CN-121985436-A - Intelligent composite material heating system for realizing low-temperature uniform solidification

CN121985436ACN 121985436 ACN121985436 ACN 121985436ACN-121985436-A

Abstract

The invention discloses an intelligent composite material heating system for realizing low-temperature uniform solidification, which comprises a uniform planar composite material heating actuator and an industrial edge computing controller, wherein a multi-layer functional material of the heating actuator is formed into a flexible whole by hot-pressing and compounding, and is divided into a plurality of independent circuit partitions, and a film temperature control sensor is embedded in each partition. The controller runs an adaptive control algorithm, and the flow comprises system self-learning and model identification, partition adaptive control and global thermal field collaborative equalization and environmental disturbance feedforward compensation. The heating system realizes high-uniformity temperature control within +/-1.0 ℃ of a large heating area in low-temperature curing below 85 ℃ through the combination of planar uniform heat sources and zonal intelligent balanced control, has high anti-interference capability and obviously reduced energy consumption, and powerfully supports high-quality low-temperature curing manufacture of composite materials, wherein steady-state precision is within +/-0.3 ℃.

Inventors

TANG SHAOCHUN
LU JIAQI
YANG GUANGJIE
CHEN CHAO
ZHANG WANJUAN
WU YAWEN

Assignees

南京大学
中材科技（酒泉）风电叶片有限公司
江苏节霸新能源材料有限公司

Dates

Publication Date: 20260505
Application Date: 20260123

Claims (8)

1. An intelligent heating system for realizing low-temperature uniform curing of composite materials, comprising: The heating actuator comprises a bionic outer protective layer, a conductive heating layer, a gradient heat-insulating layer, an insulating layer and an outer protective layer which are sequentially laminated from one side close to a working surface to one side far away from the working surface, and the heating actuator is compounded into a flexible whole through hot pressing; The heating actuator is divided into a plurality of independent circuit partitions configured according to the size and uniformity requirements of a heating area, a plurality of thin film temperature control sensors are uniformly distributed in each partition, and the sensors are packaged between the conductive heating layer and the gradient heat-insulating layer before lamination and compounding; The industrial edge computing controller is used for running the self-adaptive control algorithm and is connected with the independent circuit partitions, and each independent partition is provided with an independent control driving module; the control flow of the industrial edge computing controller comprises the following steps: S1, self-learning and model identification of a system, namely, after first power-on, sequentially applying step signals to the independent circuit partitions, recording a heating curve, automatically acquiring thermal response parameters of each partition through model fitting, and storing the thermal response parameters; S2, partitioning self-adaptive control and global thermal field collaborative equalization, wherein each partition dynamically adjusts PID control parameters to independently control according to the current temperature deviation and the deviation change rate through a fuzzy rule; meanwhile, a global temperature field map is generated based on all sensor data, when the maximum temperature difference between the partitions exceeds a set threshold value, an equalization algorithm is triggered, PID output of a high-temperature region is reduced, and feedforward compensation is applied to the low-temperature partition; And S3, environmental disturbance feedforward compensation, namely monitoring the change of the environmental temperature, and generating a feedforward compensation quantity according to a preset compensation curve to be overlapped to the control output of all the subareas when the environmental temperature is reduced to exceed a set value in unit time so as to offset heat loss in advance.
2. The intelligent heating system for the composite material for realizing low-temperature uniform curing according to claim 1, wherein the bionic external protective layer is of a composite rough structure of micro pits and nano protrusions, and a perfluoroalkyl silicon low-surface energy coating with a nanoscale thickness is grafted on the bionic external protective layer.
3. The intelligent heating system for the composite material for realizing low-temperature uniform curing according to claim 1, wherein the conductive heating layer is a polyimide film serving as a substrate film, and a carbon nanotube and graphene mixed network is formed on the surface of the polyimide film substrate film through a transfer process, and the sheet resistance of the conductive heating layer is 3.5-4.0 Ω/sq.
4. The intelligent heating system for the composite material capable of realizing low-temperature uniform curing according to claim 1, wherein the gradient heat-insulating layer is formed by compounding a plurality of layers of SiO 2 aerogel composite felts with different densities through hot pressing, the densities are distributed in a gradient manner and range from 80kg/m 3 to 180 kg/m 3 , and the thickness of the gradient heat-insulating layer is 3.0+/-0.2 mm.
5. An intelligent composite heating system for effecting low temperature uniform cure as recited in claim 1, wherein said uniform planar composite heating actuator has a weight per unit area of no greater than 1.8 kg/m 2 .
6. The intelligent heating system for low-temperature uniform curing of composite materials according to claim 1, wherein in the step S2, the dynamic adjusting PID control parameter is specifically that an actual effective value Kp_effective is calculated according to a dynamic weight coefficient K_w output by a fuzzy rule base, and a calculation formula is Kp_effective=Kp_base×K_w, wherein Kp_base is a preset basic value.
7. An intelligent heating system for a composite material for achieving low-temperature uniform curing according to claim 1, wherein in step S2, the set threshold is 1.5 ℃, and the feedforward compensation amount is +0.8 ℃ temporarily added to the temperature set value of the low-temperature zone.
8. An intelligent heating system for composite materials to achieve low temperature uniform curing according to claim 1, wherein in step S3, the unit time is 10 minutes, the set point is 3 ℃, and the amount of feedforward compensation generated is equivalent to the control output increment required to adjust the temperature set point of each zone by 0.5 ℃ as a whole.

