平面铺放的铺放头设计及仿真
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摘要
CFRP(碳纤维增强塑料)因其优异的性能，已被广泛用于宇航、导弹、火箭、飞机、汽车、化工、机械、纺织、医疗器材以及文体用品等各个领域。国外CFRP自动碳纤维带铺放工艺已经非常成熟，而该项技术目前在国内还处于起步阶段，研究开发具有我国自主知识产权的自动纤维铺放设备已成为亟待解决的课题。
本课题使用Solidworks软件设计了一台用于平面铺放的龙门式碳纤维带铺放机的铺放头。它主要包括放卷装置、切割装置、加热装置、铺放压紧装置、带缺陷检测装置、测速测压装置及底纸收卷装置。包括四个轴，在切割装置上安装了三个轴(包括两个直线运动轴和一个旋转轴)，在铺放辊上安装了一个轴，这四个轴都是在微机控制下协同运动。在铺放头内有一套碳纤维带切割机构，它可以沿着任意角度对碳纤维带进行切割，采用超声波切割刀进行切割，定位精确，切割快速，保证了碳纤维带切割边界的完整性和整齐性，为当前碳纤维带的切割难题提供了一个实用的解决方法。最终的碳纤维带铺放头能够完成整个碳纤维带放卷、切割、加热、铺放、压紧、测速、底纸回收整个铺放流程。
本课题以COSMOSWorks为平台，对铺放辊机构进行了有限元分析，验证碳纤维带的铺放过程中，滑块与滑轨之间的径向压力对滑块滑轨的磨损状况。
本课题还分别尝试使用Animator及OpenGL两种方式，对铺放的过程和线型进行了动态仿真。Animator完全集成于Solidworks中，因此其动画制作相对容易、直观，但参数化效果差；最终侧重选择了在Visual C++平台上，使用OpenGL通过编程方式对整个铺放过程进行了仿真，在仿真过程中，铺放带可以沿着横向、纵向及斜向等不同方位对碳纤维带进行铺放，同时可以修改铺放速度、铺放角度、铺放层数等参数，实现了整个铺放过程的实时动态仿真。
Carbon fiber Reinforced Plastic is widely used in military industry, rocket, aerospace, automobile, chemical industry, mechanism, textile, mechanical apparatus etc because of it's excellent mechanical specialties. The Automatic Carbon fiber tape laying technique is very mature in the abroad; however, it is still in the initial stage in the domestic. So that it is urgent to develop our own Automatic Carbon Fiber tape machine.
The paper introduces a kind of tape laying head used for depositing and compacting carbon fiber tape onto a work surface for producing a plastic article, the work surface, which is a plane with 3 meters in length and 2 meters in width. It composes of the following members: a feed reel member, a cutting member, a heat up member, a guide chute, a roller member, a tape defects detector member, a speed testing member and a take up reel member. It includes 4 movement axes. There are 3 in the cutting member (2 linear axes and 1 revolving axis) and the other 1 axis in the roller member. All 4-axis movements are CNC. There is a set of cutting mechanism in the tape laying head. It can cut the tape in any direction and an ultrasonic cutting blade is employed, which guarantees the integrity and tidiness of the cutting borderline. It provides a practical solution to the puzzle of carbon fiber tape cutting.
The paper makes a FEA on the roller member in the platform of COSMOSWorks and validates the abrasion condition between the slider and the slide-rail.
Additionally, the paper makes an attempt in simulating with two different methods, Animator and OpenGL. Finally, I choose OpenGL to make the final simulation, it simulates the course of the movement of the tape under the platform of Visual C++ to verify those regulations and which can lay the tape in and direction.
