CN109109350B - 用于过程内形成复杂形状刚性复合管的方法 - Google Patents

用于过程内形成复杂形状刚性复合管的方法 Download PDF

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CN109109350B
CN109109350B CN201810650137.XA CN201810650137A CN109109350B CN 109109350 B CN109109350 B CN 109109350B CN 201810650137 A CN201810650137 A CN 201810650137A CN 109109350 B CN109109350 B CN 109109350B
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tube
workpiece
workpiece tube
arm
bending
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CN109109350A (zh
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K.D.戈丁
林玟玲
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General Electric Co
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Abstract

本申请公开一种用于形成复合管件的方法，该方法包括以下步骤：编织多个条带以形成工件管件；使所述工件管件弯曲以形成弯曲部；以及通过继续所述编织步骤延长所述工件管件的长度。

Description

用于过程内形成复杂形状刚性复合管的方法
技术领域
本申请涉及一种用于形成复合管的方法，且更确切地说用于在单线操作中形成复杂形状刚性复合管的设备和方法。
背景技术
飞机发动机利用管道在发动机内输送流体。常规地，此管道为金属的。金属管道的一个问题是，其可能很重且难以根据需要成形。较轻的管道可由复合材料制成。复合管道的一个问题是，其较昂贵且难以成形。此外，用于使复合管道成形的常规方法常常需要针对每一形状和长度的复合管道进行单独加工。
发明内容
此问题通过用于使复合管道在柔性聚合物芯体周围在线形成和成形的设备和方法来解决。
根据本文中所描述的技术的一个方面，提供一种用于形成复合管件的方法。所述方法包括以下步骤：编织多个条带以形成工件管件；使工件管件弯曲以形成弯曲部；以及通过继续编织步骤延长工件管件的长度。
具体地，本申请技术方案1涉及一种用于形成复合管件的方法，所述方法包括以下步骤：
编织多个条带以形成工件管件；
使所述工件管件弯曲以形成弯曲部；以及
通过继续所述编织步骤延长所述工件管件的长度。
本申请技术方案2涉及根据技术方案1所述的方法，所述条带编织在聚合物管件周围以形成所述工件管件。
本申请技术方案3涉及根据技术方案2所述的方法，对所述聚合物管件进行充气。
本申请技术方案4涉及根据技术方案3所述的方法，将所述聚合物管件馈送到编织机中。
本申请技术方案5涉及根据技术方案2所述的方法，所述条带包括纤维。
本申请技术方案6涉及根据技术方案5所述的方法，所述纤维内嵌于聚合基质中以形成预浸体层。
本申请技术方案7涉及根据技术方案6所述的方法，所述条带包括邻近于所述预浸体层的热塑性层。
本申请技术方案8涉及根据技术方案1所述的方法，进一步包括旋转所述工件管件以形成另一弯曲部的步骤。
本申请技术方案9涉及根据技术方案8所述的方法，进一步包括额外延长所述工件管件的长度的步骤。
本申请技术方案10涉及根据技术方案9所述的方法，进一步包括使所述工件管件穿过尺寸环的步骤。
本申请技术方案11涉及一种用于形成复合管件的方法，所述方法包括以下步骤：
提供用于形成管件的设备，所述设备包括编织机和弯曲机，所述弯曲机包括尺寸环、加热器、第一臂、砧座和第二臂；
将多个条带编织在充气聚合物管件周围以形成工件管件；
使所述工件管件弯曲以形成弯曲部；以及
延长所述工件管件的长度。
本申请技术方案12涉及根据技术方案11所述的方法，将所述聚合物管件馈送到所述编织机中。
本申请技术方案13涉及根据技术方案12所述的方法，所述条带包括纤维。
本申请技术方案14涉及根据技术方案13所述的方法，所述纤维内嵌于聚合基质中以形成预浸体层。
