大尺寸异形构件碳纤维预成型体立体编织多耦合系统结构与动力学性能优化

Structure reinforced textiles refer to the textiles to be used as skeleton reinforced of composites. The most important category which recognized internationally is 3D braiding fabric preform of carbon fiber. The composites formed by them have special properties of light mass, high strength, high temperature resistance, high cauterization resistance, wave-absorbing and so on. The big and irregular component's 3D braiding fabric preform of carbon fibers are the most potential and high added value industrial textiles, which have strategic significance in the national cusp defense and importance livelihood industry. During 3D braiding high end structure reinforced textiles, there are complex mechanical problems, the carbon fibers are sensitive to tension and stress state, there are complex coupling such as fiber-component, spindle-rail, machine-electricity-load and so on. So 3D braiding machine is a complex multi-coupling and strong coupling system. In this program, the interaction mechanism of multi-coupling system during 3D braiding and the structure optimization and the dynamic optimization of 3D braiding machine have been put forward. Taking the big and irregular component's fabric preform of carbon fiber as the object, research on the mechanical properties and constitutive relations of carbon fiber during 3D braiding, on the precise coordinated trajectory control of multi-spindle and the spindle-rail coupling mechanism, on the precise space trajectory control of mandrel and the dynamic interaction of mandrel-knitting-fiber-spindle coupling system, on the transfer mechanism and the continuous smooth control of carbon fiber's dynamic tension and so on. The research provides support with theory and technology for designing high end 3D braiding machine.

结构增强用纺织品系指作为复合材料增强骨架的纺织品，国际公认的其最重要类别是碳纤维立体编织预成型体，由其成型的复合材料具有轻质、高强、耐高温、耐腐蚀、吸波等特性，而大尺寸异形构件碳纤维立体编织预成型体极具潜力和高附加值，在尖端国防和重要民生领域具有战略意义。高端结构增强用纺织品立体编织过程力学问题复杂，碳纤维对张力和受力状态敏感，存在复杂的纤维-构件耦合、锭-轨耦合、电-机-负载耦合等，立体编织机为复杂的多耦合、强耦合系统。本项目提出立体编织过程多耦合系统相互作用机理、立体编织机结构优化与动力学优化问题，以大尺寸异形构件碳纤维预成型体为对象，研究立体编织过程中碳纤维的力学性能和本构关系、多纱锭运动轨迹精确协同控制及锭-轨耦合机理、芯模空间运动轨迹精确控制及芯模-编织物-纤维-纱锭多耦合系统动态互作用、碳纤维动态张力传递机理及动态张力连续平滑控制等，为设计高端立体编织机提供理论与技术支持。

本项目通过对锭子位置以及运动轨迹的研究，建立了三维编织机锭子排布的数学模型，揭示了多层运动轨道锭子排布原理，解决了三维编织的工艺问题。依据编织产品结构要求，自动完成多层锭子轨道跨任意层数编织的锭子排布和运动路径。同时，通过对多层编织纱锭排布、纱锭运动轨道以及编织机锥齿轮传动系统动力学的研究，建立了编织机主传动系统动力学模型、纱线摩擦力模型，获得了编织机的运动特性和编织过程纱线摩擦力特性，形成了异形变截面三维自动连续编织机动力学设计理论和方法。.本项目针对碳纤维在立体编制过程中张力超限容差小，对受力状态和摩擦磨损非常敏感，极易在径向力、侧向力及摩擦磨损作用下损伤纤维或使纤维脆断等特点，创新研发了大储纱量张力自适应双补偿式锭子，解决了碳纤维三维编织供纱阶段摩擦起毛、输出纱线张力波动大、编织过程储纱量小的共性难题，实现了多层深交编织；研发了锭子编织——机器人牵引精确协同的伺服控制系统，满足了大规模轮系群控及多单元协同控制的精度和响应要求，大幅提高了编织精度、降低了系统能耗。.该项目研制了内环锭子轨道立体编织机、端面锭子轨道三维立体编织机及7轴联动机器人芯模牵引系统，实现了连续自动编织，编织出具有三维非正交结构、空间立体形状、变截面、变密度的大尺寸碳纤玻纤等复合材料预成型体，最大编织截面450×450mm，最大编织半径500mm。该项目研究成果填补了国内三维立体自动编织装备的空白，达到了国际先进水平。