WO2024055392A1 - 一种编织针刺一体化预制体成形方法及预制体成型装置 - Google Patents

一种编织针刺一体化预制体成形方法及预制体成型装置 Download PDF

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Publication number
WO2024055392A1
WO2024055392A1 PCT/CN2022/128612 CN2022128612W WO2024055392A1 WO 2024055392 A1 WO2024055392 A1 WO 2024055392A1 CN 2022128612 W CN2022128612 W CN 2022128612W WO 2024055392 A1 WO2024055392 A1 WO 2024055392A1
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WIPO (PCT)
Prior art keywords
mesh
arc
fabric
ring
mandrel
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PCT/CN2022/128612
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English (en)
French (fr)
Inventor
单忠德
孙正
周征西
王尧尧
汪炜昊
刘家乐
Original Assignee
南京航空航天大学
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Application filed by 南京航空航天大学 filed Critical 南京航空航天大学
Priority to EP22953358.3A priority Critical patent/EP4368758A1/en
Priority to KR1020247006345A priority patent/KR20240038775A/ko
Priority to US18/587,731 priority patent/US20240191406A1/en
Publication of WO2024055392A1 publication Critical patent/WO2024055392A1/zh

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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04C—BRAIDING OR MANUFACTURE OF LACE, INCLUDING BOBBIN-NET OR CARBONISED LACE; BRAIDING MACHINES; BRAID; LACE
    • D04C1/00—Braid or lace, e.g. pillow-lace; Processes for the manufacture thereof
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04C—BRAIDING OR MANUFACTURE OF LACE, INCLUDING BOBBIN-NET OR CARBONISED LACE; BRAIDING MACHINES; BRAID; LACE
    • D04C3/00—Braiding or lacing machines
    • D04C3/48—Auxiliary devices
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04C—BRAIDING OR MANUFACTURE OF LACE, INCLUDING BOBBIN-NET OR CARBONISED LACE; BRAIDING MACHINES; BRAID; LACE
    • D04C3/00—Braiding or lacing machines
    • D04C3/02—Braiding or lacing machines with spool carriers guided by track plates or by bobbin heads exclusively
    • D04C3/08—Braiding or lacing machines with spool carriers guided by track plates or by bobbin heads exclusively with means for superimposing threads or braids
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04C—BRAIDING OR MANUFACTURE OF LACE, INCLUDING BOBBIN-NET OR CARBONISED LACE; BRAIDING MACHINES; BRAID; LACE
    • D04C1/00—Braid or lace, e.g. pillow-lace; Processes for the manufacture thereof
    • D04C1/02—Braid or lace, e.g. pillow-lace; Processes for the manufacture thereof made from particular materials
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04C—BRAIDING OR MANUFACTURE OF LACE, INCLUDING BOBBIN-NET OR CARBONISED LACE; BRAIDING MACHINES; BRAID; LACE
    • D04C1/00—Braid or lace, e.g. pillow-lace; Processes for the manufacture thereof
    • D04C1/06—Braid or lace serving particular purposes
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04C—BRAIDING OR MANUFACTURE OF LACE, INCLUDING BOBBIN-NET OR CARBONISED LACE; BRAIDING MACHINES; BRAID; LACE
    • D04C3/00—Braiding or lacing machines
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04C—BRAIDING OR MANUFACTURE OF LACE, INCLUDING BOBBIN-NET OR CARBONISED LACE; BRAIDING MACHINES; BRAID; LACE
    • D04C3/00—Braiding or lacing machines
    • D04C3/02—Braiding or lacing machines with spool carriers guided by track plates or by bobbin heads exclusively
    • D04C3/24—Devices for controlling spool carriers to obtain patterns, e.g. devices on guides or track plates
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04C—BRAIDING OR MANUFACTURE OF LACE, INCLUDING BOBBIN-NET OR CARBONISED LACE; BRAIDING MACHINES; BRAID; LACE
    • D04C3/00—Braiding or lacing machines
    • D04C3/40—Braiding or lacing machines for making tubular braids by circulating strand supplies around braiding centre at equal distances
    • D04C3/46—Braiding or lacing machines for making tubular braids by circulating strand supplies around braiding centre at equal distances with thread carriers supported on rolls
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H18/00—Needling machines
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H18/00—Needling machines
    • D04H18/02—Needling machines with needles

Definitions

  • the invention relates to the technical field of composite material three-dimensional structure prefabricated body forming, and specifically relates to a knitting and needling integrated prefabricated body forming method and equipment.
  • Composite materials refer to new materials that are composed of various materials through composite technology.
  • the materials can not only retain the characteristics of the original components, but also achieve better performance than the original components through the composite effect of the material combination. characteristic.
  • Advanced composite materials based on fiber reinforcements are widely used in aerospace, automobiles, ships, rail transit and other fields because of their advantages such as high specific strength, high specific modulus, fatigue resistance, erosion resistance, impact resistance, and good designability.
  • Three-dimensional structural prefabricated bodies are usually obtained by textile means.
  • the corresponding woven and non-woven forming technologies mainly include three-dimensional weaving, three-dimensional braiding, three-dimensional suture, flexible guided three-dimensional weaving, three-dimensional acupuncture, etc.
