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CN-122008599-A - Automatic removing and processing method and system for damage repair area of continuous fiber composite material

CN122008599ACN 122008599 ACN122008599 ACN 122008599ACN-122008599-A

Abstract

The invention discloses a processing method and a system for automatically removing a damaged repair area of a continuous fiber composite material, and belongs to the field of repair and remanufacturing of continuous fiber composite materials. The method first secures the workpiece, discretizes the damaged area and plans the tool path. The system sequentially removes the surface paint layer and the fiber layer, namely, firstly processing the paint layer, and then carrying out layering cutting by visually detecting the fiber direction. After each layer of fiber is removed, the direction is compared by a camera, if the direction is unchanged, the current layer is continuously processed, otherwise, the path is switched until all the fibers are removed. Finally, parameters are recorded, and the process is ended. The method realizes accurate layering processing based on visual feedback, has strong universality, can be suitable for automatic removal of free-form surface composite materials and metal structures by adjusting configuration, and has good application prospect in the field of aviation external field repair.

Inventors

  • LU BINGHENG
  • TANG YONGKAI
  • FAN JUNLING
  • Jiao ting
  • YANG PENGFEI

Assignees

  • 西安增材制造国家研究院有限公司
  • 中国飞机强度研究所

Dates

Publication Date
20260512
Application Date
20260119

Claims (10)

  1. 1. The automatic removing and processing method for the damage repair area of the continuous fiber composite material is characterized by comprising the following steps of: s1, a composite material structural member (11) to be processed is arranged below a multi-degree-of-freedom motion system (3) through a vacuum chuck assembly (2), a damaged defect area (10) is formed in the composite material structural member (11), and a high-speed cutting tool (13) and a photographing camera (6) are arranged in the multi-degree-of-freedom motion system (3); S2, decomposing a damaged defect area (10) of the composite structural member (11) into a plurality of discrete points to obtain coordinates of each discrete point, and setting the distance between a high-speed cutting tool (13) and the damaged defect area (10) as a reserved mounting distance by a multi-degree-of-freedom motion system (3); S3, calculating coordinates of discrete points of a damage defect area (10) for removing the thickness of the paint layer; s4, collecting height parameters of each discrete point in the damaged defect area (10), and combining the thickness of the paint layer to obtain processing data point coordinates of each discrete point in the damaged defect area (10) with the thickness of the paint layer removed; S5, the multi-degree-of-freedom motion system (3) drives the high-speed cutting tool (13) to process the surface paint layer of the damaged defect area (10) in a linear interpolation mode according to the processing data point coordinates, and the surface paint layer is removed; S6, photographing the damaged defect area (10) by using a photographing camera (6) to obtain the laying direction of the fiber layer, and obtaining fiber cutting data coordinate points based on the processing data point coordinates of each discrete point obtained in the S4 and the thickness of the laid fiber layer; s7, the high-speed cutting tool (13) processes the fiber layer in the damaged defect area (10) according to the coordinate point of the fiber cutting data; S8, photographing a damaged defect area (10) without removing the surface fiber layer through a photographing camera (6), obtaining the laying direction of the fiber layer, comparing the laying direction of the fiber layer with the laying direction of the fibril layer obtained in the step S6, if the two are consistent, repeating the step S7 until the fiber layer in the same direction is removed, otherwise, executing the step S9; s9, the computer control system (1) calls a processing path CAM code of the direction of the next fiber layer, and repeatedly executes S6-S8 to finish the processing of the next fiber layer; S10, repeatedly executing S9 until all fiber layers in the damaged defect area (10) are removed; s11, photographing the damaged defect area (10) through a photographing camera (6), obtaining and storing a complete patch parameter image of the damaged processing area (10), and finishing processing.
  2. 2. The method for automatically removing and processing the damaged repair area of the continuous fiber composite material according to claim 1, wherein in S2, the composition path of the damaged defect area (10) processing pattern is composed of line segments, and coordinates of each discrete point are obtained after the line segments are subjected to discrete processing.
  3. 3. The automatic removal processing method for damaged repair areas of continuous fiber composite material according to claim 1, wherein in S2, the multi-degree-of-freedom motion system (3) moves the high-speed cutting tool (13) to the highest point of the damaged defect area (10), and the coordinates of the thickness of the removed paint layer at the highest point are used as the processing starting point.
  4. 4. The method according to claim 1, wherein S5 is performed on the surface layer in a path from the maximum envelope size to the minimum envelope size.
  5. 5. The method for automatically removing and processing the damaged repair area of the continuous fiber composite material according to claim 1, wherein in the step of S6, half of the number of photos is processed and fitted in the process of obtaining the laying direction of the fiber layer, so as to obtain the laying direction of the fiber layer.
  6. 6. The automatic removal processing method for damaged areas of continuous fiber composite material according to claim 1, wherein in S6, the calculation formula of the fiber cutting coordinate point is: , Wherein, the , And The coordinates of the discrete points are measured separately, Is the thickness of a single-layer fiber layer, The thickness of the paint layer is set to be equal to the thickness of the paint layer, The Z-height relative to the fiber surface is typically 0.2mm to 0.4mm thick for the data points.
  7. 7. The method according to claim 1, wherein the fiber layer processing path for the damaged defective region (10) is a path gradually reduced from the maximum outer dimension or gradually enlarged from the minimum dimension in the process of S7.
  8. 8. The method for automatically removing and processing the damaged repairing area of the continuous fiber composite material according to claim 1, wherein dust is collected by negative pressure in the process of S2-S9.
  9. 9. The automatic removal processing method for damaged areas of continuous fiber composite material according to claim 1, wherein the width of each processing is the width of a high-speed cutting tool (13) in the process of S2-S9.
  10. 10. The automatic continuous fiber composite damage repair area removing device for realizing the processing method according to claim 1 is characterized by comprising a multi-degree-of-freedom moving system (3), wherein the multi-degree-of-freedom moving system (3) is arranged on a composite structural member (11) through a vacuum chuck assembly (2), the lower end of the multi-degree-of-freedom moving system (3) is connected with a high-speed rotating main shaft (4), the front end of the high-speed rotating main shaft (4) is provided with a negative pressure collecting cover (5) and a high-speed cutting tool (13), the high-speed cutting tool (13) is arranged in the negative pressure collecting cover (5), a photographing camera (6), an ultrasonic thickness gauge (9) and a laser distance meter (7) are arranged on the high-speed rotating main shaft (4), and the negative pressure collecting cover (5) is communicated with a dust collector (8-1) through a dust collecting pipeline (8-2); the multi-degree-of-freedom motion system (3), the vacuum chuck assembly (2) and the dust collector (8-1) are all connected with the computer control system (1) through electric signals.

