JPH078498B2 - Roving prepreg laminating method and apparatus - Google Patents

Description

Detailed Description of the Invention

[0001]

The present invention relates to a roving prepreg,
In particular, the present invention relates to a roving prepreg laminating method and apparatus for making a composite material member such as a spar for a blade of a helicopter or a wind turbine that has different required strengths at various positions in the longitudinal direction.

[0002]

2. Description of the Related Art Blades for helicopters and wind turbines are cantilevered by being fixed to a rotating shaft at their base ends and rotate at a high speed. Therefore, the blade has a large weight of several hundred times its own weight. Centrifugal force acts, and further, a complicated twisting force always acts as the rotation speed increases. Therefore, the blade is lightweight and has high strength, especially in the longitudinal direction,
In addition, it is required to have a large resistance to twisting.

Therefore, a composite material is used as the blade material, and the basic structure thereof is, as shown schematically in FIGS. 1 and 2, extending over substantially the entire length of the blade 1 and serving as a spine. A rigid hollow spar 2, a material (honeycomb material or the like) 4 provided on the rear edge of the spar 2 to form an airfoil with the spar 2, a nose weight 5 provided in contact with the front edge of the spar 2, and these It consists of a skin 6 that wraps together. The spar 2 and the skin 6 are made of a composite material.

According to this manufacturing method, an uncured skin material is laminated by hand lay-up on the mold surface of a bisecting / curing die, and a prepreg roving is laminated inside the laminate in the longitudinal direction to form a belt shape. The prepreg is provided, for example, on the outer surface of an airbag to form a rectangular hollow cylindrical member having a cross-sectional shape as shown in FIG. 2 and a rounded front end, and a core material (honeycomb material) 4 and a nose weight. In many cases, the two molds are placed on a predetermined position in the mold together with 5, and then the two molds are superposed and cured by heating. Reference numeral 3 in FIG. 1 is a mounting hole for mounting the blade 1 on the rotary shaft.

Now, the belt-like roving prepreg used as the material for the above-mentioned spar 2 is conventionally as shown in FIG.
A polyethylene terephthalate (product name Mylar) sheet 14 is attached to the surface of a laminating jig formed by bridging plates 13 made of Teflon resin, nylon resin, etc., on cylindrical members 11 and 12 provided upright on both ends of the substrate 10. Then, a roving material impregnated with a resin is wound and laminated by an automatic laminating device so as to have a predetermined height and a predetermined thickness.

Roving prepreg 15 automatically laminated
After setting, remove one cylindrical member 12, cut at the rear end 16 as shown in FIG. 4, open on both sides after cutting, and remove the Teflon resin / nylon resin plate 13 and polyethylene terephthalate sheet 14 described above. Remove. The other cylindrical member 11 uses a bushing provided with a mounting hole 3 for mounting the blade 1 on a rotary shaft, and is screwed and mounted on a jig. The fitting 17 attached to the bushing 11 shown in FIG. 3 is also attached to the blade.

The thus obtained roving prepreg for a blade spar has the same amount of lamination in any cross section. However, since the blade of the helicopter is rotated at a high speed in a cantilevered state at the base end portion as described above, the external force applied to the blade is not uniform from the base end portion to the tip end, and the tip of the blade is not uniform. In the vicinity, the force acting on the blade gradually decreases toward the end. Therefore, it is desirable from the viewpoint of weight reduction that the thickness of the roving prepreg is tapered so that the cross section of the spar, which is mainly responsible for the strength of the blade, gradually decreases in the vicinity of the tip toward the tip.

As a prior art relating to a method of manufacturing a composite material blade such as the above-mentioned helicopter blade, there is Japanese Patent Laid-Open No. 53-2.
899 and JP-A-63-179707.