  • Three-dimensional needle punching technology is a method that alternately superimposes two-dimensional fabrics and mesh layers, and then inserts needles to form reinforcements between fabric layers.
  • its process is simple and low-cost. It was cheap and got a lot of attention.
  • the currently used needle punching/two-dimensional fabric composite forming technology is concerned, the two-dimensional fabric forming, laying and needling processes are independent. Each process in the middle requires manual participation.
  • the purpose of the present invention is to address the deficiencies in the prior art and propose a knitting and needle punching integrated preform forming method to realize the integrated automatic forming of continuous knitting and needle punching of multi-layer knitted fabrics.
  • the invention also provides a preform forming device that implements the above knitting and needle punching integrated preform forming method.
  • the present invention adopts the following technical solution: a knitting and needle punching integrated prefabricated body forming method and equipment, the specific contents of which are as follows:
  • a knitting and needling integrated preform forming method which is characterized by including the following steps:
  • the grabbing device at one end of the knitting machine grabs one end of the mandrel, and the mandrel moves along the axis of the mandrel to cover the surface of the mandrel with the yarn.
  • the preform is mainly acupunctured by an automatic acupuncture device.
  • the preform forming device provided by the present invention to realize the above knitting and needle punching integrated preform forming method adopts the following technical solution.
  • the prefabricated body forming device includes: a knitting machine, a special-shaped structure mold, a core mold grabbing device located at both ends of the knitting machine, an automatic mesh tire laying device and an automatic acupuncture device;
  • the core mold grabbing device includes a clamping claw, The clamping jaw is installed on the clamping jaw mounting platform, and the clamping jaw mounting platform is equipped with a motion device that moves the grabbing device horizontally;
  • the automatic mesh tire laying device includes a first mechanical arm, a first arc Shaped support ring, limiting roller, driving gear, mesh tire winding wheel, mesh tire cutting knife, vacuum adsorption device, adhesive release device, first arc tooth ring and mesh tire laying platform, first arc support
  • the ring is installed on the first mechanical arm, the first limiting roller, the first driving gear and the first arc-shaped ring are installed on the first arc-shaped support ring, and the mesh tire winding wheel and mesh tire laying platform are installed on the first arc-shaped support ring.
  • the mesh tire cutting knife, vacuum adsorption device and adhesive release device are installed on the mesh tire laying table, and the first mechanical arm is connected to the device capable of horizontal movement; at least one device is installed on the inside of the first curved toothed ring.
  • the automatic acupuncture device for mesh tires includes a second mechanical arm, a second The arc-shaped support ring, the second arc-toothed ring, the second limiting roller, the second driving gear and the acupuncture head, the second arc-shaped support ring is installed on the second mechanical arm, the second arc-toothed ring, the second limiting roller
  • the bit roller and the second drive gear are both installed on the second arc-shaped support ring
  • the acupuncture head is installed on the second arc-shaped tooth ring
  • the second mechanical arm is equipped with a device that enables it to move horizontally
  • the second arc-shaped tooth At least two second driving gears are installed inside the ring.
  • the rotation of the two second driving gears drives the second arc toothed ring and the second arc-shaped support ring to rotate forward or reversely.
  • the clamping jaws of the two grabbing devices pull the mandrel and the fabric to move horizontally independently or cooperatively on the left and right sides of the knitting plane along the axis of the knitting ring without interfering with the yarn.
  • the grabbing device The clamping claws exert a certain pre-tightening force on the mandrel and the fabric so that the fabric can adhere closely to and completely cover the surface of the mandrel, forming the same fabric profile as the surface of the mandrel.
  • clamping jaws can automatically release or clamp the mandrel and the end of the fabric through control, including using one of pneumatic, electromagnetic or mechanical means.
  • the mesh placement and pre-needle punching are realized through the collaborative cooperation of the automatic laying device and the automatic acupuncture device, so that the mesh tires completely fit the surface of the woven fabric.
  • the mesh tire winding wheel in the automatic mesh tire laying device is wrapped with mesh tires, and is used to provide mesh tires to the mesh tire laying platform (14).
  • the first arc-shaped support ring, the first limiter The position roller and the first driving gear are used to realize the rotation of the first arc tooth around the center and limit its movement trajectory within the annular range.
  • the acupuncture head in the automatic acupuncture device releases the lancet and pulls the lancet out of the fabric; a sensor is installed above the acupuncture head to sense the relative position of the lancet and the fabric surface, and regulates the needle according to the collected position information.
  • the motion posture of the second robotic arm; in addition, the needles of the needle-punching head are parallel to the normal direction of the fabric plane.
  • first arc-shaped support ring is provided with connection holes for installing the mesh tire laying platform
  • second arc-shaped support ring is provided with connection holes for installing the acupuncture head.
  • first arc-shaped support ring and the first arc-shaped support ring are both equipped with position sensors for determining the positions of the first arc-toothed ring and the second arc-toothed ring, and preventing the first arc-shaped toothed ring and the second arc-shaped toothed ring from being moved.
  • the ring gear is separated from the constraints of the first driving gear, the second driving gear and the first limiting roller and the second limiting roller. .