本课题使用Solidworks软件设计了一台用于平面铺放的龙门式碳纤维带铺放机的铺放头。它主要包括放卷装置、切割装置、加热装置、铺放压紧装置、带缺陷检测装置、测速测压装置及底纸收卷装置。包括四个轴，在切割装置上安装了三个轴(包括两个直线运动轴和一个旋转轴)，在铺放辊上安装了一个轴，这四个轴都是在微机控制下协同运动。在铺放头内有一套碳纤维带切割机构，它可以沿着任意角度对碳纤维带进行切割，采用超声波切割刀进行切割，定位精确，切割快速，保证了碳纤维带切割边界的完整性和整齐性，为当前碳纤维带的切割难题提供了一个实用的解决方法。最终的碳纤维带铺放头能够完成整个碳纤维带放卷、切割、加热、铺放、压紧、测速、底纸回收整个铺放流程。
本课题以COSMOSWorks为平台，对铺放辊机构进行了有限元分析，验证碳纤维带的铺放过程中，滑块与滑轨之间的径向压力对滑块滑轨的磨损状况。
本课题还分别尝试使用Animator及OpenGL两种方式，对铺放的过程和线型进行了动态仿真。Animator完全集成于Solidworks中，因此其动画制作相对容易、直观，但参数化效果差；最终侧重选择了在Visual C++平台上，使用OpenGL通过编程方式对整个铺放过程进行了仿真，在仿真过程中，铺放带可以沿着横向、纵向及斜向等不同方位对碳纤维带进行铺放，同时可以修改铺放速度、铺放角度、铺放层数等参数，实现了整个铺放过程的实时动态仿真。
Carbon fiber Reinforced Plastic is widely used in military industry, rocket, aerospace, automobile, chemical industry, mechanism, textile, mechanical apparatus etc because of it's excellent mechanical specialties. The Automatic Carbon fiber tape laying technique is very mature in the abroad; however, it is still in the initial stage in the domestic. So that it is urgent to develop our own Automatic Carbon Fiber tape machine.
The paper introduces a kind of tape laying head used for depositing and compacting carbon fiber tape onto a work surface for producing a plastic article, the work surface, which is a plane with 3 meters in length and 2 meters in width. It composes of the following members: a feed reel member, a cutting member, a heat up member, a guide chute, a roller member, a tape defects detector member, a speed testing member and a take up reel member. It includes 4 movement axes. There are 3 in the cutting member (2 linear axes and 1 revolving axis) and the other 1 axis in the roller member. All 4-axis movements are CNC. There is a set of cutting mechanism in the tape laying head. It can cut the tape in any direction and an ultrasonic cutting blade is employed, which guarantees the integrity and tidiness of the cutting borderline. It provides a practical solution to the puzzle of carbon fiber tape cutting.
The paper makes a FEA on the roller member in the platform of COSMOSWorks and validates the abrasion condition between the slider and the slide-rail.
Additionally, the paper makes an attempt in simulating with two different methods, Animator and OpenGL. Finally, I choose OpenGL to make the final simulation, it simulates the course of the movement of the tape under the platform of Visual C++ to verify those regulations and which can lay the tape in and direction.
引文
[1] 碳纤维的需求、前景和研发新动向．http://www.carbonfiber.cc/TradeNews/ViewTradeInfo.aspx?InfoId=342
[2] 李勇，肖军．复合材料纤维铺放技术及其应用．纤维复合材料，2002．(9)：39-41
[3] 苏玉堂，鲁博．纤维缠绕复合材料结构制造技术．中国玻璃钢工业协会：2003
[4] 自动化的重要进展．http://www.aviationnow.com.cn/webviews/dongtai/content.aspx?newsid=20070422091434765&classid=7
[5] 韩振宇，孟庆鑫，路华，等．新型纤维铺放头的方案设计与实验研究．玻璃钢／复合材料，2007．(3)：25-27
[6] 徐再，吴耀楚，田会方．FRP铺放成型技术的研究，玻璃钢／复合材料，2002．(5)：44-46
[7] 丁韬．自动纤维铺放机．航空制造技术，2007．(9)：60-64
[8] 陈亚莉．复合材料在飞机上的新应用．航空维修与工程，2005．(3)：31-32
[9] 胡仁喜，张红松，刘昌丽．SolidWorks 2007中文版机械设计工程实践．科学出版社：2007
[10] 谢昱北．SolidWorks 2007中文版机械设计与典型范例．电子工业出版社：2007
[11] 岳荣刚，宋凌珺．SolidWorks 2006零件与装配设计教程．冶金工业出版社：2006
