碳纤维增强复合材料安全关键部件的径向编织自动化成型研究

Research on Automated Radial Braiding Forming of Carbon Fiber Reinforced Composite Safety-Critical Components

摘要: 在汽车工业向电动化、智能化转型背景下，轻量化是解决续航里程焦虑、提升整车能效及动态性能的核心路径，碳纤维增强复合材料(CFRP)是实现目标的关键材料。本文聚焦两类对结构可靠性要求高的CFRP关键部件：轮圈与高压储氢气瓶。轮圈轻量化对车辆NVH和操控稳定性影响大，储氢气瓶结构完整性关乎整车安全。但传统手工叠层工艺效率低、质量一致性差，制约了高性能复合材料部件规模化应用。本文从高级研发工程师视角，剖析碳纤维轮圈市场驱动力与制造瓶颈，阐述复合材料径向编织自动化预成型技术原理与优势，结合轮圈开发实例，探讨该技术作为平台化制造工艺在推动安全关键部件产业化中的应用潜力与未来挑战，为探究复合材料部件失效机理与防护技术提供制造端参考。

Abstract: Against the backdrop of the automotive industry’s transition toward electrification and intelligence, lightweighting has emerged as a core pathway to address range anxiety, enhance vehicle energy efficiency, and improve dynamic performance. Carbon fiber reinforced composites (CFRP) serve as a critical material in achieving these goals. This study focuses on two types of CFRP safety-critical components with high reliability requirements: wheel rims and high-pressure hydrogen storage tanks. Lightweight wheel rims significantly impact vehicle NVH (Noise, Vibration, and Harshness) and handling stability, while the structural integrity of hydrogen storage tanks is vital for overall vehicle safety. However, traditional manual layup processes suffer from low efficiency and inconsistent quality, hindering the large-scale application of high-performance composite components. From the perspective of a senior R&D engineer, this paper analyzes market drivers and manufacturing bottlenecks for carbon fiber wheel rims, elucidates the principles and advantages of automated radial braiding preforming technology for composites, and explores its potential as a platform manufacturing process in industrializing safety-critical components through case studies on wheel rim development. The study also discusses future challenges and provides manufacturing-side insights for investigating composite component failure mechanisms and protective technologies.