纤维丝铺放靴控制系统的设计研究
摘要
随着复合材料的应用领域的不断扩大,对复合材料成型技术水平提出了更高的要求。碳纤维是复合材料的一种,具有质量轻、强度高、防腐蚀等优点,已广泛应用于航空航天领域。
本文主要研究纤维丝铺放成型技术,它是在纤维缠绕成型和自动窄带铺放基础上发展起来的全自动制造技术,对制品的适应性更强,多用于有凸凹曲面、具有沟槽等外形相对复杂的纤维增强制品。纤维铺放设备是由计算机控制的,铺放设备按照计算机设定的轨迹完成纤维铺放任务。在铺放过程中,根据铺放构件的外形,铺放设备可以实现变角度铺放,还可以自适应的增减丝束路数。目前,在国内对纤维丝铺放设备的研究仍处于初步阶段,必须要致力于对这一先进技术的研究,才能使其在国防领域广泛应用。
本课题所研究的六路纤维丝铺放靴控制系统,采用主流的IPC机+PMAC多轴运动控制卡的开放式控制方式。IPC机作为上位机完成系统级的控制任务如上下位机的通讯、状态监控,人机界面管理等；PMAC运动控制卡作为下位机主要完成铺放靴的实时运动轨迹控制及纤维丝铺放过程中的逻辑控制功能。在纤维丝铺放过程中,纤维丝从纱团送出后,需要经过导向、夹紧、重送、剪切装置后被送到构件表面,在铺放靴的一定压力下,按照程序设定的铺放路径将经加热装置加热后的纤维丝压紧到构件表面,完成良好的铺放任务。本文中,需要对六路铺放靴的压力进行单独控制,通过压力检测装置将铺放靴对纤维丝的压力反馈给PMAC卡,经PMAC计算后,获得补偿信号驱动伺服电机带动铺放靴做相应的运动来减小误差；还需要对这六路铺放靴的整体进行旋转运动控制,来实现对形面复杂构件的铺放任务。
根据六路纤维丝控制系统的硬件平台,开发出系统的应用程序软件。本系统的应用软件分为人机交互平台和PMAC运动控制程序两部分。系统的人机界面是基于Windows操作平台下,使用Visual C++6.0作为程序开发工具,利用PMAC控制卡提供的PCOMM32动态链接库和Windows的API函数开发出来的；系统的运动控制程序是利用PMAC卡自带的PEWIN32执行软件来编写和执行的。
With constantly expanded applications of composite material, they propose a higher demand for molding technology of composite material. Carbon fiber, a kind of composite material, has been widely used in aerospace field with its advantages, such as light weight, strong strength and anticorrosion etc.
This paper mainly studies technology of filament placement molding,which is a kind of fully automatic manufacturing technique developed on the basis of fiber winding and automatic band placement, so it has a strong adaptability of products, and can be used for fiber reinforced products with concavo-convex curved surfaces and relatively complex from such as grooves. Fiber placement equipments, controlled by computer, can complete the assignment of fiber placement according to scheduled track set by computer. In the placement process, placement equipment can realize variable-angle placement, and also adaptively increase or decrease fiber tow points according to the shape of components. At present, as the research of filament placement device is still at a preliminary stage in the domestic, we must commit to the research of this advanced technology, making a wide use in defense filed..
The control system of six -fiber tows placement boots, proposed in this project, adopts the mainstream open control mode of IPC+PMAC. IPC, as host computer, completes system-level control tasks such as communications between upper and lower computers, condition monitoring, human interface management etc; PMAC takes charge of logical control and real-time motion track control of placement boots. In the process of fiber placement, fibers sent from the yarn group, will go into the surface of the component, after guide, clamping, re-send and cut devices, then in the lead of constant pressure of placement boots, fibers will compress to the component according to the given path set by programs and through heating unit, so placement task can be completed successfully. In this paper, the pressure of the six placement boots needs to be controlled separately, the pressure for filament, tested by pressure testing devices, will feedback to PMAC card; then, compensating signal can be obtained after calculation by PMAC; eventually, errors can reduced by signal driving the servo motor to promote placement boots to take corresponding motion. Moreover, overall control of rotate motion of six placement boots is in need, to fulfill placement task for complex-shaped surface components.
According to the hardware platform of the six fiber placement control system, application software is developed. Software of this system is divided into two parts: human-machine interface and PMAC motion control program. The human-machine interface, based on Windows system, is developed by using Visual C++6.0 as program development tool, and employing PCOMM32 dynamic link library provided by PMAC and Windows API functions; the motion control programs are written and executed by PEWIN32 executive software of PMAC of its own.
