head 406 extrudes the material wire 405 to a heating channel with a heater, and is heated to a molten state to be extruded from a nozzle, so that a molten deposition material 407 is formed; along with the movement of the spray head 406, the fused deposition material 407 falls into the preheated composite material damaged area, scans and stacks the fused deposition thermoplastic composite material wire material layer by layer in the damaged area until the 3D printing of the model of the area to be repaired is completed in the damaged area, and then the fused deposition material is solidified and molded to complete the repair work of the damaged area;
the post-maintenance treatment subsystem 5 of the damaged area of the thermoplastic composite structure consists of a post-maintenance residual stress eliminating system 501 and a post-maintenance surface treatment system 502; the residual stress eliminating system 501 performs ultrasonic impact or hot air blowing operation on a maintenance area of the thermoplastic composite material structure which is completed with 3D printing maintenance to eliminate internal residual stress; then, polishing, cleaning and paint repairing operations are performed on the surface of the maintained area by the maintained surface treatment system 502;
the thermoplastic composite material part 6 with damage contains a damage area 7, and when the thermoplastic composite material part is large in size, the part with the damage area 7 is detached by using a manipulator 8 for maintenance; when the thermoplastic composite material part is smaller in size, the damaged thermoplastic composite material part 6 is directly maintained;
the manipulator 8 is controlled by the computer 202, and has the main functions of disassembling and installing the thermoplastic composite material structure on parts in equipment and moving the thermoplastic composite material structure in the operations of scanning, preprocessing, maintaining and post-maintaining damaged areas, wherein hilly array protrusions made of rubber materials are arranged on the inner sides of claws at the end parts 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 repaired thermoplastic composite structure 11 is a thermoplastic composite structural member which has been repaired and installed, the damaged area 7 on the thermoplastic composite structural member has been repaired, the service function of the repaired thermoplastic composite component is the same as that of the undamaged thermoplastic composite component, and the mechanical properties of the repaired thermoplastic composite component, such as tension, compression, bending, shearing and fatigue, are not lower than 85% of those of the undamaged thermoplastic composite component.
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 thermoplastic composite material structure is characterized by comprising a thermoplastic composite material structure damage identification and positioning and assessment subsystem, an acoustic emission sensor, a low-noise signal wire, a preamplifier, a signal acquisition and analysis device, a damage identification and assessment system and a damage positioning system; scanning imaging subsystem of damaged area of thermoplastic composite structure, three-dimensional laser scanner, computer, and model of area to be repaired; the device comprises a thermoplastic composite structure damaged area pretreatment subsystem, a damaged area pretreatment control system, a decontamination device and a heating device; the thermoplastic composite structure damage area maintenance subsystem, the fused deposition 3D printing control system, a feed box, a spray head control module, a rolling roller, a material wire, a spray head and fused deposition materials; a post-maintenance treatment subsystem for the damaged area of the thermoplastic composite structure, a post-maintenance residual stress eliminating system and a post-maintenance surface treatment system; the device comprises a damaged thermoplastic composite part, a damaged area, a manipulator, a thermoplastic composite structure to be repaired, a thermoplastic composite structure in repair and a thermoplastic composite structure after repair;
the damage identification, positioning and evaluation subsystem of the thermoplastic composite structure consists of an acoustic emission sensor, a low-noise signal wire, a preamplifier, a signal acquisition and analysis device, a damage identification and evaluation 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 thermoplastic composite material part containing the damage, so that a cylindrical shape is formed, and compared with the current square and diamond arrangement forms, the acoustic emission sensor 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 the damage is realized; the acoustic emission sensor is connected with the pre-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 thermoplastic composite structure damaged area scanning imaging subsystem consists of a three-dimensional laser scanner, a computer and a model of an area to be repaired, and has the main functions of scanning imaging and modeling the damaged area; after obtaining the damage position information transmitted by the damage positioning system, the three-dimensional laser scanner performs laser scanning on a damage region on the thermoplastic composite material component containing the damage, creates point clouds on the geometric surface of the damage region in a computer, interpolates the point clouds to build a three-dimensional model of the damage region, performs Boolean operation on the three-dimensional model and a thermoplastic composite material structural complete model 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 3D printing identifiable STL format file, and obtains the model of the region to be repaired;