  • the beneficial effects of the present invention are: on the basis of the traditional 2.5D knitting machine, the present invention innovatively proposes reciprocating weaving on the surface of the mandrel and laying out mesh tires for pre-needle punching, and finally full needle punching.
  • the method of needle punching a device that can integrate automatic continuous weaving and automatic continuous needle punching of two-dimensional fabrics has been built.
  • the method and equipment proposed by this invention can realize the integrated automatic forming of continuous weaving and needle punching of multi-layer woven fabrics, which can greatly improve the weaving efficiency.
  • Needle punched three-dimensional structure prefabricated body forming efficiency and product reliability.
  • Figure 1 is a flow chart of a knitting and needle punching integrated forming method of the present invention
  • Figure 2 is a schematic structural diagram of the knitting and needle punching integrated forming equipment according to the present invention (direction 1);
  • Figure 3 is a schematic structural diagram of the knitting and needle punching integrated forming equipment according to the present invention (direction 2);
  • Figure 4 is a schematic diagram of the gripper (12) of the gripping device of the present invention grabbing the mandrel and weaving in its direction;
  • Figure 5 is a schematic diagram of the gripper (22) of the gripping device of the present invention gripping the core mold that has been braided and covered;
  • Figure 6 is a schematic diagram of the device equipped with the acupuncture head and mesh tire laying platform according to the present invention.
  • Figure 7 is a schematic diagram of the mesh tire laying and pre-acupuncture process according to the present invention.
  • Figure 8 is a schematic diagram of completing one week of mesh tire laying and mesh tire cutting according to the present invention.
  • Figure 9 is a schematic diagram of the weaving process on the surface of the mesh according to the present invention.
  • Figure 10 is a schematic diagram of the braided layer-mesh layer-braided layer sector section of the present invention.
  • Figure 11 is a schematic diagram comparing the results of pre-acupuncture and main acupuncture according to the present invention.
  • Figure 12 is a schematic fan-shaped cross-section of the final product according to the present invention.
  • the present invention provides an integrated knitting and needle punching method.
  • a forming method is provided and a corresponding preform forming device is provided according to the method.
  • the embodiment of the preform forming device is that the preform forming device includes: a knitting machine, a special-shaped structure mold, a core mold grabbing device located at both ends of the knitting machine, and an automatic mesh tire laying device. and automatic acupuncture devices.
  • the core mold grabbing device includes two identical structures and are respectively installed at both axial ends of the knitting machine.
  • the core mold grabbing device located at one end includes a clamping claw 12 and a clamping claw mounting platform 13.
  • the clamping claw 12 is installed on On the clamping jaw mounting platform 13, a moving device is installed on the clamping jaw mounting platform 13 to move the grabbing device horizontally in the axial direction.
  • the core mold grabbing device located at the other end includes a clamping jaw 22 and a clamping jaw mounting platform 23.
  • the clamping jaw 22 is installed on the clamping jaw mounting platform 23.
  • the clamping jaw mounting platform 23 is equipped with a device that enables the grabbing device to move horizontally in the axial direction. Sports equipment.
  • the clamping claws of the two grabbing devices pull the mandrel and the fabric to move horizontally independently or cooperatively on the left and right sides of the knitting plane along the axis of the knitting ring without interfering with the yarn.
  • the clamping claws on the grabbing device Apply a certain pre-tightening force to the mandrel and the fabric so that the fabric can adhere closely to and completely cover the surface of the mandrel, forming the same fabric profile as the surface of the mandrel.
  • the clamping jaws automatically release or clamp the mandrel and the end of the fabric through control, including using one of pneumatic, electromagnetic or mechanical methods.
  • the automatic laying device of mesh tires includes a first mechanical arm 2, a first arc-shaped support ring 3, a limiting roller 4, a driving gear 8, a mesh tire winding wheel 5, a mesh tire cutting knife 6, and a vacuum adsorption device. 7.
  • the adhesive release device 11, the first arc tooth ring 19 and the tire laying platform 14, the first arc support ring 3 is installed on the first mechanical arm 2, the first limiting roller 4, the first drive
  • the gear 8 and the first arc-toothed ring 19 are installed on the first arc-shaped support ring 3.
  • the mesh tire winding wheel 5 and the mesh tire laying platform 14 are installed on the first arc-toothed ring 19.
  • the adsorption device 7 and the adhesive release device 11 are installed on the tire laying platform, and the first mechanical arm 2 is connected to a device capable of horizontal movement; at least two first drive gears 8 are installed inside the first arc tooth ring 19, The rotation of the two first driving gears 8 drives the first arc toothed ring 19 and the first arc-shaped support ring 3 to rotate forward or reversely.
  • the automatic acupuncture device for mesh tires includes a second mechanical arm 15, a second arc-shaped support ring 16, a second arc tooth ring 18, a second limiting roller 29, a second driving gear 20 and a needling head 9, The second arc-shaped support ring 18 is installed on the second mechanical arm 15.
  • the second arc-shaped tooth ring 18, the second limiting roller 19, and the second driving gear 20 are all installed on the second arc-shaped support ring 16.
  • the head 9 is installed on the second arc-toothed ring 18, and the second mechanical arm 15 is equipped with a device that enables it to move horizontally; at least two second drive gears 20 are installed inside the second arc-toothed ring 18, and two second drive gears 20 are installed on the inside of the second arc-toothed ring 18.
