The Design Of Automatic Preforming System For Composite Battery Box

With the problem of automobile exhaust pollution and energy shortage becoming more and more serious,the use of electric vehicles is a world-recognized solution,and its endurance has become the standard by which electric cars are measured.The b attery quality of electric vehicles accounts for 1/3?1/5 of the quality of the whole vehicle,which takes up a lot of space.As the carrying and protecting device of the battery,the battery box is mostly made of metal material,which results in the heavy of the car and affects the use efficiency of the battery.Continuous fiber reinforced composite products formed by prepreg molding process have the advantages of light weight,corrosion resistance,high specific strength and so on,which can be used in the manufacturing of composite battery box.However,the direct stacking of single layer prepreg in the production process will lead to local accumulation,tearing and stratification of products,and affecting product quality.Therefore,it is necessary to pre-press forming before the multi-layer pre-prepreg molding.The dissertation mainly studies the preforming process of composite battery box,and designs the automatic preforming system of composite battery box.The dissertation analysis the preforming process of composite battery box,and the unfolding algorithm and pre-pressing method of preform are mainly studied.For the unfolding calculation of fabric preform,the finite element inverse approach is used as unfolding algorithm,and the solution obtained by arc length mapping method is used as the initial solution.Using ABAQUS,the iterative equation is solved,and the unfolding program of finite element inverse algorithm is written,which realized the unfolding of fabric preform.In order to study the pre-pressing method of the preform,the software pre-pressing process of the pre-compression method is firstly carried out,and the shortage of the overall pre-pressing method is found.Then the step-by-step pre-press forming is pr oposed and the pre-press forming optimization direction model is established.Calculate th e optimal direction of the step-by-step pre-press forming,and finally comp,lete the design of the preform pre-pressing process.Design the composite battery box automatic preforming system,control system developed by the Visual Studio 2013 PC interface,combined with the finite element inverse algorithm is a slick implementation of a real-time,the preforming body with TIA Portal V15 write the Siemens S7-1200 PLC under a machine program,the program divides the modular implement the real-time communication of the PC and each location and control,completed on the system of preforming design.The automatic preforming system for composite battery box designed in the dissertation can realize a variety of models and sizes of battery box shell expansion,and according to the expansion trajectory for coutting of prepreg.The design of step-by-step pre-press forming realizes multi-layer prepreg fast,high-quality,high-efficiency pre-pressing molding,and realizes the automatic production of the pre-forming body of the composite battery box,and improves the production efficiency and quality.