【作者】 许家忠；

【导师】 尤波；

【作者基本信息】 哈尔滨理工大学 ， 机械制造及其自动化， 2007， 博士

【摘要】 二十世纪六十年代美国首先研制出高压玻璃钢管道,并替代钢管用于石油集输管路,取得了良好的经济效益和社会效益。我国在三次采油的初期从国外引进高压玻璃钢管,以解决聚合物对钢管的腐蚀问题。为打破国外垄断,填补国内空白,开发具有自主知识产权的高压玻璃钢管生产线就成为我国玻璃钢管行业迫切需要解决的课题。目前,我国生产高压玻璃钢管的方法是用三台独立的设备进行管道缠绕,固化和脱模,采用外固化工艺进行管道固化,这增加了设备成本和生产成本,而且管道固化效率低、质量差。而内加热式固化则是将浸渍树脂的纤维缠绕在可加热的金属芯模外面,模腔中的热能通过金属管壁可直接传给纤维树脂层,这种工艺可极大地提高固化效率和质量。本文以传统的高压玻璃钢管生产技术为基础,将蒸汽加热芯模技术引入到高压玻璃钢管固化工艺,研制了仅用一台机床就能完成高压玻璃钢管缠绕、固化和脱膜三道工序的制造系统。该系统将传统的缠绕和脱模设备合为一体,采用内部可通饱和水蒸汽,冷却水和压缩空气的中空芯轴实现管道的缠绕、内加热固化、冷却和吹扫工艺。为深入研究复合材料固化成型时内部变化历程,分析其机理,本文针对玻璃钢管固化中同时存在且相互联系的四方面历程:热化学历程、纤维运动历程、气泡活动历程和应力应变历程进行了分析,根据四方面历程建立了四个模型。热化学模型描述管道固化过程中温度、固化度和固化反应速率的关系及其变化;纤维运动模型描述固化过程中纤维的张力变化、运动状态和各时刻的位置;应力模型给出管体内的应力和应变的分布;气泡活动模型描述了固化过程中管体内气泡的形成、变化和运动机理。这些模型为科学地设计和优化玻璃钢管道缠绕和固化工艺提供了理论依据。固化工艺曲线的选择和设计是影响管道质量的重要因素,但是管道固化过程涉及到热传导和放热性化学反应两个方面,是一个复杂的耦合过程。本文根据建立的热化学模型,采用有限元法实现了管道固化过程中温度和固化度的分布及其变化规律的数值模拟研究,采用质量集中技术提高求解的精度和稳定性,采用自适应时间步控制提高求解效率。以有限元软件ANSYS和APDL为平台开发了管道固化过程的数值模拟程序,对高压管道固化过程进行了数值模拟和分析,为固化制度的设计提供了一种有效的分析工具。缠绕工艺方面提出了基于电子齿轮的控制方式实现缠绕机的同步运动控制,该控制方式将传统的数控缠绕机的两轴伺服控制简化为单轴伺服跟踪控制。设计了基于DSP和CPLD的能实现变齿轮比控制的位置同步运动控制器。采用自适应模糊PID控制策略实现小车跟踪主轴的同步运动控制,基于MATLAB的仿真表明,与常规PID控制器相比较,模糊PID控制器能提高控制系统的鲁棒性和动静态性能。本课题研制的内加热式高压玻璃钢管生产线已应用于大庆汉维长垣高压玻璃钢管道有限公司,取得了良好的应用效果。对两种不同工艺生产的管道性能对比试验表明:内固化生产的管道性能优于外固化管道,内固化管的弹性极限比外固化管提高了8.12%,爆破压力提高了8.50%。实践证明,内固化工艺实现了高压玻璃钢管快速、高效的工业化制造,结束了我国不能自主生产符合美国API标准的高压玻璃钢管道的历史。最后,作者对全文工作进行了总结,并提出了今后需进一步研究的内容。更多还原