本文主要研究纤维丝铺放成型技术,它是在纤维缠绕成型和自动窄带铺放基础上发展起来的全自动制造技术,对制品的适应性更强,多用于有凸凹曲面、具有沟槽等外形相对复杂的纤维增强制品。纤维铺放设备是由计算机控制的,铺放设备按照计算机设定的轨迹完成纤维铺放任务。在铺放过程中,根据铺放构件的外形,铺放设备可以实现变角度铺放,还可以自适应的增减丝束路数。目前,在国内对纤维丝铺放设备的研究仍处于初步阶段,必须要致力于对这一先进技术的研究,才能使其在国防领域广泛应用。
本课题所研究的六路纤维丝铺放靴控制系统,采用主流的IPC机+PMAC多轴运动控制卡的开放式控制方式。IPC机作为上位机完成系统级的控制任务如上下位机的通讯、状态监控,人机界面管理等；PMAC运动控制卡作为下位机主要完成铺放靴的实时运动轨迹控制及纤维丝铺放过程中的逻辑控制功能。在纤维丝铺放过程中,纤维丝从纱团送出后,需要经过导向、夹紧、重送、剪切装置后被送到构件表面,在铺放靴的一定压力下,按照程序设定的铺放路径将经加热装置加热后的纤维丝压紧到构件表面,完成良好的铺放任务。本文中,需要对六路铺放靴的压力进行单独控制,通过压力检测装置将铺放靴对纤维丝的压力反馈给PMAC卡,经PMAC计算后,获得补偿信号驱动伺服电机带动铺放靴做相应的运动来减小误差；还需要对这六路铺放靴的整体进行旋转运动控制,来实现对形面复杂构件的铺放任务。
根据六路纤维丝控制系统的硬件平台,开发出系统的应用程序软件。本系统的应用软件分为人机交互平台和PMAC运动控制程序两部分。系统的人机界面是基于Windows操作平台下,使用Visual C++6.0作为程序开发工具,利用PMAC控制卡提供的PCOMM32动态链接库和Windows的API函数开发出来的；系统的运动控制程序是利用PMAC卡自带的PEWIN32执行软件来编写和执行的。
With constantly expanded applications of composite material, they propose a higher demand for molding technology of composite material. Carbon fiber, a kind of composite material, has been widely used in aerospace field with its advantages, such as light weight, strong strength and anticorrosion etc.
This paper mainly studies technology of filament placement molding,which is a kind of fully automatic manufacturing technique developed on the basis of fiber winding and automatic band placement, so it has a strong adaptability of products, and can be used for fiber reinforced products with concavo-convex curved surfaces and relatively complex from such as grooves. Fiber placement equipments, controlled by computer, can complete the assignment of fiber placement according to scheduled track set by computer. In the placement process, placement equipment can realize variable-angle placement, and also adaptively increase or decrease fiber tow points according to the shape of components. At present, as the research of filament placement device is still at a preliminary stage in the domestic, we must commit to the research of this advanced technology, making a wide use in defense filed..
The control system of six -fiber tows placement boots, proposed in this project, adopts the mainstream open control mode of IPC+PMAC. IPC, as host computer, completes system-level control tasks such as communications between upper and lower computers, condition monitoring, human interface management etc; PMAC takes charge of logical control and real-time motion track control of placement boots. In the process of fiber placement, fibers sent from the yarn group, will go into the surface of the component, after guide, clamping, re-send and cut devices, then in the lead of constant pressure of placement boots, fibers will compress to the component according to the given path set by programs and through heating unit, so placement task can be completed successfully. In this paper, the pressure of the six placement boots needs to be controlled separately, the pressure for filament, tested by pressure testing devices, will feedback to PMAC card; then, compensating signal can be obtained after calculation by PMAC; eventually, errors can reduced by signal driving the servo motor to promote placement boots to take corresponding motion. Moreover, overall control of rotate motion of six placement boots is in need, to fulfill placement task for complex-shaped surface components.
According to the hardware platform of the six fiber placement control system, application software is developed. Software of this system is divided into two parts: human-machine interface and PMAC motion control program. The human-machine interface, based on Windows system, is developed by using Visual C++6.0 as program development tool, and employing PCOMM32 dynamic link library provided by PMAC and Windows API functions; the motion control programs are written and executed by PEWIN32 executive software of PMAC of its own.
引文
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[16]Adriana W. Blom, Mostafa M. Abdalla, Zafer Gurdal. Optimization of course locations in fiber-placed panels for general fiber angle distributions. Composites Science and Technology, 2010(70):564-570.
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[21]周焱,安鲁陵,周来水.复合材料自动铺丝路径生成技术研究[J].航空精密制造技术,2006(2)：39-41.
[22]王志辉,郑强.基于PMAC的四轴纤维缠绕机数控系统的设计[J].机械制造,2007(526)：26-28.
[23]俞建峰,周杰.基于运动控制的纤维缠绕机控制系统的设计[J].江南大学学报,2009(2)：159-163.
[24]何江华.玻璃钢缠绕机控制系统设计[D].哈尔滨理工大学硕士学位论文.2009.
[25]陈兴建.数控纤维缠绕张力的模糊PID控制系统研究[D].南京航空航天大学学位论文,2007.
[26]M.A.Lamontia,M.B.Gruber,B.J.Waibel. Conformable Compaction System Used in Automated Fiber Placement of Large Composite Aerospace Structures, USA.2002:30-42.