本申请技术方案15涉及根据技术方案14所述的方法，所述条带包括邻近于所述预浸体层的热塑性层。
本申请技术方案16涉及根据技术方案11所述的方法，进一步包括旋转所述工件管件以形成另一弯曲部的步骤。
本申请技术方案17涉及根据技术方案16所述的方法，进一步包括额外延长所述工件管件的长度的步骤。
本申请技术方案18涉及根据技术方案17所述的方法，进一步包括使所述工件管件穿过尺寸环的步骤。
附图说明
可参考以下结合附图做出的描述最佳理解本发明，在附图中：
图1是包括定位在弯曲设备附近的编织机的管件形成设备的示意性侧视图；
图2是根据本文中所描述的方法制造的管件的透视图；
图3展示根据本文中所描述的方法使用以形成图2的管道的复合带的侧视图；
图4是在制造初始弯曲部之前第一级配置中弯曲设备的示意图；
图5是在制造初始弯曲部之后第二级配置中定位的弯曲设备的示意图；
图6是第二级和第三级配置之间的过渡中定位的弯曲设备的示意图；
图7是第二级和第三级配置之间进一步过渡中定位的弯曲设备的示意图；
图8是第三级配置中定位的弯曲设备的示意图；
图9是从第三级配置发生的再对准旋转步骤期间弯曲设备的示意图；
图10是弯曲之前工件管件的透视图；
图11是根据本文中所描述的方法已完成第一弯曲部之后图10中展示的工件管件的透视图；
图12是形成第二弯曲部之前工件管件已围绕轴线旋转之后图11中展示的工件管件的透视图；以及
图13是已形成第二弯曲部之后图12中展示的工件管件的透视图。
具体实施方式
参看图式，其中相同参考标号遍及各图表示相同元件，图1描绘管件形成设备10。管件形成设备10被配置成在单线操作中制造复合管道100，图2。如所展示，最终产品复合管道100包括弯曲部104和直线区段105，其定位于第一端102和第二端106之间。复合管件100包括编织外部区段107和内壁108。
如所说明，弯曲部104约为90°。应了解，弯曲部104可以是其它角度。还应了解，复合管道100被视为刚性的。如本文中所使用，术语“刚性”指代被配置成在如所属领域的技术人员将理解的预期操作条件下大体保持其形状的管道。
现参看图1，管件形成设备10包括编织机12和弯曲机40。编织机12被配置成接纳聚合物管道22的工作端。聚合物管道22可以是PTFE(例如，TEFLON)或其它热塑性聚合物，例如聚酯、耐纶、聚丙烯、聚醚酰亚胺、聚砜等。根据所说明的实施例，聚合物管道22被配置成在形成和弯曲过程期间以例如空气、氮气、氦气、氩气或其组合等气体充气。聚合物管道22还可以被配置成以例如水或油等液体充气。经充气聚合物管道22从大体连续源(未图示)引入到编织机12中。
编织机12还被配置成接纳多个碳纤维带条带30。如图3中所示，条带30各自包括热塑性膜层32和预浸体基质层34。如本文中所使用，术语“预浸体”指代以热塑性材料预浸的纤维材料。多个连续纤维36嵌入于预浸体基质层34的热塑性材料35内。如本文中所使用，术语“连续纤维”指代比切段纤维长的丝，如所属领域的技术人员将理解。根据所说明的实施例，连续纤维36是碳纤维。借助于实例而非限制，连续纤维36可以是以下中的一个：玻璃、KEVLAR、NEXTEL、碳化硅、金属或其组合。
编织机12被配置成将条带30编织在管道22周围。以此方式，形成工件管件50。工件管件50围绕到端部52的轴线51从编织机12延伸穿过尺寸环24且进入弯曲机40。参看图4，弯曲机40包括加热器42、第一臂44、第二臂46和砧座48。工件管件50包括编织外部区段57和内壁58，参看图12。编织外部区段57由多个条带30形成，且内壁58由管道22形成。编织机12、第二臂46和工件50被配置成围绕工件管件50的轴线51旋转。
弯曲机40的部件被配置成在五个不同配置之间移动。参看图1，弯曲机40被配置成使得工件管件50可在编织或形成步骤期间延伸穿过其中。存在弯曲机40在弯曲过程期间移动穿过的四个额外级。
弯曲机40被配置成在工件管件50上执行弯曲步骤之前移动到图4中展示的第一级中。在此方面，第一臂44被配置成在其中第一臂44与工件管件50隔离开的第一位置和其中第一臂44的夹持部分45与工件管件50接合的第二位置之间移动。第一臂44夹持部分45被配置成导引和保持工件管件50。当工件管件50保持在夹持部分中时，工件管件50可相对于夹持部分45移动。