  • the rotation of the driving gear 20 drives the second arc toothed ring 18 and the second arc-shaped support ring 16 to rotate forward or reversely.
  • the first arc-shaped support ring 3 is provided with connection holes for installing the mesh tire laying platform 14, and the second arc-shaped support ring 16 is provided with connection holes for installing the acupuncture head 9.
  • the first arc-shaped support ring 3 and the first arc-shaped support ring 16 are both equipped with position sensors 27 for determining the positions of the first arc-toothed ring 18 and the second arc-toothed ring 19 and preventing the first arc-toothed ring 18 and
  • the second spiral ring 19 is separated from the constraints of the first driving gear 8 and the second driving gear 20 and the first limiting roller 4 and the second limiting roller 29 .
  • the mesh tire winding wheel 5 in the automatic mesh tire laying device is wrapped with mesh tires and is used to provide mesh tires to the mesh tire laying platform 14.
  • the first driving gear 8 is used to realize the rotation of the first arc-toothed ring 19 around the center and limit its movement trajectory within the annular range.
  • the acupuncture head 9 in the automatic acupuncture device releases the lancet and pulls the lancet out of the fabric; a sensor is installed above the acupuncture head 9 to sense the relative position of the lancet and the fabric surface, and regulates the first step according to the collected position information.
  • the motion posture of the second robot arm 15; in addition, the needles of the needle-punching head 9 are parallel to the normal direction of the fabric plane.
  • the mesh placement and pre-needle punching are realized through the cooperation of the automatic laying device and the automatic acupuncture device, so that the mesh tires completely fit the surface of the woven fabric.
  • the embodiment of the knitting and needle punching integrated forming method provided by the present invention is: (1) By arranging grabbing devices at both ends of the 2.5D knitting machine 1, see Figure 4, so that the clamping claws 12 on one of the grabbing devices can grab Take one end of the core mold 21 so that the braiding core mold 21 can move along the axis of the knitting machine in the direction shown by an arrow, so that the yarn 24 forms the first layer of fabric 25 on the surface of the core mold;
  • the automatic mesh tire laying device and the automatic acupuncture device move to the side of the fabric and mold through the horizontal motion device and start working.
  • the mesh tire winding wheel 5 begins to gradually release the mesh tires 26 through rotation, and the vacuum adsorption device 7 Start to tightly adsorb the mesh tire 26 to the end of the mesh tire laying platform 14, the first mechanical arm 2, the first arc support ring 3 and the first arc tooth ring 19 (driven by the first drive gear 8, the first limit
  • the roller 4 (limited position) is linked to make the end of the mesh tire laying platform 14 press the mesh tire 26 on the surface of the first layer of fabric 25 with appropriate pre-pressure.
  • the adhesive release device 11 releases the adhesive to press the mesh tire 26 Stick to the surface of the first layer of fabric 25, and then the vacuum adsorption device 7 stops operating.
  • the acupuncture device senses its distance from the mesh tire 26 through the distance sensor, and processes the distance information to adjust the second The positions of the robotic arm 15, the second arc-shaped support ring 16, and the second arc-toothed ring 19 send the acupuncture head 9 to the designated position, and the acupuncture head 9 rotates to the normal direction of the plane of the first layer of fabric 25 to perform pre-needling. prick.
  • the mesh tire 26 is cut by the mesh tire cutting knife 6, and the empty adsorption device 7 is started again to tightly adsorb the mesh tire 26 to the mesh tire laying table 14. department.
  • Figure 11 shows a comparison of the effects of pre-acupuncture (a) and main acupuncture (b).