the thermoplastic composite structure damage area pretreatment subsystem consists of a damage area pretreatment control system, a decontamination device and a heating device, and has the main functions of cleaning and preheating the damage area to be repaired; firstly, a damage area pretreatment control system controls a decontamination device to brush and wipe a damage area on a thermoplastic composite structure to be repaired, which is grasped by a manipulator, by using a steel wire brush, so that the surface of the composite material in the damage area is roughened, and a fused deposition material is attached to the surface of the damage area during 3D printing maintenance and is tightly combined with the composite structure; then, the damaged area pretreatment control systemControlling the pollutant removing device to compress air to the damaged area, wherein the air pressure of the compressed air is between 0.1 and 0.3MPa, and cleaning dust and impurities on the surface of the damaged area; finally, the damage area pretreatment control system controls the heating device to preheat the composite material of the damage area in an infrared heating mode, so as to facilitate engineering application and improve the bonding strength of the 3D printed molten material and the composite material of the damage area, and the preheating temperature (T p Units: the value at degrees celsius is the glass transition temperature (T) of the thermoplastic matrix polymer material in the composite material g Units: temperature of melting point (T) m Units: average value in degrees centigrade plus 10 degrees centigrade, i.e. T p ＝(T g +T m )/2+10；
The thermoplastic composite structure damaged area maintenance subsystem consists of a fused deposition 3D printing control system, a feed box, a spray head control module, a rolling roller, material wires, a spray head and fused deposition materials; slicing the model of the area to be repaired by the fused deposition 3D printing control system, and generating a numerical control movement instruction of the spray head control module according to the plane geometric information of each layer of slice; the short glass fiber reinforced nylon composite material, the continuous glass fiber reinforced nylon composite material, the short carbon fiber reinforced nylon composite material, the continuous carbon fiber reinforced nylon composite material, the short glass fiber reinforced polypropylene composite material, the continuous glass fiber reinforced polypropylene composite material, the short carbon fiber reinforced polypropylene composite material and the continuous carbon fiber reinforced polypropylene composite material are deposited in a melting mode to form 3D consumable materials, the shape is a wire shape, the shape is a disc-shaped coiled material, the disc-shaped coiled materials are circumferentially arrayed, the requirement of materials with different types of structures is met, and the adaptability and the universality of a maintenance system are improved; when a certain thermoplastic composite material is needed, the feeding box rotates to transfer the material to the discharging hole, the driving roller in the rolling roller rotates anticlockwise, the driven roller rotates clockwise, so that the material wire of the composite material is pulled out and conveyed into the spray head, the electrically driven wire driving wheel arranged in the spray head extrudes the material wire to a heating channel with a heater, and the material wire is extruded from the nozzle when heated to a molten state, so that a molten deposition material is formed; along with the movement of the spray head, the fused deposition material falls into the preheated damaged area of the composite material, scans and stacks the fused deposition thermoplastic composite material wires layer by layer in the damaged area until the 3D printing of the model of the area to be repaired is completed in the damaged area, and then the fused deposition material is solidified and molded to complete the repair work of the damaged area.
2. The damage monitoring and online maintenance system for a thermoplastic composite structure of claim 1, wherein: the post-maintenance treatment subsystem for the damaged area of the thermoplastic composite structure consists of a post-maintenance residual stress eliminating system and a post-maintenance surface treatment system; the residual stress eliminating system performs ultrasonic impact or hot air blowing operation on a maintenance area of the thermoplastic composite material structure which is subjected to 3D printing maintenance, so as to eliminate internal residual stress; and then polishing, cleaning and paint repairing the surface of the maintained area by a surface treatment system after maintenance.
3. The damage monitoring and online maintenance system for a thermoplastic composite structure of claim 1, wherein: the thermoplastic composite material part with the damage comprises a damage area, and when the thermoplastic composite material part is large in size, the part with the damage area is detached by using a manipulator for maintenance; when the thermoplastic composite part is smaller in size, the damaged thermoplastic composite part is directly repaired.
4. The damage monitoring and online maintenance system for a thermoplastic composite structure of claim 1, wherein: the manipulator is controlled by a computer, and has the main functions of disassembling and installing the thermoplastic composite material structure on a part in equipment and moving the thermoplastic composite material structure in the operations of scanning, preprocessing, maintaining and post-maintaining damaged areas, wherein the inner side of a claw at the end part of the manipulator is provided with a hilly array bulge made of rubber materials, 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.
5. The damage monitoring and online maintenance system for a thermoplastic composite structure of claim 1, wherein: the repaired thermoplastic composite structure is a thermoplastic composite structural member which is completed in maintenance and installation, the damaged area on the thermoplastic composite structural member is repaired, the service function of the repaired thermoplastic composite structural member is the same as that of an undamaged thermoplastic composite structural member, and the mechanical properties of the repaired thermoplastic composite structural member in terms of tension, compression, bending, shearing and fatigue are not lower than 85% of that of the undamaged thermoplastic composite structural member.
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| CN114372317A (en) * | 2021-12-30 | 2022-04-19 | 中国飞机强度研究所 | Damage positioning method in composite material detection and maintenance |
| CN115091794A (en) * | 2022-07-28 | 2022-09-23 | 大连理工大学 | Method for repairing damage of thermoplastic composite material |
| CN116176014A (en) * | 2022-12-27 | 2023-05-30 | 西北工业大学 | In-situ repair method for damaged component of composite material based on continuous fiber additive manufacturing |
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