[0009]

DISCLOSURE OF THE INVENTION The present invention, like a roving prepreg used for a spar material for a blade of a helicopter, forms a taper corresponding to a required strength in the longitudinal direction of a member formed by the prepreg. It is an object of the present invention to provide a method for laminating roving prepreg and a device therefor.

[0010]

In order to solve the above-mentioned problems, the roving prepreg laminating method of the present invention is rounded in the plane of the loop of the roving material around which both ends are wound, and is perpendicular to the plane. Roving prepreg manufactured by laminating a plurality of roving layers formed by winding a roving material impregnated with a resin in a loop shape on an elongated jig having a predetermined thickness and winding the roving material in a predetermined width in the thickness direction of the jig. In the laminating method, after winding a certain number of layers on the roving layer, each time one layer is wound, a certain length is cut from one end of the jig, and the cutting length becomes the upper layer. By increasing the number, a taper is provided near one end of the laminated roving prepreg according to the required strength distribution in the longitudinal direction of the member obtained by curing the roving prepreg. The features.

In the laminating apparatus for carrying out this method, after the roving layer is wound around the jig by a certain number of layers, the inner surface of the tip is provided at the end on the side where the taper is formed, every time the roving layer is wound once. A roving layer wound around a jig can be brought into contact with the tip of the roving layer and extends to a position on both sides from the tip, and has a generally "U" -shaped cross section having a cutting guide groove on the outer surface near the rear end. A set of cutting caps, and the length from the apex of the "U" shape of the cutting caps to the cutting guide groove is the roving wound around the jig when the respective cutting caps are covered. Depending on the number of layers, the roving layer is lengthened by a constant length as the number of roving layers increases, and the roving layer formed by winding the roving on the cutting cap is covered with the roving layer. In the cutting guide groove And a means for cutting the cutting cap together with the cut roving layer from the jig, and then replacing the cutting cap of the next size on the roving layer on the jig and covering it. .

[0012]

As described above, after the roving layer has been wound around the jig for a certain number of layers, the roving layer is wound around the jig with the front end of the inner surface in contact with the front end of the roving layer. Have a cutting guide groove on the outer surface immediately adjacent to the rear end at positions where they differ by a certain length. A pair of cutting caps having a generally "U" -shaped cross section have a short length from the front end to the guide groove. Replace and install, and each time one is installed, one layer of roving layer is wound around the jig so as to cover the roving layer, and form the roving layer on the cutting cap along the cutting guide groove of the cutting cap. By cutting and removing the roving layer in front of the cut portion together with the cutting cap, the cutting cap is sequentially replaced and the cutting line of each roving layer is gradually changed from the lower layer to the upper layer. Retracted by an amount, roving layer number decreases as the front end, it is possible to form a taper corresponding to the longitudinal direction of the required intensity distribution of the resulting member by curing the roving prepreg roving prepreg. If you cut the loop-shaped roving prepreg at the end on the side where the taper is provided, band-shaped roving prepreg is formed at both ends, and a spar is formed so that the end with the taper comes to the tip of the blade. If a blade such as a helicopter is attached, a spar can be constructed according to the required strength distribution.

[0013]

Embodiments of the present invention will be described below in detail with reference to the drawings.

In FIG. 5, the stacking jig described in FIG. 3 and one of the cutting caps for cutting the roving layers wound around the stacking jig at different positions are associated with each other. FIG.

The cutting cap 20 is located on the side of the cylindrical member 12 of the jig, on the roving layer having a predetermined number of layers formed thereon, and behind the center of curvature of the portion of the roving layer wound around the cylindrical member 12. It has a U-shaped cross section and is extended by a length l ₁ on both sides. A cutting guide groove 21 is provided in the vertical direction on the outer surface of the cap 20 at a position slightly apart from the ends of the U-shaped legs by a slight distance l ₂ . The cutting cap 20 is made of a light metal such as aluminum, and it is convenient to handle that the inner surface is coated with Teflon.
The groove is preferably a groove, and the roving layer is accurately cut by running a cutter along the groove 21 on the roving layer laminated on the groove.