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Nonwoven Fabrics (AREA)
  • Tires In General (AREA)
  • Moulding By Coating Moulds (AREA)

Abstract

一种编织针刺一体化预制体成形方法，包括以下步骤：通过在编织机（1）两端布置抓取装置，让芯模（21）能沿着编织机（1）轴线朝某一个方向运动同时编织形成芯模（21）表面的第一层织物（25）；随后通过网胎自动铺放装置在第一层织物（25）上方铺放网胎（26）且使针刺装置对网胎（26）层进行预针刺使网胎（26）能贴合编织织物表面；编织机（1）再次启动，芯模（21）朝着反方向运动同时编织形成网胎（26）表面的第二层织物（28）；重复上述步骤，实现多层编织织物和网胎（26）交替贴合；最后，通过自动针刺装置对预制体进行主针刺进一步实现其Z向增强。其同时提供了实现该编织针刺一体化预制体成形方法使用的预制体成形装置。

Description

一种编织针刺一体化预制体成形方法及预制体成型装置 技术领域
本发明涉及复合材料三维结构预制体成形技术领域，具体涉及一种编织针刺一体化预制体成形方法及设备。
背景技术
复合材料指由各种材料通过复合技术组合而成的新型材料，该材料既能保留原有各组分的特点，又能通过材料组合的复合效应使得材料整体获得相对原有组分更加优异的特性。基于纤维增强体的先进复合材料因具有比强度高、比模量高、耐疲劳、抗侵蚀、抗冲击、可设计性好等优点，在航空航天、汽车船舶、轨道交通等领域应用广泛。
预制体作为先进复合材料的增强体，是影响其力学性能的决定性因素。二维层合预制体复合材料发展较早，技术较为成熟，是目前应用最为广泛的复合材料，不过其层间强度低，抗剪切和抗冲击性弱等缺点阻碍了其在高层间剪切应力和高冲击等复杂极端环境下的推广应用。具备层间增强纤维的三维结构预制体复合材料与传统的二维结构复合材料相比，三维层间增强预制体复合材料克服了二维结构预制体复合材料抗冲击性能差、易分层等缺点，具有优异的力学性能，越来越受到重视。
三维结构预制体通常利用纺织手段获得，与之相应的织造和非织造成形技术主要有三维机织、三维编织、三维缝合、柔性导向三维织造、三维针刺等。三维针刺技术是将二维织物与网胎层层交互叠合后，将刺针刺入以形成织物层间增强相的方法，与其它三维结构预制体成形技术相比，其工艺简单，成本低廉，受到了极大关注。就目前采用的针刺/二维织物复合成形技术而言，二维织物成形、铺放和针刺过程是独立开来的，中间每个流程都需要人工参与，生产效率底，产品质量难以保证，然而随着复合材料行业越来越追求预制体成形技术的高效、低成本化，目前亟需自动化针刺/二维织物一体化成形方法与设备来实现这一追求。
发明内容
本发明的目的针对现有技术中的不足，提出了一种编织针刺一体化预制体成形方法，以实现多层编织织物的连续编织与针刺的一体化自动成形。
本发明还提供了一种实现上述编织针刺一体化预制体成形方法的预制体成型装置
为实现上述技术目的，本发明采用如下技术方案：一种编织针刺一体化预制 体成形方法及设备，其具体内容如下：
一种编织针刺一体化预制体成形方法，其特征在于，包括以下步骤：
(1)通过在编织机两端分别布置一个抓取装置，使位于编织机一端抓取装置抓取芯模一个端部，芯模沿着芯模轴线运动，使纱线在芯模表面形成覆盖芯模表面第一层织物；
(2)在完成步骤(1)中第一次织物的覆盖之后停止编织；
(3)通过网胎自动铺放装置在覆盖在芯模表面的第一层织物上铺放网胎，针刺装置进行预针刺使网胎贴合第一层织物表面；
(4)原来抓取芯模的抓取装置释放芯模的端部；
(5)编织机再次启动，同时使另一端的抓取装置抓取芯模另一端部朝着步骤(1)中沿着芯模轴线运动方向的反方向运动，继续第二层织物编织，并使第二层织物紧贴并且完全覆盖网胎表面；
(6)重复上述步骤，实现多层编织织物和网胎交替紧密贴合形成预制体；
(7)最后，通过自动针刺装置对预制体进行主针刺。
而本发明提供的实现上述编织针刺一体化预制体成形方法使用的预制体成形装置，采用以下技术方案。
该预制体成形装置包括：编织机、异形结构模具、分别位于编织机两端的芯模抓取装置、网胎自动铺放装置以及自动针刺装置；所述的芯模抓取装置包括夹爪、夹爪安装台，夹爪安装在夹爪安装台上，夹爪安装台上安装有使抓取装置水平移动的运动装置；所述的网胎自动铺放装置包括第一机械臂、第一弧形支持环、限位辊轮、驱动齿轮、网胎绕卷轮、网胎裁剪刀、真空吸附装置、粘结剂释放装置、第一弧齿环以及网胎铺放台，第一弧形支持环安装在第一机械臂上，第一限位辊轮、第一驱动齿轮以及第一弧齿环安装在第一弧形支持环上，网胎绕卷轮以及网胎铺放台安装在第一弧齿环上，网胎裁剪刀、真空吸附装置和粘结剂释放装置安装在网胎铺放台上，第一机械臂与能水平运动的装置相连；第一弧齿环内侧至少安装有两个第一驱动齿轮，两个第一驱动齿轮转动带动第一弧齿环及第一弧形支持环正转或反转；所述的网胎自动针刺装置包括第二机械臂、第二弧形支持环、第二弧齿环、第二限位辊轮、第二驱动齿轮以及针刺头，第二弧形支持环安装在第二机械臂上，第二弧齿环、第二限位辊轮、第二驱动齿轮均安装在第二弧 形支持环上，针刺头安装在第二弧齿环上，第二机械臂上安装有能使其水平运动的装置；第二弧齿环内侧至少安装有两个第二驱动齿轮，两个第二驱动齿轮转动带动第二弧齿环及第二弧形支持环正转或反转。