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[31]富宏亚,韩振宇,路华.纤维缠绕/铺带/铺丝成型设备的发展状况[J].航空制造技术,2009(22)：43-46.
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[2]徐再,吴耀楚,等.FRP铺放成型技术的研究[J].玻璃钢/复合材料,2002(5)：44-46
[3]田会方,吴猛.纤维带铺放控制系统的设计研究[J].机械工程与自动化,2008(2)：135-137.
[4]刘恒娟.基于PMAC的开放式数控系统的研究[J].组合机床与自动化,2004(2)：84-86.
[5]王志辉,吕佳.纤维铺放头机构的研究[J].设计计算,2007(12)：73-74.
[6]于传浩,吴耀楚,王志辉.复杂纤维增强塑料构件的铺放成型技术的研究[C].玻璃钢学
会第十五届全国玻璃钢/复合材料学术年会论文集,2003：152-154.
[7]李开越,高殿斌,等.航空用预浸纤维带铺放装备设计[J].机械设计,2008,25(3)：60-62.
[8]胡二乐,杨涛,等.风力叶片纤维带铺放头设计[J].机械设计与制造,2009(5)：32-34.
[9]林福建.自动铺丝束成型的关键技术[J].设计与研究,2005(3)：25-26.
[10]苏玉堂,等.纤维缠绕复合材料结构制造技术[M].中国玻璃钢工业协会,2003.
[11]Bijan Shirinzadeh, Gursel Alici, Chee Wei Foong, GaryCassidy. Fabrication process of open surfaces byrobotic fibre placement. Robotics and Computer-Integrated Manufacturing,2004(20): 17-28.
[12]Pierre Debout, Helene Chanal, Emmanuel Duc. Tool path smoothing of a redundant machine: Application to Automated Fiber Placement. Computer-Aided Design,2011(43):122-132.
[13]Bijan Shirinzadeh, Gary Cassidy, Denny Oetomo, Gursel Alici, Marcelo H. Ang Jr. Trajectory generation for open-contoured structures in robotic Fibre placement. Robotics and Computer-Integrated Manufacturing,2007(23):380-394.
[14]C.D. Rudd, M.R. Turner, A.C. Long, V. Middleton. Tow placement studies for liquid composite moulding, Composites.1999(30):1105-1121.
[15]P. Mattheij, K. Gliesche, D. Feltin.3D reinforced stitched carbon/epoxy laminates made by tailored fibre placement, Composites.2000(31):571-581.
[16]Adriana W. Blom, Mostafa M. Abdalla, Zafer Gurdal. Optimization of course locations in fiber-placed panels for general fiber angle distributions. Composites Science and Technology, 2010(70):564-570.
[17]安鲁陵,许斌.复合材料纤维铺放自动编程技术研究[J].工程设计学报,2005,12(02)：80-84.
[18]韩振宇,邵忠喜,路华,富宏亚.七自由度四丝束纤维铺放机及数控系统的开发[J].材料工程,2009(2)：211-215.
[19]韩振宇,孟庆鑫,路华,富宏亚.新型纤维铺放头的方案设计与实验研究[J].玻璃钢／复合材料,2007(3)：45-47.
[20]邵忠喜,富宏亚,韩振宇.纤维铺放设备机械手臂末端运动轨迹的后置处理技术研究[J].宇航学报,2008(6)：2023-2029.
[21]周焱,安鲁陵,周来水.复合材料自动铺丝路径生成技术研究[J].航空精密制造技术,2006(2)：39-41.
[22]王志辉,郑强.基于PMAC的四轴纤维缠绕机数控系统的设计[J].机械制造,2007(526)：26-28.
[23]俞建峰,周杰.基于运动控制的纤维缠绕机控制系统的设计[J].江南大学学报,2009(2)：159-163.
[24]何江华.玻璃钢缠绕机控制系统设计[D].哈尔滨理工大学硕士学位论文.2009.
[25]陈兴建.数控纤维缠绕张力的模糊PID控制系统研究[D].南京航空航天大学学位论文,2007.
[26]M.A.Lamontia,M.B.Gruber,B.J.Waibel. Conformable Compaction System Used in Automated Fiber Placement of Large Composite Aerospace Structures, USA.2002:30-42.
[27]Daniel L.Automated Tap Placement with In-Site Electron Beam Cure. SAMPE,2000,36(2): 11-33.
[28]Delta Tau Data System,Inc. PMAC PCI Hardware Reference Manual,2003.
[29]Delta Tau Data System, Inc. PMAC2 PCI Hardware Reference Manual,2004.
[30]文小军.风力发电叶片铺放机设计与仿真研究[D].武汉理工大学硕十学位论文,2010.
[31]富宏亚,韩振宇,路华.纤维缠绕/铺带/铺丝成型设备的发展状况[J].航空制造技术,2009(22)：43-46.
[32]王天宇,梁宪珠,杨进军.飞机复合材料构件自动铺丝束铺放典型设备[J].航空制造技术,2008(4)：42-44.
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