Description

Intelligent composite material heating system for realizing low-temperature uniform solidification Technical Field The invention relates to the technical field of composite material preparation, in particular to an intelligent composite material heating system for realizing low-temperature uniform solidification. Background In the manufacture of high-end composite materials, curing processes are being developed toward medium and low temperatures, such as from above 120 ℃ to below 85 ℃ in the conventional art, in order to reduce internal residual stresses, improve mechanical properties and reduce energy consumption. However, the reduction of curing temperature places near-critical demands on the temperature uniformity and control accuracy of the heating system, making current conventional heating and temperature control techniques very challenging. At present, a silica gel heating blanket based on a metal heating wire is commonly adopted in the industry, and is matched with a wide-range universal PID temperature controller to carry out solidification heating. Such heating systems, when applied to low temperature curing scenes, expose the following inherent drawbacks: 1) The problem of low-temperature uniformity trap is that the traditional metal heating wire is a linear heat source, the heating power density is low under low-temperature setting, the influence of environmental heat dissipation is relatively increased, the surface of the heating blanket is seriously uneven in a stripe shape, and the temperature difference is high by Yu ℃. The resin is extremely sensitive to temperature at low temperature, and the non-uniformity can directly lead to different curing reaction rates of all parts of the component, so that partial curing degree deficiency or performance difference is caused, and the partial curing degree deficiency or performance difference becomes a serious quality hidden trouble. 2) The problem of insufficient control precision in the low-temperature zone is that the general temperature controller has poor relative control precision in the low-temperature zone near 85 ℃ under the design of wide range (such as 0-300 ℃), is easily influenced by small disturbance such as environmental temperature fluctuation, workshop air flow and the like, is difficult to realize stable control within +/-1 ℃, and has poor process repeatability. 3) The system has no global thermal field management capability, and the existing system generally treats the whole heating area as a single homogeneous object to control, so that the problems of uneven heat capacity and asymmetric heat loss of a large-sized component caused by structural differences and geometric shapes can not be solved. Therefore, the prior art constitutes a technical contradiction that the reduction of the curing temperature is beneficial to improving the performance and saving energy of products in theory, but the traditional heating and control technology can not provide a uniform and stable thermal field at low temperature, so that the technology is forced to return to the old way with high energy consumption and high stress, and the development of the advanced manufacturing technology of the composite material is severely restricted. Disclosure of Invention The embodiment of the application solves the problems of poor thermal field uniformity, insufficient control precision and no global thermal field management capability of a composite material low-temperature curing process in the prior art by providing the intelligent heating system for the composite material for realizing low-temperature uniform curing, and realizes the technical effects of high uniformity and high-precision temperature control on low-temperature curing heating of a large-sized component under a low-temperature condition by combining a planar uniform heating actuator with an intelligent control system with self-learning, partition cooperation and feedforward compensation functions. The embodiment of the application provides an intelligent heating system for a composite material for realizing low-temperature uniform solidification, which comprises the following components: The heating actuator comprises a bionic outer protective layer, a conductive heating layer, a gradient heat-insulating layer, an insulating layer and an outer protective layer which are sequentially laminated from one side close to a working surface to one side far away from the working surface, and the heating actuator is compounded into a flexible whole through hot pressing; The heating actuator is divided into a plurality of independent circuit partitions configured according to the size and uniformity requirements of a heating area, a plurality of thin film temperature control sensors are uniformly distributed in each partition, and the sensors are packaged between the conductive heating layer and the gradient heat-insulating layer before lamination and compounding; The industrial edge computing controller