空间构件FW/FP柔性制造技术的研究——计算机控制部分
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摘要
纤维增强复合材料与一般的金属材料相比，具有质轻、高强度、耐腐蚀性、抗冲击性、整体成型容易等优点，在各行各业已经获得普遍的应用，特别是在航空航天工业中。复合材料结构正在逐步取代金属结构，占驻有利地位。
纤维缠绕／纤维铺放技术是加工增强型复合材料成型技术中的一种，其生产装备为机电气一体化设备。欧美发达国家于上个世纪七十年代就开始研究它，已经取得了很大的进展。目前该技术、设备在我国发展尚属起步。因此，对该课题进行研究已经迫在眉睫。该课题的研究能弥补国内有关这方面的空白，对我国的民用工业、特别对于国防工业的发展具有重要的意义。
本课题的研究目标就是在已有五轴数控纤维缠绕机的基础上增加纤维铺放执行机构的计算机控制，研究开发纤维缠绕／纤维铺放机的6-7轴联动的计算机控制系统，实现复杂形体的纤维缠绕／纤维铺放成型。
纤维增强复合材料铺放成型技术是在手工迭层铺放和纤维缠绕工艺的基础上发展起来的一种机械化、自动化成型工艺。在纤维铺放成型技术中，主要采用铺放头机构实现纤维的铺放。该机构包括进料装置、加压装置、剪切装置等。它们使用电机和气缸作为驱动执行元件。纤维缠绕／纤维铺放成型技术的控制系统主要是采用计算机数控技术来实现。
本文主要就是实现对进料装置、加压装置、剪切装置的计算机控制。它包括总线设计、接口设计、系统的总体设计以及软件编制等。总线采用ISA内部总线；接口主要有模拟量输入接口、模拟量输出接口、开关量输入输出接口等，课题分别选用PC-6330D型A／D板卡、基于ISA总线的型号为PCL-728的D／A板卡、型号为IPC-5375的I／O板卡；另外，课题选用了微动式行程开关、压力变送器作为传感元件检测系统，选用继电器、电磁控制换向阀实现对气缸、电机的控制；采用VC++6.0编制控制软件，实现了纤维铺放技术的计算机控制。
通过系统安装、调试证明，该计算机控制系统能够实现纤维铺放过程中的进料、加压、剪切的自动控制，完成一个完整的铺放过程。
Fiber reinforced plastics have used widely in every walk of life, especially in aviation and spaceflight because they have more merits than common metal materials, such as light quality, high intensity and so on.They have replaced metal step by step and hold an advantaged position .
Fiber winding / fiber placement is one of means that we machining fiber reinforced plastics, Its furnishment is the equipment of the combination of mechanism and electron .The developed countries in Occident have researched it and have made progress in 1970'So At present, the development of the technology and the furnishment is inchoate in our country. Therefore, it is very necessitous to research this task. It not only can make up for the vacancy about this area in our country , but also makes a great contribution to the industry and national defense project.
The research goal of the task is to add the equipment of fiber placement controlled by computer in the base of existent five-axes numerical control fiber winding machine, research and empolder the six to seven axes linkage computer control system of the fiber winding / fiber placement machine, and realize fiber winding / fiber placement of complicated form and structure.
The placement molding technology of fiber reinforced plastics has been developed from the bases of filament winding and fiber bespreading .It is a mechanization and automation molding technics. In the technology of fiber placement molding , it is main to use the assembly of placement delivery head. It includes adding means, compaction means, cutting means and so on. They have used the bicycle pump and the motor for the performance setup .The control system of the fiber winding / fiber placement is usual to adapt computer numerical control .
The goal of the paper is to realize the computer numerical control of the adding means, the compaction means and the cutting means. It includes Bus design, interfaces design, system collectivity design and programming. We use ISA Bus. And the interfaces have analog input, analog output and digital input / output. We have used differently cards, such as PC-6330D A/D card, PCL-728 D/A card based ISA Bus, IPC-5375 I/O card and so on. In addition, we select micro-stir switches and pressure sensors as sensor elements to inspect the system and choose relays and induction valves to control the bicycle pump and the motor. We program control software by VC++6.0 and achieve the computer control of fiber placement technology.
It is proved in system fixing and testing that the control system can realize the automation of the movement of adding, compaction and cutting, and complete a whole placement process.
