复合材料自动铺带控制及工艺关键技术研究
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摘要
复合材料成型自动化是复合材料制造技术发展的必然趋势。自动铺放技术是复合材料成型自动化的典型代表,其集机电装备技术、CAD/CAM软件技术和材料工艺技术于一体,涉及自动铺放装备技术、预浸料切割技术、铺放CAD/CAM技术、自动铺放工艺技术、铺放质量监控、模具技术、成本分析等多个研究方向。
本文以南京航空航天大学自主研制的多台自动铺带机及其配套工艺技术研究为背景,对自动铺带机数控技术等进行了深入的理论分析和应用研究,着重研究了自动铺带机预浸带输送控制技术和自动铺带成型压力控制技术,并以自主研制自动铺带机为平台,对自动铺带制造技术进行了理论分析和试验研究。
1.基于龙门式标准自动铺带机和主轴+小车卧式自动铺带机,分别从数控系统、伺服系统以及各核心子控制系统等多个方面对自动铺带机数控技术进行了详细的分析论证,给出了符合国内应用需求的自动铺带机关键数控技术的设计方案。
2.针对自动铺带过程中预浸带输送的特殊要求,研制了自动铺带成型预浸带输送系统,实现转矩模式和位置模式两种预浸带进给模式,保障预浸带的精确进给,并与两套切割系统相结合完成预浸带插补切割。
3.根据自动铺带成型工艺对预浸带输送系统的要求,经运动学和动力学分析,建立预浸带输送的数学模型,并提出一种适应于预浸带在转矩模式下输送的精密控制策略;自行推导设计模型参考自适应控制(MRAC)仿真模型,并在Matlab/Simulink仿真平台上进行仿真验证。
4.为解决自动铺带过程中起始预浸带位置定位不精确的问题,通过分析其机理,借助自适应送带系统,提出一种与切带动作相结合的定位方案,并研制了相应的位置模式下预浸带输送控制系统。
5.通过对自动铺带成型工艺过程的分析,指出自动铺带成型过程中预浸带在成型压力作用下蠕变及回复的连续动态过程;据此,分析论述自动铺带成型工艺参数协调控制问题,提出了自动铺带成型工艺参数控制原则。基于对自动铺带成型工艺参数影响因素的分析,综合考虑自动铺带工艺参数的限制条件,提出了自动铺带成型工艺参数优化控制总体方案。
6.通过分析成型压力与铺带头压力之间的夹角和铺放速率对成型构件质量的影响,结合自动铺带CAM软件,提出了一种基于铺放速率变化的分阶段适应性调节成型压力的工艺参数控制策略,并以南京航空航天大学研制的自动铺带机非标数控系统为平台,研制自动铺带机成型压力控制系统。
7.基于工艺实验,结合国内外自动铺放制造技术发展现状,分别从成型工艺参数、成型工艺过程、固化(固结)技术和设计工艺性四个方面对自动铺带制造技术进行了深入的研究。
Composite material processing automation is the inevitable development uptrend of the composite manufacturing technique. Automated placement technique is the representative of composite material processing automation, which includes mechanical and electronic technique, CAD/CAM software and material processing technique. Automated placement technique is composed of automated placement equipment, prepreg cutting, placement CAD/CAM, and automated placement processing, quality supervising, tools technique, cost analysis and so on.
In this dissertation, based on the Automated Tape Placement (ATP) machines developed by Nanjing University of Aeronautics and Astronautics and associated processing technology, ATP numerical control technology is theoretically analyzed and application researched in depth. The prepreg tape feeding control technology and processing pressure control technology are emphatically analyzed and studyed in ATP. The ATP manufacturing technology is analyzed theoretically and studied experimentally based on the ATP machines.
Based on the gantry ATP machine and principal axis dolly horizontal ATP machine, the ATP numerical control technology is detailed analyzed and researched in numerical control system, servo system and several sub-control systems. The design scheme of the key numerical control technology is proposed in ATP, which is suitable in China.
According to the special need of prepreg feeding in ATP processing, the ATP prepreg tape feeding system is developed, with torque and position two prepreg tape feeding modes. The prepreg is fed and interpolation cut accurately combined with two prepreg tape cutting systems.
The performance requirement of the prepreg feeding system is analyzed in ATP. The importance of the prepreg precision feeding control technique is validated through kinematics and dynamic analysis, upon which a mathematics model for the prepreg feeding is designed. The control strategy is proposed for the prepreg feeding in view of the performance requirements. The Model Reference Adaptive Control (MRAC) model is simulated and verified in the Matlab/Simulink software platform.
To solve the problem of inaccuracy for prepreg starting in the ATP processing, the control strategy is set up combined with prepreg tape cutting. The prepreg tape feeding system in the position mode is developed combined with self-adapting prepreg tape feeding system.
The analysis of ATP processing reveals that ATP is sequential and dynamics process of creeping and reversion of the prepreg under processing pressure. Hereby, the coordinated control problem of ATP parameters is analyzed and discussed. The ATP processing technology control principle is presented. According to the analysis of ATP processing parameter influence factors, the whole optimized control strategy of ATP processing parameters is proposed combined with the comprehensive consideration of the ATP processing parameter restrictions.
According to the analysis, the product quality is influenced by the angle between processing pressure and ATP header pressure, and the placement velocity. Hereby, the parameters control strategy is advanced combined with CAM software, in which the processing pressure is adjusted by stages according to placement velocity changing. The processing pressure control system is developed based on the special ATP numerical control system made by Nanjing University of Aeronautics and Astronautics.
