面向大型飞机复材壁板的自动铺丝系统集成与协同控制研究

Research on integration and coordinated control of an automated fiber placement (AFP) system for large aircraft composite panels

  • 摘要: 针对目前大型飞机复材壁板在高速铺丝过程中的多变量强耦合与端头质量缺陷问题,研制了一套16丝束自动铺丝(automated fiber placement, AFP)系统。该系统通过引入基于速度前馈的温度自适应控制及基于自适应死区的张力控制算法,评估了多源动态干扰因素,获得了加热功率、执行张力与机床进给速度之间的精准匹配关系,并构建了针对切断重送物理迟滞的自适应时间补偿机制。同时开发了一套总控软件,实现了大尺寸复材构件的高效、高质量自动化铺放。试验结果表明,在500 mm/s的阶跃突变速度下,动态温差被控制在±1.9 ℃内,多路张力稳定在0.4~1.3 N,切送端头绝对误差小于±0.8 mm,完全可以满足实际的高精度成形工艺需求。研究为大型航空复材构件的自动化制造奠定了技术基础。

     

    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.

     

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