进一步的，两台抓取装置的夹爪均牵引芯模和织物沿编织环轴线在编织平面左右两侧水平独立或者协同运动，并不与纱线干涉，同时在编织过程中，抓取装置上的夹爪给芯模与织物施加一定的预紧力使织物能紧贴并且完全覆盖芯模表面，形成与芯模表面相同的织物轮廓。
进一步的，所述的夹爪通过控制自动释放或夹紧芯模与织物端部，包括采用气动、电磁或机械中的一种方式。
进一步的，网胎铺放和预针刺是通过自动铺放装置以及自动针刺装置协同配合实现的，使网胎完全贴合编织织物表面。
进一步的，所述的网胎自动铺放装置中的网胎绕卷轮上缠绕着网胎，用于向网胎铺放平台(14)提供网胎，第一弧形支持环、第一限位辊轮、第一驱动齿轮用于实现第一弧齿环绕中心旋转并将其运动轨迹限制在环形范围内，真空吸附装置启动时在真空吸附装置表面形成负压紧紧吸附网胎，粘结剂释放装置释放粘结剂使网胎黏附在织物表面，并通过网胎铺放平台端部的挤压将网胎粘到织物表面。
进一步的，所述的自动针刺装置中的针刺头释放刺针并将刺针从织物中拔出；针刺头上方安装有传感器用于感知刺针与织物表面的相对位置，根据采集所得位置信息调控第二机械臂的运动姿态；此外，针刺头的刺针与织物平面的法向平行。
进一步的，第一弧形支持环上设有连接孔位用于安装网胎铺放平台，第二弧形支持环上设有连接孔位用于安装针刺头。
进一步的，第一弧形支持环、第一弧形支持环均安装有位置传感器，用于确定第一弧齿环、第二弧齿环的位置，并防止第一弧齿环、第二弧齿环脱离第一驱动齿轮、第二驱动齿轮和第一限位辊轮、第二限位辊轮的束缚。。
与现有技术相比，本发明的有益效果是：本发明在传统2.5D编织机的基础上创新性地提出往复贴合芯模表面编织并铺放网胎进行预针刺，最后进行全针刺的方法；搭建了一种能集成二维织物自动连续编织、自动连续针刺的设备。相较于现有的全手工或半自动织物铺放与纤维Z向增强复合技术，该发明提出的方法和设备可以实现多层编织织物的连续编织与针刺的一体化自动成形，能大大提 高编织/针刺三维结构预制体成形效率及产品的可靠性。
附图说明
图1为本发明一种编织针刺一体化成形方法流程图；
图2为本发明所述编织针刺一体化成形设备结构示意图(方向1)；
图3为本发明所述编织针刺一体化成形设备结构示意图(方向2)；
图4为本发明所述抓取装置夹爪(12)抓取芯模朝其所在方向编织示意图；
图5为本发明所述抓取装置夹爪(22)抓取已完成编织覆盖的芯模示意图；
图6为本发明所述搭载针刺头和网胎铺放平台的装置示意图；
图7为本发明所述网胎铺放和预针刺过程示意图；
图8为本发明所述完成网胎铺放一周以及网胎剪裁示意图；
图9为本发明所述在网胎表面编织过程示意图；
图10为本发明所述编织层—网胎层—编织层扇形截面示意图；
图11为本发明所述预针刺与主针刺结果对比示意图；
图12为本发明所述最终产品扇形截面示意图。
具体实施方式
下面结合附图对本发明的技术方案作进一步地说明。
针对传统编织/针刺工艺复合过程中二维织物制备、铺放与针刺各个过程相互独立，均需依赖人工参与而产生的效率低、成本高等问题，本发明提供了一种编织针刺一体化成形方法并根据该方法提供了相应的预制体成形装置。
如图2至图7所示，该预制体成形装置的实施例为，预制体成形装置包括：编织机、异形结构模具、分别位于编织机两端的芯模抓取装置、网胎自动铺放装置以及自动针刺装置。
所述的芯模抓取装置包括两个结构相同并分别设置于编织机的轴向两端，位于其中一端的芯模抓取装置包括夹爪12、夹爪安装台13，夹爪12安装在夹爪安装台13上，夹爪安装台13上安装有使抓取装置沿轴向水平移动的运动装置。位于另一端的芯模抓取装置包括夹爪22、夹爪安装台23，夹爪22安装在夹爪安装台23上，夹爪安装台23上安装有使抓取装置沿轴向水平移动的运动装置。两台抓取装置的夹爪均牵引芯模和织物沿编织环轴线在编织平面左右两侧水平独立或者协同运动，并不与纱线干涉，同时在编织过程中，抓取装置上的夹爪给芯模与织物施加一定的预紧力使织物能紧贴并且完全覆盖芯模表面，形成与芯模表面 相同的织物轮廓。所述的夹爪通过控制自动释放或夹紧芯模与织物端部，包括采用气动、电磁或机械中的一种方式。