[12] 王志辉，曹德华．纤维铺放系统的机构分析．中国水运，2006．(2)：82-83
[13] 田会方，黄亚辉．纤维铺放机的机构设计及仿真．机械工程师，2005．(8)：92-94
[14] 于传浩，吴耀楚，王志辉．FRP铺放技术的机构分析．武汉化工学院学报，2003．(2)：54-56
[15] Hogg, Merrill W. Method for laying composite tape. United States Patent, 20060073309, 2006-04-06
[16] Martin, James P. Multiple tape laying apparatus and method. United States Patent, 20050061422, 2005-03-24
[17] Zaba]los, Kenneth P. Device for laying tape materials for aerospace applications. United States Patent, 20060118244, 2006-06-08
[18] Grimshaw, Michael N. Method for laying cut composite tape on a mold having scrap removal. United States Patent, 5114519, 1992-05-19
[19] Dawn K. Russell. INCORPORATING ENVIRONMENTAL ISSUES IN A FILAMENT WINDING COMPOSITE MANUFACTURING SYSTEM SIMULATION. Winter Simulation Conference: 1998
[20] Bell ,P.R.,et al. Review of Point-to-point Network Routing Algorithms. IEEE Commun. Magazien, 1996 (1)
[21] Sharp, Terrance M. Robotic tape applicator and method. United States Patent, 7093641, 2006-08-22
[22] 超声波切割应用技术. http://www.discousa.com/cn_s/solution/library/usw.html
[23] Messner, Bernd A. K. Tape laying head with curved tape laying capability and improved adaptive steering. United States Patent, 5431749, 1995-07-11
[24] Blaimschein, Gottfried. Method and apparatus for laying strips of tape material. United States Patent, 5402962, 1995-04-04
[25] Grimshaw, Michael N.; Peterson, David A. Tape laying apparatus and method, United States Patent, 5352306, 1994-10-04
[26] Grimshaw, Michael N.; Peterson, David A. Tape laying and compaction apparatus. United States Patent, 5314563. 1994-05-24
[27] Peterson, David A. Tape laying apparatus. United States Patent, 5269869, 1993-12-14
[28] Krogager, Max; Weidmann, Bjorn; Petersson, Mikael. AUTOMATIC TAPE LAYING APPARATUS AND METHOD. United States Patent, 20060289111, 2006-12-28
[29] Andersen, Stig Jarle; Stangeland, .O slashed, ivind. Method and apparatus for laying elongated articles. United States Patent, 6641330, 2003-11-04
[30] Redd, Bryan; Enders, Mark L.; Young, Michael H. Combination filament winding and tape laying apparatus and method for making and using the same. United States Patent, 5145543, 1992-09-08
[31] 江洪，陈燎，王智等．SolidWorks有限元分析实例解析．机械工业出版社：2007
[32] SolidWorks公司著．COSMOS基础教程．机械工业出版社：2007
[33] SolidWorks动画演示与运动分析实例解析．机械工业出版社：2006
[34] 陈芝．OpenGL三维图形系统开发与实用技术．重庆大学出版社：2003
[35] 李颖．Open GL函数与范例解析手册．国防工业出版社：2002
[36] 和平鸽工作室．OpenGL高级编程与可视化系统开发．中国水利水电出版社：2006
[37] 郭兆荣，李菁，王彦．Visum C++OpenGL应用程序开发．人民邮电出版社：2006
[38] 邓郯祥．OpenGL编程指南．人民邮电出版社：2005
[39] Richard S．Wright，Jr．，Benjamin Lipchak．OpenGL超级宝典．人民邮电出版社：2005
[40] David J．Kruglinski．Visual C++技术内幕(第四版)．清华大学出版社：2002
[41] Eugene Olafsen等．MFC Visual C++6编程技术内幕．机械工业出版社：2000
[42] Lippman, Stanley B. C++ primer. Posts & Telecom Press:2006
[2] 李勇，肖军．复合材料纤维铺放技术及其应用．纤维复合材料，2002．(9)：39-41
[3] 苏玉堂，鲁博．纤维缠绕复合材料结构制造技术．中国玻璃钢工业协会：2003
[4] 自动化的重要进展．http://www.aviationnow.com.cn/webviews/dongtai/content.aspx?newsid=20070422091434765&classid=7
[5] 韩振宇，孟庆鑫，路华，等．新型纤维铺放头的方案设计与实验研究．玻璃钢／复合材料，2007．(3)：25-27