纤维缠绕／纤维铺放技术是加工增强型复合材料成型技术中的一种，其生产装备为机电气一体化设备。欧美发达国家于上个世纪七十年代就开始研究它，已经取得了很大的进展。目前该技术、设备在我国发展尚属起步。因此，对该课题进行研究已经迫在眉睫。该课题的研究能弥补国内有关这方面的空白，对我国的民用工业、特别对于国防工业的发展具有重要的意义。
本课题的研究目标就是在已有五轴数控纤维缠绕机的基础上增加纤维铺放执行机构的计算机控制，研究开发纤维缠绕／纤维铺放机的6-7轴联动的计算机控制系统，实现复杂形体的纤维缠绕／纤维铺放成型。
纤维增强复合材料铺放成型技术是在手工迭层铺放和纤维缠绕工艺的基础上发展起来的一种机械化、自动化成型工艺。在纤维铺放成型技术中，主要采用铺放头机构实现纤维的铺放。该机构包括进料装置、加压装置、剪切装置等。它们使用电机和气缸作为驱动执行元件。纤维缠绕／纤维铺放成型技术的控制系统主要是采用计算机数控技术来实现。
本文主要就是实现对进料装置、加压装置、剪切装置的计算机控制。它包括总线设计、接口设计、系统的总体设计以及软件编制等。总线采用ISA内部总线；接口主要有模拟量输入接口、模拟量输出接口、开关量输入输出接口等，课题分别选用PC-6330D型A／D板卡、基于ISA总线的型号为PCL-728的D／A板卡、型号为IPC-5375的I／O板卡；另外，课题选用了微动式行程开关、压力变送器作为传感元件检测系统，选用继电器、电磁控制换向阀实现对气缸、电机的控制；采用VC++6.0编制控制软件，实现了纤维铺放技术的计算机控制。
通过系统安装、调试证明，该计算机控制系统能够实现纤维铺放过程中的进料、加压、剪切的自动控制，完成一个完整的铺放过程。
Fiber reinforced plastics have used widely in every walk of life, especially in aviation and spaceflight because they have more merits than common metal materials, such as light quality, high intensity and so on.They have replaced metal step by step and hold an advantaged position .
Fiber winding / fiber placement is one of means that we machining fiber reinforced plastics, Its furnishment is the equipment of the combination of mechanism and electron .The developed countries in Occident have researched it and have made progress in 1970'So At present, the development of the technology and the furnishment is inchoate in our country. Therefore, it is very necessitous to research this task. It not only can make up for the vacancy about this area in our country , but also makes a great contribution to the industry and national defense project.
The research goal of the task is to add the equipment of fiber placement controlled by computer in the base of existent five-axes numerical control fiber winding machine, research and empolder the six to seven axes linkage computer control system of the fiber winding / fiber placement machine, and realize fiber winding / fiber placement of complicated form and structure.
The placement molding technology of fiber reinforced plastics has been developed from the bases of filament winding and fiber bespreading .It is a mechanization and automation molding technics. In the technology of fiber placement molding , it is main to use the assembly of placement delivery head. It includes adding means, compaction means, cutting means and so on. They have used the bicycle pump and the motor for the performance setup .The control system of the fiber winding / fiber placement is usual to adapt computer numerical control .
The goal of the paper is to realize the computer numerical control of the adding means, the compaction means and the cutting means. It includes Bus design, interfaces design, system collectivity design and programming. We use ISA Bus. And the interfaces have analog input, analog output and digital input / output. We have used differently cards, such as PC-6330D A/D card, PCL-728 D/A card based ISA Bus, IPC-5375 I/O card and so on. In addition, we select micro-stir switches and pressure sensors as sensor elements to inspect the system and choose relays and induction valves to control the bicycle pump and the motor. We program control software by VC++6.0 and achieve the computer control of fiber placement technology.
It is proved in system fixing and testing that the control system can realize the automation of the movement of adding, compaction and cutting, and complete a whole placement process.