将在下文描述图5中展示的第二级。工件50在第一级和第二级之间的过渡期间弯曲。关于此过渡，第一臂44被配置成在第一位置和第二位置之间围绕枢转点43枢转。弯曲机40的砧座48也可在第一位置和第二位置之间移动。砧座48被配置成与第一臂44随着它们在相应第一和第二位置之间移动而协作移动。在第一级中，当第一臂44和砧座48两者处于第一位置中时，砧座48定位到第一臂44的左侧，如图4所示。
工件管件50的端部52定位成在弯曲机40处于第二级时比弯曲机40处于第一级时更接近第一臂44。并且，当设备10处于第二级时，砧座48定位于第一臂44上方使得砧座48在第一臂44和工件50之间。砧座48定位成使得其限定工件管件50内的曲线56的至少一部分。
当弯曲机40处于第三级配置时，其被配置成旋转使得工件50连同编织机12一起围绕轴线51旋转。第二级和第三级之间的过渡在图6和图7中展示。第二臂46被配置成在图8中展示的第三级中从预备位置移动到第一夹持位置。第二臂46还被配置成在其第一夹持位置和第二夹持位置之间移动。此移动通常在工件围绕轴线51旋转的步骤期间发生。最后，第二臂46被配置成在第二位置和预备位置之间移动。
本文中所描述的技术可通过其操作的描述而更好地理解。在管件编织或形成步骤中，管道22经充气和定位使得其延伸穿过编织机12。复合纤维条带30编织在管道22周围。以此方式，工件管件50围绕轴线51而形成。工件管件50连续形成且前向推进穿过管件形成设备10的尺寸环24。在管件形成步骤期间，弯曲机40经定位使得第一臂44和第二臂46脱离工件管件50。
当工件管件50达到预定长度时，停止管件形成步骤。根据所说明的实施例，起始其中操作加热器42的加热步骤。加热器42操作直至工件管件50的区56定位在加热器42的范围内且已加热使得复合纤维条带30的热塑性膜层32已达到预定温度。应了解，所述预定温度低于熔融点且经挑选以促进弯曲。所述预定温度优选地高于玻璃转变温度。
在加热区56已达到预定温度之后，开始弯曲操作。弯曲机定位在如图4所示的第一级中，使得第一臂44的夹持部分45接合工件管件50且加热区56定位在砧座48附近。
工件管件50在弯曲步骤期间弯曲以形成弯曲部54。随着弯曲机40从上文描述的第一级配置过渡到图5中展示的第二级配置而发生弯曲步骤。区56在砧座48周围弯曲以形成弯曲部54，使得弯曲部54具有预定半径和预定角度。通过将展示工件管件50在第一弯曲部之前的图10与展示工件管件50在第一弯曲部之后的图11进行比较来说明此弯曲部，包括弯曲部54和直线区段55。在所说明的实施例中，预定角度近似为90°。允许工件管件50在冷却步骤期间冷却。
在冷却步骤之后，操作第二臂46使得接合部分47接合工件50。砧座48和第一臂44脱离工件50。换句话说，弯曲机40移动到如图8所示的第三级配置。
现参看图9，操作编织机12和第二臂46使得工件管件围绕轴线51旋转预定量使得其处于用于后续弯曲步骤的位置中。此旋转由图11和图12进一步说明。图11展示在旋转之前定位在第一弯曲部之后的工件管件50，且图12展示在旋转之后定位的工件管件50使得工件管件50的端部52处于不同平面。上文所描述的过程可重复以使得工件管件50具有如图13说明形成于其中的额外弯曲部52。在此方面，弯曲机40返回到适于管件形成的配置，且管件形成步骤开始。根据需要起始后续步骤。此可根据需要重复直至工件管件50可随后被切割以形成管件100。
根据替代实施例，可操作加热器42以加热工件管件50的所有部分，包括将不会弯曲的部分。根据另一替代实施例，直至形成所有弯曲部之后才加热工件管件50以形成管件100。此最终加热可远离设备10而离线完成。
本发明是一种用于在线形成复合管道的设备和方法。所公开技术的商业优点包括：与常规方法相比制造速度增加、与常规方法相比所需的加工减少，以及相对于以常规方法制造的管道所产生的成本降低。
上文已描述一种用于刚性复合管道，且更确切地说用于在单线操作中形成复杂形状的刚性复合管道的设备和方法。在本说明书中所公开的所有特征(包括任何所附权利要求书、摘要和图式)和/或如此公开的任何方法或过程的所有步骤可按任何组合形式组合，此些特征和/或步骤中的至少一些相互排斥的组合除外。
本说明书(包括任何所附权利要求书、摘要和图式)中所公开的每个特征可以替换为用于相同、等效或类似目的的替代特征，除非另有明确陈述。因此，除非另有明确陈述，否则所公开的每个特征仅为一系列通用的等效或类似特征的一个实例。
本发明并不限于前述实施例的细节。本发明扩展到本说明书(包括任何所附权利要求书、摘要和附图)中所公开的特征的任何新颖特征或新颖特征组合，或扩展到如此公开的任何方法或过程的步骤的任何新颖步骤或任何新颖步骤组合。