Description

Automatic removing and processing method and system for damage repair area of continuous fiber composite material Technical Field The invention belongs to the field of continuous fiber composite material repair and remanufacturing, and particularly relates to a continuous fiber composite material damage repair area automatic removal processing method and system. Background In the aerospace field, carbon fiber composites are critical to achieving aircraft weight reduction. The application of the material greatly reduces the weight of the aircraft, effectively reduces the fuel consumption and the operation cost, simultaneously improves the structural strength and the service life of the aircraft, and enhances the safety and the comfort of the flight. However, carbon fiber composite materials also have certain challenges in aviation application, the external field flying environment facing aviation aircrafts, especially military aviation equipment is relatively bad, the aircraft is easy to collide with environment foreign objects in the high-speed flying and take-off and landing processes, and meanwhile, the aircraft composite material structure is possibly damaged due to mechanical load and environmental factors in the use process. When the damage is not treated in time, the damage is gradually expanded due to the subsequent load action, so that the overall strength is greatly reduced. For example, an impact damage of 5mm diameter, if not repaired, may reduce the stiffness of the material by more than 30% under cyclic loading. Carbon fibers bear the main load (about 90% or more) of the CFRP structure, and once the fibers break or interlaminar separation occurs, the damaged defective areas cannot effectively transmit stress, and the load concentration in adjacent areas can be caused. For example, if not repaired, tiny delamination of the aircraft wing skin may cause cracks to propagate in the fiber direction during flight due to repeated aerodynamic loading, ultimately affecting the overall load carrying capacity of the wing, and even causing structural failure. Unlike welding or riveting repair of metal parts, the repair mode of the damaged defective area by the carbon fiber composite material at present is mainly maintained by processes such as cementing patches, the structural strength can be achieved by the maintenance mode (more than 85% of the original performance can be recovered under ideal conditions), the repairing process of the cementing patches is to polish and dig original materials of the damaged defective area according to certain design rule requirements, the conventional circular stepped structure, continuous conical structure and special square repair structure are carried out, the structural design can effectively reduce stress concentration, the thickness is transited according to the step (the thickness difference of each step is less than or equal to 0.5mm, the fiber design direction of the patches is preferably consistent with the thickness of fibers of each layer of paving angle), the steps of (1) visual inspection and professional ultrasonic detection are carried out on the damaged defective area, the damaged defective area is determined, and (2) the materials for removing the damaged defective area of continuous fibers of a flyer are polished according to the design rule requirements of the repair process, the material removal of the damaged defective area of the flyer is carried out by manual fiber, the manual fiber has the polishing requirements, the polishing requirements and the special performance is guaranteed, the safety and the safety performance of the repair system is guaranteed by the special-type of the special-shaped fiber polishing structure is guaranteed, the special-type fiber polishing requirements are met, the safety requirements are met by the requirements of the safety and the performance of the repair process are met, and the safety requirements are well-safe and the safety and the performance are guaranteed by the safety and the performance of a special-oriented operation, the polishing machine not only can get rid of the problems of low precision, low efficiency, dependence on talents with professional skills and the like of the aircraft aviation equipment damage defect area depending on manual polishing, but also can avoid harm of fiber dust generated by polishing and removal to the health of operators. Disclosure of Invention The invention aims to overcome the defects of the prior art, and provides a processing method and a processing system for automatically removing a damaged repair area of a continuous fiber composite material, so as to solve the problems that the damaged repair area of an aircraft and aviation equipment in the prior art depends on manual polishing, has low precision and low efficiency, depends on talents with professional skills and the like, and fiber dust generated by polishing and removing is easy to damage the body health of operators