引文
[01] 赵渠森．材料与工艺在“买得起复合材料”中的作用．玻璃钢/复合材料．2000，11：41．
[02] 蒋鞠慧．复合材料加筋壳稳定性研究．玻璃钢/复合材料．2001，2：5
[03] 杜志强，刘士华．FRP 缠绕成型 CAD/CAM 系统研究．玻璃钢/复合材料．2001，3：32
[04] 田晶．纤维缠绕玻璃钢壳体开口补强环的研制．纤维复合材料．2001，18(3)：31
[05] 陈绍杰．先进复合材料的民用研究与发展．高科技纤维与应用．2000，11
[06] 田会方，吴耀楚．4-D 微机控制 FRP 球形容器 FW 线型生成及运动控制方程．武汉工业大学学报．1997，19(3)：57
[07] 张福承．机头雷达罩及其纤维缠绕法．纤维复合材料．2000，17(1)：30
[08] 杨佑发，钟正华．纤维缠绕火箭发动机壳体的非线性稳定．湖南大学学报．1996(02)
[09] 徐再，吴耀楚，田会方．纤维铺放成型技术的研究．玻璃钢/复合材料．2002(5)
[10] 冷兴武．纤维缠绕原理，武汉：武汉工业大学出版社，1990
[11] 冷兴武，王文达，张立国．缠绕工艺．武汉：武汉工业大学出版社，1995，11
[12] 刘亚雄，谢怀勤．复合材料工艺及设备．武汉：武汉工业大学出版社，1993，159
[13] 陈绍杰，复合材料结构修理指南．北京：北京航空工业出版社，2001，11
[14] 陈祥宝，包建文，娄葵阳．树脂基复合材料制造技术．北京：北京化学工业出版社，2000，1：4
[15] 黄发荣，焦扬声，郑安呐．塑料工业手册(不饱和聚酯树脂)．北京：北京化学工业出版社，2001，3：335
[16] 陈祥宝．塑料工业手册(热固性塑料加工工艺与设备)．北京：北京化学工业出版社，2001，1：217
[17] 焦生杰等．工程机械机电液一体化．北京：人民交通出版社，2000
[18] 焦振学．微机数控技术．北京：北京理工大学出版社，2000
[19] 徐元昌．流体传动与控制．上海：同济大学出版社，1998
[20] 任玉田．机床计算机数控技术．北京：北京理工大学出版社，1996
[21] 严爱珍．机床数控原理与系统．北京：机械工业出版社，1999
[22] 冯勇等．现代计算机数控系统．北京：机械工业出版社，1996
[23] 唐仲文等．机电一体化技术手册．北京：机械工业出版社，1999
[24] 王占民．近代液压控制．北京：机械工业出版社，1997
[25] 季维发．机电一体化技术．北京：电子工业出版社，1995
[26] 徐元昌．机械电子技术．上海：同济大学出版社，1995
[27] 熊音斌．VC++6．0程序设计培训教程．北京：清华大学出版社，2002
[28] 朱昆泉，许林发．建材机械工程手册．武汉：武汉工业大学出版社，2000
[29] 徐薇莉，曹柱中，田作华．自动控制理论与设计．上海：上海交通大学出版社，2001，9
[30] 黄开榜，贾延林，王永章．多轴联动多功能微机控制纤维缠绕机控制系统的设计．宇航学报．1997，02
[31] 王亮清，那海涛．JKRC120/800B 型微机数控纤维缠绕机控制软件的研制．宇航材料工艺．1994，24(3)：38
[32] Hawley AV and Douglas M. 53rd Annual Conference On Mass Properties Engineering. SAVE, Long Beach, California, May 1994
[33] W. O. Sunafrank et al. Development of Composites Tape Laying Process for Advanced Fibrous Reinforced Composites Structures. Mar, 1971
[34] Kober J F. The 36th Annual Conference, Reinforced Plastical Composites Institute, The Society of the Plastics Industry. February 1987:16
[35] A. Mills. Automation of carbon fibre preform manufacture for affordable aerospace applications. Composites. 2001, 32(8): 955
[36] R. Cole, A. Johnston and A. Jodoin. Fire Performance and Structural Evaluation of Aircraft Composite Materials. COMPOSITES IN MANUFACTURING. 2001, 17:1
[37] R. E. Allred, T. J. Doak, A. B. Coons and G. C. Newmeister. Tertiary Recyclig of Cured Composite Aircraft Parts. COMPOSITES IN MANUFACTURING. 1997, 13(4):1
[38] Hart Smith LJ. Lessons Learned From The DC-10 Carbon-Epoxy Rudder Program. SAE Aerospace Technology Conference and Exposition. 1986
[39] Sarhadi M. Euriscon. Robotics Comput Aided Manufact. Malaga, Spain.