Claims (18)

1.一种用于形成复合管件的方法，所述方法包括以下步骤：
提供用于形成管件的设备，所述设备包括编织机和弯曲机，所述弯曲机包括尺寸环、加热器、第一臂、砧座和第二臂；
编织多个条带以形成工件管件；
使所述工件管件弯曲以形成弯曲部；以及
通过继续所述编织步骤延长所述工件管件的长度。
2.根据权利要求1所述的方法，其特征在于：所述条带编织在聚合物管件周围以形成所述工件管件。
3.根据权利要求2所述的方法，其特征在于：对所述聚合物管件进行充气。
4.根据权利要求3所述的方法，其特征在于：将所述聚合物管件馈送到所述编织机中。
5.根据权利要求2所述的方法，其特征在于：所述条带包括纤维。
6.根据权利要求5所述的方法，其特征在于：所述纤维内嵌于聚合基质中以形成预浸体层。
7.根据权利要求6所述的方法，其特征在于：所述条带包括邻近于所述预浸体层的热塑性层。
8.根据权利要求1所述的方法，其特征在于，进一步包括旋转所述工件管件以形成另一弯曲部的步骤。
9.根据权利要求8所述的方法，其特征在于，进一步包括额外延长所述工件管件的长度的步骤。
10.根据权利要求9所述的方法，其特征在于，进一步包括使所述工件管件穿过尺寸环的步骤。
11.一种用于形成复合管件的方法，所述方法包括以下步骤：
提供用于形成管件的设备，所述设备包括编织机和弯曲机，所述弯曲机包括尺寸环、加热器、第一臂、砧座和第二臂；
将多个条带编织在充气聚合物管件周围以形成工件管件；
使所述工件管件弯曲以形成弯曲部；以及
延长所述工件管件的长度。
12.根据权利要求11所述的方法，其特征在于：将所述聚合物管件馈送到所述编织机中。
13.根据权利要求12所述的方法，其特征在于：所述条带包括纤维。
14.根据权利要求13所述的方法，其特征在于：所述纤维内嵌于聚合基质中以形成预浸体层。
15.根据权利要求14所述的方法，其特征在于：所述条带包括邻近于所述预浸体层的热塑性层。
16.根据权利要求11所述的方法，其特征在于，进一步包括旋转所述工件管件以形成另一弯曲部的步骤。
17.根据权利要求16所述的方法，其特征在于，进一步包括额外延长所述工件管件的长度的步骤。
18.根据权利要求17所述的方法，其特征在于，进一步包括使所述工件管件穿过尺寸环的步骤。
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