The cutting cap 20 is provided with a group of cutting caps each consisting of a set in which the length of l ₁ is gradually increased with a constant difference. The distance between the U-shaped legs increases by the thickness of one layer of the roving layer as the length l ₁ increases. The length l ₂ is the same for each cap.

Referring to FIG. 6, the set of cutting caps 20 described above is shown.
Is used to form a required taper at one end of the roving prepreg, and a laminating process is shown in the order of working steps.
In this figure, contrary to FIGS. 3 to 5, the left end portion is the taper forming portion.

The roving prepreg 25 is wound while the laminating head 24 revolves around the laminating jig 23,
The roving layer is formed one by one. FIG. 5A shows a state immediately after the start of stacking, and the end on the taper forming side is the stacking start position 26. FIG. 1B shows a laminated head 2 in which one roving layer is formed by a roving prepreg and one roving prepreg is located on the bushing side.
4 shows the state of being connected. In this state, the cutting surface cap 20a is attached to the end portion on the side where the taper is formed (FIG. (B)), and the roving layer 27 is formed on the jig 23 by winding the cap 20a so as to cover it. (Fig. (C)). Next, a cutter is run along the guide 21 from above the roving layer 27 at the position of the cutting guide 21 of the cutting cap 20a, so that the roving layer 27 is cut at that position. Then, as shown in FIG. 3D, if the front end of the roving layer 27 is pulled together with the cutting cap 20a in the direction indicated by the arrow, the front of the cut portion of the roving layer 27 can be removed separately from the rear thereof.

Next, as shown in FIG. 5 (e), the cutting cap 20 having a step length longer than that of the cutting cap 20a.
b is attached to the same end. In this case, the rear ends of the legs of the cutting cap 20b are covered on the uppermost roving layer 27 wound around the jig by a length longer than that of the cap 20a. Next, as shown in FIG. 6F, a roving layer 28 is formed thereon, a cutting cap 20b is formed, and a cutting guide groove 21 of the cap 20b is used for cutting with a cutter. Next, as shown in FIG. 6G, the cutting cap 20b is pulled together with the roving layer 28 thereon in the direction of the arrow, and the front portion of the cutting portion of the roving layer 28 is removed.

By repeating the same steps below,
The length of the roving layers that are sequentially laminated and removed increases by a certain length, and a taper shape that gradually reduces the amount of roving prepreg at the blade tip as required for a blade spar material or the like can be obtained.

FIG. 7 is a view showing an example of a roving prepreg automatic laminating apparatus for carrying out the roving prepreg laminating method of the present invention described above.

A guide rail 30 is provided surrounding the stacking jig 23 mounted on the jig substrate 10, and a stacking head 24 including a material supply reel 31 is provided around the jig 23 along the guide rail. It is designed to turn. In this example, the turning is performed by the stacking head turning chain 32. A cap mounting device 34 that moves forward and backward by a cylinder 33 is provided so as to face the end of the jig 23 on which the roving prepreg is to be tapered. Beside the retracted position of the cap mounting device 34,
A turret type cap holder 35 is provided so as to be proximate to and detachable from the cap mounting device 34, and the cap mounting device 34 is passed in order from the one having a shorter length of l ₁ of the cap group. Covers the roving layer wrapped around the jig in place at the required time according to the above process. A cutter 36 having a blade whose upper and lower edges can move in the longitudinal direction is provided across both sides of the end of the jig.

With this apparatus, one end of the roving layer laminated on the jig 23 up to a predetermined number of layers is sequentially covered with a cap having a short length of l ₁ , and one layer of the roving layer is wound on the cap and is guided along the cutting guide. The layer is cut to remove the cap, and at the same time, the action of removing the roving layer in front of the cut portion is automatically repeated.By repeating this operation a predetermined number of times, the roving layer having the required number of layers is formed. In addition, a roving prepreg having a required tapered portion at one end is automatically manufactured.