The ATP manufacturing technology is researched in parameters, processing, curing (consolidation) technology and design manufacturability based on processing experiments, combined with the ATP manufacturing status home and abroad.
本文以南京航空航天大学自主研制的多台自动铺带机及其配套工艺技术研究为背景,对自动铺带机数控技术等进行了深入的理论分析和应用研究,着重研究了自动铺带机预浸带输送控制技术和自动铺带成型压力控制技术,并以自主研制自动铺带机为平台,对自动铺带制造技术进行了理论分析和试验研究。
1.基于龙门式标准自动铺带机和主轴+小车卧式自动铺带机,分别从数控系统、伺服系统以及各核心子控制系统等多个方面对自动铺带机数控技术进行了详细的分析论证,给出了符合国内应用需求的自动铺带机关键数控技术的设计方案。
2.针对自动铺带过程中预浸带输送的特殊要求,研制了自动铺带成型预浸带输送系统,实现转矩模式和位置模式两种预浸带进给模式,保障预浸带的精确进给,并与两套切割系统相结合完成预浸带插补切割。
3.根据自动铺带成型工艺对预浸带输送系统的要求,经运动学和动力学分析,建立预浸带输送的数学模型,并提出一种适应于预浸带在转矩模式下输送的精密控制策略;自行推导设计模型参考自适应控制(MRAC)仿真模型,并在Matlab/Simulink仿真平台上进行仿真验证。
4.为解决自动铺带过程中起始预浸带位置定位不精确的问题,通过分析其机理,借助自适应送带系统,提出一种与切带动作相结合的定位方案,并研制了相应的位置模式下预浸带输送控制系统。
5.通过对自动铺带成型工艺过程的分析,指出自动铺带成型过程中预浸带在成型压力作用下蠕变及回复的连续动态过程;据此,分析论述自动铺带成型工艺参数协调控制问题,提出了自动铺带成型工艺参数控制原则。基于对自动铺带成型工艺参数影响因素的分析,综合考虑自动铺带工艺参数的限制条件,提出了自动铺带成型工艺参数优化控制总体方案。
6.通过分析成型压力与铺带头压力之间的夹角和铺放速率对成型构件质量的影响,结合自动铺带CAM软件,提出了一种基于铺放速率变化的分阶段适应性调节成型压力的工艺参数控制策略,并以南京航空航天大学研制的自动铺带机非标数控系统为平台,研制自动铺带机成型压力控制系统。
7.基于工艺实验,结合国内外自动铺放制造技术发展现状,分别从成型工艺参数、成型工艺过程、固化(固结)技术和设计工艺性四个方面对自动铺带制造技术进行了深入的研究。
Composite material processing automation is the inevitable development uptrend of the composite manufacturing technique. Automated placement technique is the representative of composite material processing automation, which includes mechanical and electronic technique, CAD/CAM software and material processing technique. Automated placement technique is composed of automated placement equipment, prepreg cutting, placement CAD/CAM, and automated placement processing, quality supervising, tools technique, cost analysis and so on.
In this dissertation, based on the Automated Tape Placement (ATP) machines developed by Nanjing University of Aeronautics and Astronautics and associated processing technology, ATP numerical control technology is theoretically analyzed and application researched in depth. The prepreg tape feeding control technology and processing pressure control technology are emphatically analyzed and studyed in ATP. The ATP manufacturing technology is analyzed theoretically and studied experimentally based on the ATP machines.
Based on the gantry ATP machine and principal axis dolly horizontal ATP machine, the ATP numerical control technology is detailed analyzed and researched in numerical control system, servo system and several sub-control systems. The design scheme of the key numerical control technology is proposed in ATP, which is suitable in China.
According to the special need of prepreg feeding in ATP processing, the ATP prepreg tape feeding system is developed, with torque and position two prepreg tape feeding modes. The prepreg is fed and interpolation cut accurately combined with two prepreg tape cutting systems.
The performance requirement of the prepreg feeding system is analyzed in ATP. The importance of the prepreg precision feeding control technique is validated through kinematics and dynamic analysis, upon which a mathematics model for the prepreg feeding is designed. The control strategy is proposed for the prepreg feeding in view of the performance requirements. The Model Reference Adaptive Control (MRAC) model is simulated and verified in the Matlab/Simulink software platform.
To solve the problem of inaccuracy for prepreg starting in the ATP processing, the control strategy is set up combined with prepreg tape cutting. The prepreg tape feeding system in the position mode is developed combined with self-adapting prepreg tape feeding system.
The analysis of ATP processing reveals that ATP is sequential and dynamics process of creeping and reversion of the prepreg under processing pressure. Hereby, the coordinated control problem of ATP parameters is analyzed and discussed. The ATP processing technology control principle is presented. According to the analysis of ATP processing parameter influence factors, the whole optimized control strategy of ATP processing parameters is proposed combined with the comprehensive consideration of the ATP processing parameter restrictions.
According to the analysis, the product quality is influenced by the angle between processing pressure and ATP header pressure, and the placement velocity. Hereby, the parameters control strategy is advanced combined with CAM software, in which the processing pressure is adjusted by stages according to placement velocity changing. The processing pressure control system is developed based on the special ATP numerical control system made by Nanjing University of Aeronautics and Astronautics.
The ATP manufacturing technology is researched in parameters, processing, curing (consolidation) technology and design manufacturability based on processing experiments, combined with the ATP manufacturing status home and abroad.
引文
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