所述的网胎自动铺放装置包括第一机械臂2、第一弧形支持环3、限位辊轮4、驱动齿轮8、网胎绕卷轮5、网胎裁剪刀6、真空吸附装置7、粘结剂释放装置11、第一弧齿环19以及网胎铺放台14，第一弧形支持环3安装在第一机械臂2上，第一限位辊轮4、第一驱动齿轮8以及第一弧齿环19安装在第一弧形支持环3上，网胎绕卷轮5以及网胎铺放台14安装在第一弧齿环19上，网胎裁剪刀6、真空吸附装置7和粘结剂释放装置11安装在网胎铺放台上，第一机械臂2与能水平运动的装置相连；第一弧齿环19内侧至少安装有两个第一驱动齿轮8，两个第一驱动齿轮8转动带动第一弧齿环19及第一弧形支持环3正转或反转。所述的网胎自动针刺装置包括第二机械臂15、第二弧形支持环16、第二弧齿环18、第二限位辊轮29、第二驱动齿轮20以及针刺头9，第二弧形支持环18安装在第二机械臂15上，第二弧齿环18、第二限位辊轮19、第二驱动齿轮20均安装在第二弧形支持环16上，针刺头9安装在第二弧齿环18上，第二机械臂15上安装有能使其水平运动的装置；第二弧齿环18内侧至少安装有两个第二驱动齿轮20，两个第二驱动齿轮20转动带动第二弧齿环18及第二弧形支持环16正转或反转。所述第一弧形支持环3上设有连接孔位用于安装网胎铺放平台14，第二弧形支持环16上设有连接孔位，用于安装针刺头9。第一弧形支持环3、第一弧形支持环16均安装有位置传感器27，用于确定第一弧齿环18、第二弧齿环19的位置，并防止第一弧齿环18、第二弧齿环19脱离第一驱动齿轮8、第二驱动齿轮20和第一限位辊轮4、第二限位辊轮29的束缚。
所述的网胎自动铺放装置中的网胎绕卷轮5上缠绕着网胎，用于向网胎铺放平台14提供网胎，第一弧形支持环3、第一限位辊轮4、第一驱动齿轮8用于实现第一弧齿环19绕中心旋转并将其运动轨迹限制在环形范围内，真空吸附装置7启动时在真空吸附装置7表面形成负压紧紧吸附网胎，粘结剂释放装置11释放粘结剂使网胎黏附在织物表面，并通过网胎铺放平台14端部的挤压将网胎粘到织物表面。所述的自动针刺装置中的针刺头9释放刺针并将刺针从织物中拔出；针刺头9上方安装有传感器用于感知刺针与织物表面的相对位置，根据采集所得位置信息调控第二机械臂15的运动姿态；此外，针刺头9的刺针与织物平面的 法向平行。网胎铺放和预针刺是通过自动铺放装置以及自动针刺装置协同配合实现的，使网胎完全贴合编织织物表面。
本发明提供的编织针刺一体化成形方法的实施例为：(1)通过在2.5D编织机1两端布置抓取装置，参见图4，使其中一台抓取装置上的夹爪12抓取芯模21一个端部，让编织芯模21能沿着编织机轴线朝某箭头所示方向运动，使纱线24在芯模表面形成第一层织物25；
(2)参见图5，在完成步骤(1)中第一次织物的覆盖之后停止编织，使另一端的抓取装置上的夹爪22抓取芯模21的另一个端部；
(3)参见图7，网胎自动铺放装置与自动针刺装置通过水平运动装置移动到织物和模具侧面开始工作，网胎绕卷轮5开始通过旋转逐步释放网胎26，真空吸附装置7启动将网胎26紧紧吸附在网胎铺放台14端部，第一机械臂2、第一弧形支持环3以及第一弧齿环19(通过第一驱动齿轮8驱动，第一限位辊轮4限位)联动使网胎铺放台14端部以适当的预压力将网胎26压在第一层织物25表面，同时粘结剂释放装置11释放粘结剂将网胎26粘在第一层织物25表面，随后真空吸附装置7停止动作，与在网胎26铺放的同时，针刺装置通过距离传感器感知其与网胎26的距离，通过处理距离信息，调整第二机械臂15、第二弧形支持环16以及第二弧齿环19的位姿，将针刺头9送到指定位置，针刺头9旋转到第一层织物25平面法向，进行预针刺。参见图8，完成网胎铺放与预针刺一圈后，通过网胎裁剪刀6裁断网胎26，并再次启动空吸附装置7将网胎26紧紧吸附在网胎铺放台14端部。
(4)芯模抓取装置上的夹爪12释放芯模；
(5)参见图9，编织机再次启动，同时使抓取装置上的夹爪22抓取芯模朝着反方向运动，开始使纱线24编织而形成第二层织物28，并使第二层织物28能紧贴并且完全覆盖网胎26表面，目前所得编织层—针刺层—编织层预制体扇形截面如图10所示；
(6)重复上述步骤，实现多层编织织物和网胎交替贴合，所得预制体扇形截面参见图12；
(7)最后，如图5所示，通过自动针刺装置对预制体进行主针刺，如图11为预针刺(a)与主针刺(b)效果对比图。
以上仅是本发明的优选实施方式，本发明的保护范围并不仅局限于上述实施例，凡属于本发明思路下的技术方案均属于本发明的保护范围。应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理前提下的若干改进和润饰，应视为本发明的保护范围。

Claims (9)

  1. 一种编织针刺一体化预制体成形方法，其特征在于，包括以下步骤：
    (1)通过在编织机两端分别布置一个抓取装置，使位于编织机一端抓取装置抓取芯模一个端部，芯模沿着芯模轴线运动，使纱线在芯模表面形成覆盖芯模表面第一层织物；