【Abstract】 In the 1960s, the high-pressure FRP pipe was first developed in the United States. It soon took the place of the steel tube to be applied in the technological pipe line of petroleum collection and transportation, which achieved great economic and social benefits. The high pressure FRP pipe was introduced to China in the early years of three oil extraction to solve the steel tube corrosion problem caused by polymer. In order to break the international monopolization and fill in the blank of this field in China, designing the product line of high pressure FRP pipe with independent intellectual property right is becoming an urgent task for our FRP pipe industry.At present, three independent pieces of equipment are used to carry through winding, curing and extraction of FRP pipe. The external heating curing technique is used to cure the pipe, which increases the cost of equipment and production. In addition, the process of curing in the oven has many disadvantages like the low heat conduction efficiency and poor curing quality. The advanced internal heating curing technique adopts the method of winding the metal mandrel with the fiber and resin layers which can be heated inside. The heat energy in mandrel cavity can transfer to winding fiber layers directly through the metal pipe. By this way the curing efficiency and quality are improved greatly. In this paper the high pressure FRP pipe manufacturing system which adopts internal heating curing technique is designed, and the theoretical analysis and systemic study of the key technologies of winding and curing of FRP pipe are also conducted.Based on the traditional production technology of high pressure FRP pipes, the technology of heating the mandrel by steam is introduced into the curing process of FRP pipe, and the first high pressure FRP pipe production system in our country which only one machine tool is used to perform three processes of winding, curing and extraction is designed. This system integrates the traditional winding and extraction machines into one machine tool, and the hollow mandrel in which saturated steam, cooling water and compressed air can circulate is used to accomplish the winding, curing, cooling and sweeping.In order to study the internal course and analysis its mechanism of FRP pipe curing process, the cocurrencing and interrelating four courses during cure process are analyzed. They are chemical principle, the resin motion principle, the void action principle and the stress principle. Four mathematical models of curing processes of FRP pipe from four aspects are built. The thermal chemical model describes the relations of temperature and curing rate. The fiber motion model describes the tension variation, motion state and position of fiber in the process. The stress model describes the distribution of the stress and the strain in the pipe. The air hole movement model describes the generation, variation and movement of air hole inside the pipes. These models provide theoretic bases of scientifically design and optimize winding and curing process of FRP pipe.The selection and design of curing process curves is important factor that affect the quality of FRP pipe. The curing process of epoxy FRP pipe involves the heat conduction, thermosetting chemical reaction and the interaction between them, which is a complex coupling process. A finite element method is employed to study the distribution and change principle of temperature and curing degree during the cure process of FRP pipe. The lumped-mass approach is adopted to improve calculation precision, and the adaptive time step control to improve calculation efficiency. Based on the finite element software ANSYS and APDL the numerical simulation program of FRP pipe is developed. Curing process numerical simulation and analysis of high pressure FRP pipe is conducted, which is an effective way of designing the curing curve of FRP pipe.The control mode of electronic-gearing is proposed to realize winding synchronous motion control, which simplify the two axis servo control of traditional numerical control winding machine into one axis servo tracking control. Based on DSP and CPLD, the position synchronous motion controller which can perform none-uniform speed ratio control is developed. The control strategy of parameters self-tuning fuzzy PID is adopted to realize synchronous motion control. Simulation based on MATLAB shows that the fuzzy-PID controller can improve the robustness, the dynamic and static performance of the control system compared with ordinary PID controller. The internal heating curing high pressure FRP pipe product line developed in this paper has been applied in Daqing Hanwei Changyuan FRP Pipe Inc. and proves to be successful. The performance comparison test of pipelines manufactured by two different processes shows that the performance of the pipes manufactured by internal heating curing process is better. The elastic limit is 8.12% higher and the bursting pressure is 8.5% higher than the pipes manufactured by the external heating curing process. It proves that the internal heating curing process has achieved speediness and high efficiency in industrialized manufacturing of epoxy FRP pipe. It ends the history that we can’t manufacture high pressure FRP pipe that agree with American API standard by ourselves.Finally, all the work in this paper is summarized and some further investigation contents are also proposed.更多还原