[6] 徐再，吴耀楚，田会方．FRP铺放成型技术的研究，玻璃钢／复合材料，2002．(5)：44-46
[7] 丁韬．自动纤维铺放机．航空制造技术，2007．(9)：60-64
[8] 陈亚莉．复合材料在飞机上的新应用．航空维修与工程，2005．(3)：31-32
[9] 胡仁喜，张红松，刘昌丽．SolidWorks 2007中文版机械设计工程实践．科学出版社：2007
[10] 谢昱北．SolidWorks 2007中文版机械设计与典型范例．电子工业出版社：2007
[11] 岳荣刚，宋凌珺．SolidWorks 2006零件与装配设计教程．冶金工业出版社：2006
[12] 王志辉，曹德华．纤维铺放系统的机构分析．中国水运，2006．(2)：82-83
[13] 田会方，黄亚辉．纤维铺放机的机构设计及仿真．机械工程师，2005．(8)：92-94
[14] 于传浩，吴耀楚，王志辉．FRP铺放技术的机构分析．武汉化工学院学报，2003．(2)：54-56
[15] Hogg, Merrill W. Method for laying composite tape. United States Patent, 20060073309, 2006-04-06
[16] Martin, James P. Multiple tape laying apparatus and method. United States Patent, 20050061422, 2005-03-24
[17] Zaba]los, Kenneth P. Device for laying tape materials for aerospace applications. United States Patent, 20060118244, 2006-06-08
[18] Grimshaw, Michael N. Method for laying cut composite tape on a mold having scrap removal. United States Patent, 5114519, 1992-05-19
[19] Dawn K. Russell. INCORPORATING ENVIRONMENTAL ISSUES IN A FILAMENT WINDING COMPOSITE MANUFACTURING SYSTEM SIMULATION. Winter Simulation Conference: 1998
[20] Bell ,P.R.,et al. Review of Point-to-point Network Routing Algorithms. IEEE Commun. Magazien, 1996 (1)
[21] Sharp, Terrance M. Robotic tape applicator and method. United States Patent, 7093641, 2006-08-22
[22] 超声波切割应用技术. http://www.discousa.com/cn_s/solution/library/usw.html
[23] Messner, Bernd A. K. Tape laying head with curved tape laying capability and improved adaptive steering. United States Patent, 5431749, 1995-07-11
[24] Blaimschein, Gottfried. Method and apparatus for laying strips of tape material. United States Patent, 5402962, 1995-04-04
[25] Grimshaw, Michael N.; Peterson, David A. Tape laying apparatus and method, United States Patent, 5352306, 1994-10-04
[26] Grimshaw, Michael N.; Peterson, David A. Tape laying and compaction apparatus. United States Patent, 5314563. 1994-05-24
[27] Peterson, David A. Tape laying apparatus. United States Patent, 5269869, 1993-12-14
[28] Krogager, Max; Weidmann, Bjorn; Petersson, Mikael. AUTOMATIC TAPE LAYING APPARATUS AND METHOD. United States Patent, 20060289111, 2006-12-28
[29] Andersen, Stig Jarle; Stangeland, .O slashed, ivind. Method and apparatus for laying elongated articles. United States Patent, 6641330, 2003-11-04
[30] Redd, Bryan; Enders, Mark L.; Young, Michael H. Combination filament winding and tape laying apparatus and method for making and using the same. United States Patent, 5145543, 1992-09-08
[31] 江洪，陈燎，王智等．SolidWorks有限元分析实例解析．机械工业出版社：2007
[32] SolidWorks公司著．COSMOS基础教程．机械工业出版社：2007
[33] SolidWorks动画演示与运动分析实例解析．机械工业出版社：2006
[34] 陈芝．OpenGL三维图形系统开发与实用技术．重庆大学出版社：2003
[35] 李颖．Open GL函数与范例解析手册．国防工业出版社：2002
[36] 和平鸽工作室．OpenGL高级编程与可视化系统开发．中国水利水电出版社：2006
[37] 郭兆荣，李菁，王彦．Visum C++OpenGL应用程序开发．人民邮电出版社：2006
[38] 邓郯祥．OpenGL编程指南．人民邮电出版社：2005
[39] Richard S．Wright，Jr．，Benjamin Lipchak．OpenGL超级宝典．人民邮电出版社：2005
[40] David J．Kruglinski．Visual C++技术内幕(第四版)．清华大学出版社：2002
[41] Eugene Olafsen等．MFC Visual C++6编程技术内幕．机械工业出版社：2000
[42] Lippman, Stanley B. C++ primer. Posts & Telecom Press:2006