Abstract:
Aiming at the multivariable strong coupling and end-placement quality defects during the high-speed automated fiber placement (AFP) process of large aircraft composite panels, a 16-tow AFP system was developed. By introducing a velocity feedforward-based temperature adaptive control and an adaptive dead-zone-based tension control algorithm, this system evaluated multi-source dynamic interference factors, obtained an accurate matching relationship among heating power, execution tension, and machine feed rate, and constructed an adaptive time compensation mechanism aiming at the physical delay of cutting and re-feeding. Meanwhile, a master control software was developed, achieving efficient and high-quality automated placement of large-size composite components. Experimental results show that under a step-change speed of 500 mm/s, the dynamic temperature difference is controlled within ±1.9 ℃, the multi-channel tension is stabilized at 0.4-1.3 N, and the absolute error of the cutting and feeding ends is less than ±0.8 mm, which fully meets the practical requirements of high-precision molding processes. This lays a solid technological foundation for the automated manufacturing of large aviation composite components.