1994, 11 (4) : 335
[40] Rudd C and Long A. ICAC Glasgow. September 1997
[41] Klein, Allen J. Automated Tape Laying. Advanced Composites. Jan/Feb. 1989
[42] Hercules Incorporated. Fiber Placement , the Key Technology for Affordable High Performance Structure. Jan. 1990
[43] Benson Dexter H , Johnson N and Harris E. Recent Progress in NASA Langley Textile Reinforced Composites Research Programme. Second NASA Advanced Composites Technology Conference. 1992
[44] Hawley AV and Douglas M. 53rd Annual Conference On Mass Properties Engineering. SAVE, Long Beach , California, May 1994
[02] 蒋鞠慧．复合材料加筋壳稳定性研究．玻璃钢/复合材料．2001，2：5
[03] 杜志强，刘士华．FRP 缠绕成型 CAD/CAM 系统研究．玻璃钢/复合材料．2001，3：32
[04] 田晶．纤维缠绕玻璃钢壳体开口补强环的研制．纤维复合材料．2001，18(3)：31
[05] 陈绍杰．先进复合材料的民用研究与发展．高科技纤维与应用．2000，11
[06] 田会方，吴耀楚．4-D 微机控制 FRP 球形容器 FW 线型生成及运动控制方程．武汉工业大学学报．1997，19(3)：57
[07] 张福承．机头雷达罩及其纤维缠绕法．纤维复合材料．2000，17(1)：30
[08] 杨佑发，钟正华．纤维缠绕火箭发动机壳体的非线性稳定．湖南大学学报．1996(02)
[09] 徐再，吴耀楚，田会方．纤维铺放成型技术的研究．玻璃钢/复合材料．2002(5)
[10] 冷兴武．纤维缠绕原理，武汉：武汉工业大学出版社，1990
[11] 冷兴武，王文达，张立国．缠绕工艺．武汉：武汉工业大学出版社，1995，11
[12] 刘亚雄，谢怀勤．复合材料工艺及设备．武汉：武汉工业大学出版社，1993，159
[13] 陈绍杰，复合材料结构修理指南．北京：北京航空工业出版社，2001，11
[14] 陈祥宝，包建文，娄葵阳．树脂基复合材料制造技术．北京：北京化学工业出版社，2000，1：4
[15] 黄发荣，焦扬声，郑安呐．塑料工业手册(不饱和聚酯树脂)．北京：北京化学工业出版社，2001，3：335
[16] 陈祥宝．塑料工业手册(热固性塑料加工工艺与设备)．北京：北京化学工业出版社，2001，1：217
[17] 焦生杰等．工程机械机电液一体化．北京：人民交通出版社，2000
[18] 焦振学．微机数控技术．北京：北京理工大学出版社，2000
[19] 徐元昌．流体传动与控制．上海：同济大学出版社，1998
[20] 任玉田．机床计算机数控技术．北京：北京理工大学出版社，1996
[21] 严爱珍．机床数控原理与系统．北京：机械工业出版社，1999
[22] 冯勇等．现代计算机数控系统．北京：机械工业出版社，1996
[23] 唐仲文等．机电一体化技术手册．北京：机械工业出版社，1999
[24] 王占民．近代液压控制．北京：机械工业出版社，1997
[25] 季维发．机电一体化技术．北京：电子工业出版社，1995
[26] 徐元昌．机械电子技术．上海：同济大学出版社，1995
[27] 熊音斌．VC++6．0程序设计培训教程．北京：清华大学出版社，2002
[28] 朱昆泉，许林发．建材机械工程手册．武汉：武汉工业大学出版社，2000
[29] 徐薇莉，曹柱中，田作华．自动控制理论与设计．上海：上海交通大学出版社，2001，9
[30] 黄开榜，贾延林，王永章．多轴联动多功能微机控制纤维缠绕机控制系统的设计．宇航学报．1997，02
[31] 王亮清，那海涛．JKRC120/800B 型微机数控纤维缠绕机控制软件的研制．宇航材料工艺．1994，24(3)：38
[32] Hawley AV and Douglas M. 53rd Annual Conference On Mass Properties Engineering. SAVE, Long Beach, California, May 1994
[33] W. O. Sunafrank et al. Development of Composites Tape Laying Process for Advanced Fibrous Reinforced Composites Structures. Mar, 1971
[34] Kober J F. The 36th Annual Conference, Reinforced Plastical Composites Institute, The Society of the Plastics Industry. February 1987:16
[35] A. Mills. Automation of carbon fibre preform manufacture for affordable aerospace applications. Composites. 2001, 32(8): 955
[36] R. Cole, A. Johnston and A. Jodoin. Fire Performance and Structural Evaluation of Aircraft Composite Materials. COMPOSITES IN MANUFACTURING. 2001, 17:1
[37] R. E. Allred, T. J. Doak, A. B. Coons and G. C. Newmeister. Tertiary Recyclig of Cured Composite Aircraft Parts. COMPOSITES IN MANUFACTURING. 1997, 13(4):1
[38] Hart Smith LJ. Lessons Learned From The DC-10 Carbon-Epoxy Rudder Program. SAE Aerospace Technology Conference and Exposition. 1986
[39] Sarhadi M. Euriscon. Robotics Comput Aided Manufact. Malaga, Spain.
1994, 11 (4) : 335
[40] Rudd C and Long A. ICAC Glasgow. September 1997
[41] Klein, Allen J. Automated Tape Laying. Advanced Composites. Jan/Feb. 1989
[42] Hercules Incorporated. Fiber Placement , the Key Technology for Affordable High Performance Structure. Jan. 1990
[43] Benson Dexter H , Johnson N and Harris E. Recent Progress in NASA Langley Textile Reinforced Composites Research Programme. Second NASA Advanced Composites Technology Conference. 1992
[44] Hawley AV and Douglas M. 53rd Annual Conference On Mass Properties Engineering. SAVE, Long Beach , California, May 1994