    (2)在完成步骤(1)中第一次织物的覆盖之后停止编织；
    (3)通过网胎自动铺放装置在覆盖在芯模表面的第一层织物上铺放网胎，针刺装置进行预针刺使网胎贴合第一层织物表面；
    (4)原来抓取芯模的抓取装置释放芯模的端部；
    (5)编织机再次启动，同时使另一端的抓取装置抓取芯模另一端部朝着步骤(1)中沿着芯模轴线运动方向的反方向运动，继续第二层织物编织，并使第二层织物紧贴并且完全覆盖网胎表面；
    (6)重复上述步骤，实现多层编织织物和网胎交替紧密贴合形成预制体；
    (7)最后，通过自动针刺装置对预制体进行主针刺。
  2. 一种实现如权利要求1所述编织针刺一体化预制体成形方法使用的预制体成形装置，其特征在于，具体包括：编织机、异形结构模具、分别位于编织机两端的芯模抓取装置、网胎自动铺放装置以及自动针刺装置；
    所述的芯模抓取装置包括夹爪(12)、夹爪安装台(13)，夹爪(12)安装在夹爪安装台(13)上，夹爪安装台(13)上安装有使抓取装置水平移动的运动装置；
    所述的网胎自动铺放装置包括第一机械臂(2)、第一弧形支持环(3)、限位辊轮(4)、驱动齿轮(8)、网胎绕卷轮(5)、网胎裁剪刀(6)、真空吸附装置(7)、粘结剂释放装置(11)、第一弧齿环(19)以及网胎铺放台(14)，第一弧形支持环(3)安装在第一机械臂(2)上，第一限位辊轮(4)、第一驱动齿轮(8)以及第一弧齿环(19)安装在第一弧形支持环(3)上，网胎绕卷轮(5)以及网胎铺放台(14)安装在第一弧齿环(19)上，网胎裁剪刀(6)、真空吸附装置(7)和粘结剂释放装置(11)安装在网胎铺放台上，第一机械臂(2)与能水平运动的装置相连；第一弧齿环(19)内侧至少安装有两个第一驱动齿轮(8)，两个第一驱动齿轮(8)转动带动第一弧齿环(19)及第一弧形支持环(3)正转或反转；
    所述的网胎自动针刺装置包括第二机械臂(15)、第二弧形支持环(16)、第二弧齿环(18)、第二限位辊轮(29)、第二驱动齿轮(20)以及针刺头(9)，第二弧形支持环(18)安装在第二机械臂(15)上，第二弧齿环(18)、第二限位辊轮(19)、第二驱动齿轮(20)均安装在第二弧形支持环(16)上，针刺头(9)安装在第二弧齿环(18)上，第二机械臂(15)上安装有能使其水平运动的装置； 第二弧齿环(18)内侧至少安装有两个第二驱动齿轮(20)，两个第二驱动齿轮(20)转动带动第二弧齿环(18)及第二弧形支持环(16)正转或反转。
  3. 根据权利要求2所述的预制体成型装置，其特征在于，两台抓取装置的夹爪均牵引芯模和织物沿编织环轴线在编织平面左右两侧水平独立或者协同运动，并不与纱线干涉，同时在编织过程中，抓取装置上的夹爪给芯模与织物施加一定的预紧力使织物能紧贴并且完全覆盖芯模表面，形成与芯模表面相同的织物轮廓。
  4. 根据权利要求3所述的预制体成型装置，其特征在于，所述的夹爪通过控制自动释放或夹紧芯模与织物端部，包括采用气动、电磁或机械中的一种方式。
  5. 根据权利要求2所述的预制体成型装置，其特征在于，网胎铺放和预针刺是通过自动铺放装置以及自动针刺装置协同配合实现的，使网胎完全贴合编织织物表面。
  6. 根据权利要求2所述的预制体成型装置，其特征在于，所述的网胎自动铺放装置中的网胎绕卷轮(5)上缠绕着网胎，用于向网胎铺放平台(14)提供网胎，第一弧形支持环(3)、第一限位辊轮(4)、第一驱动齿轮(8)用于实现第一弧齿环(19)绕中心旋转并将其运动轨迹限制在环形范围内，真空吸附装置(7)启动时在真空吸附装置(7)表面形成负压紧紧吸附网胎，粘结剂释放装置(11)释放粘结剂使网胎黏附在织物表面，并通过网胎铺放平台(14)端部的挤压将网胎粘到织物表面。
  7. 根据权利要求2所述的预制体成型装置，其特征在于，所述的自动针刺装置中的针刺头(9)释放刺针并将刺针从织物中拔出；针刺头(9)上方安装有传感器用于感知刺针与织物表面的相对位置，根据采集所得位置信息调控第二机械臂(15)的运动姿态；此外，针刺头(9)的刺针与织物平面的法向平行。
  8. 根据权利要求2所述的的预制体成型装置，其特征在于，所述第一弧形支持环(3)上设有连接孔位用于安装网胎铺放平台(14)，第二弧形支持环(16)上设有连接孔位，用于安装针刺头(9)。
  9. 根据权利要求3所述的的预制体成型装置，其特征在于，第一弧形支持环(3)、第一弧形支持环(16)均安装有位置传感器(27)，用于确定第一弧齿环(18)、第二弧齿环(19)的位置，并防止第一弧齿环(18)、第二弧齿环(19)脱离第一驱动齿轮(8)、第二驱动齿轮(20)和第一限位辊轮(4)、第二限位辊轮(29)的束缚。
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