[0024]

As described above, according to the present invention, the number of layers and the taper corresponding to the required strength distribution in the longitudinal direction of the member formed by hardening the roving prepreg, such as the spar for blades of helicopters, wind turbines, etc. It is possible to easily obtain a roving prepreg having the above, and it is possible to reduce the weight.

Further, the method and apparatus of the present invention can be easily automated as described above, and as a result, the number of man-hours required for lamination can be greatly reduced and a certain quality can be secured.

[Brief description of drawings]

FIG. 1 is a perspective view showing the basic structure of a blade of a helicopter.

FIG. 2 is a sectional view thereof.

FIG. 3 is a perspective view showing a configuration of a roving prepreg laminating jig for a spar of a blade.

FIG. 4 is a perspective view showing a state in which one end of a loop-shaped roving prepreg laminated by the jig is cut and opened on both sides.

FIG. 5 is a perspective view showing one of the cutting caps according to the present invention in association with a roving prepreg laminating jig.

FIG. 6 is an explanatory diagram sequentially showing a step of laminating a roving prepreg according to the method of the present invention.

FIG. 7 is a perspective view showing the configuration of an example of the roving prepreg automatic laminating apparatus of the present invention for carrying out the method of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 blade 2 spar 11, 12 cylindrical member 15 roving prepreg 16 cutting line 20 cutting cap 21 cutting guide 23 laminating jig 24 laminating head 25 roving prepreg 27 roving layer 30 guide rail 34 cap mounting device 35 cap holder 36 cutter

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Akira Sugiyama 1 Kawasaki-cho, Kakamigahara-shi, Gifu Kawasaki Heavy Industries Ltd. Gifu factory

Claims (2)

[Claims] 1. A roving material which is rounded in a plane of a roving material whose both ends are wound and which is impregnated with resin in an elongated jig having a predetermined thickness in a direction perpendicular to the surface is wound in a loop shape. In the method for laminating a roving prepreg, which is manufactured by laminating a plurality of roving layers formed by winding a predetermined width in the thickness direction of the jig, after winding a certain number of layers of the roving layer, each time one layer is wound. Then, cut only a certain length of the layer from one end of the jig, increase the cutting length toward the upper layer, and cure the roving prepreg near one end of the laminated roving prepreg. A laminating method characterized in that a taper is provided in accordance with a required strength distribution in the longitudinal direction of the member thus obtained. 2. A roving material which is rounded in the plane of a loop of roving material whose both ends are wound and which is impregnated with resin in an elongated jig having a predetermined thickness in a direction perpendicular to the surface is wound in a loop shape. A laminating apparatus for a roving prepreg manufactured by laminating a plurality of layers of the jig, wherein a lamination thickness near one end of the jig of the roving prepreg is obtained by curing the roving prepreg. In a laminating apparatus that forms a taper such that the taper becomes thinner toward the end according to the required strength distribution in the longitudinal direction of the member, the laminating apparatus described above comprises winding a certain number of roving layers around the jig, and then winding one layer. Each time it is attached, the end on the side of forming the taper can be covered by contacting the inner surface of the tip with the tip of the roving layer wound on a jig, and extend to a position on both sides from the tip. There is a set of cutting caps having a substantially "U" -shaped cross section having a cutting guide groove on the outer surface immediately adjacent to the rear end thereof, and a length from the apex of the "U" -shape of the cutting cap group to the cutting guide groove. According to the number of roving layers wound around the jig when the respective cutting caps are covered, the length is increased by a fixed length as the number of roving layers increases, and the cutting caps are covered. Roving layer formed by winding roving on it, means for cutting along the cutting guide groove of the cutting cap, after removing the cutting cap together with the cut roving layer from the jig, the following A roving prepreg laminating apparatus having means for replacing a sized cutting cap on a roving layer on a jig and covering it.