CN115551691A - 用于制造加固型材的方法和设备 - Google Patents
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Abstract
一种由至少一个从预浸渍的纤维料幅上切割出来的层(1、2、3)制造加固型材的方法,将所述层放置在确定型材形状的型芯(4)上并且固持在型芯(4)上的放置区域(6)中,并且从所述放置区域(6)开始横向于型材纵向地渐进地将所述层压到所述型芯(4)上直至到达型材纵向边缘。为了创造有利的制造条件,在此建议,借助既沿型芯(4)的周向也沿型芯(4)的纵向相互错开地布置的、能够朝型芯(4)的成型面施加作用的多个成型冲头(8)将所述层(1、2、3)沿着所述型芯(4)的纵向逐步地渐进地成型地压到所述型芯(4)上。
Description
技术领域
本发明涉及一种由至少一个从预浸渍的纤维料幅上切割出来的层制造加固型材的方法,将所述层放置在确定型材形状的型芯上并且固持在型芯上的放置区域中,并且从所述放置区域开始横向于型材纵向地渐进地将所述层压到所述型芯上直至到达型材纵向边缘,并且本发明还涉及一种用于实施所述方法的设备。
尤其在飞机工业中使用由纤维复合材料构成的沿着弯曲的面延伸的加固型材。这意味着,从预浸渍的纤维料幅中切割出来的用于逐层地构造这种加固型材的层不仅必须与横向于型材纵向的型材横截面对应地成型,而且还必须沿着型材纵向遵循空间曲线。为此使用预设型材形状、沿着纵向遵循空间上的预定曲线的型芯,待制造的加固型材的各个单独的层成型地被压到型芯上。在此应当避免影响加固型材的机械性能的褶皱和空洞,该褶皱和空洞往往导致在成型地压到型芯上时耗费时间地手动地敷设各个层。
背景技术
为了机械地由纤维复合体制造多层的加固型材建议(WO 2010/100386A2)借助滚子将从储备卷轴上抽出的之后构成层的纤维料幅连续地压到连续地与滚子相对地输送的型芯上,其中,通过既沿型芯的纵向也横向于型芯的纵向相对彼此错开的滚子将各个纤维料幅首先在放置区域中固持在型芯上并且从该放置区域出发借助沿型芯的进给方向间隔距离地依次相续的滚子横向于型材纵向渐进地将纤维料幅压到型芯上直至达到型材纵向边缘,滚子对应于各个成型面和成型面之间的过渡部。然而不利的是,纤维料幅波状地堆积在在挤压压力的作用下滚动的滚子前面,这尤其会引起褶皱的产生。
为了避免该缺点,已知(US 2016/0354982 A1)将从预浸渍的纤维料幅中切割出来的各个层依次地放置在型芯上或者上一个施加在型芯上的层上,并且在该位置上借助压紧装置相对于型芯固持,之后以固持的放置区域为出发点,通过成型装置将层横向于型材纵向渐进地成型地压到型芯上直至达到型材纵向边缘,成型装置在型材形状通常相对于居中的放置区域的两侧很大程度上对称的情况下具有作用在各个层上的成型工具,成型工具在其被加载时首先紧接着放置区域将层压到型芯上并且之后横向于型芯的纵轴线在应用相应压力的情况下沿着层滑动直至到达纵向边缘。层的由此产生的沿着型芯的成型面横向于型材纵向的伸展(Ausstreifen)可确保各个层的无折叠的成型,然而这只能通过对层施加附加的负压来实现。由于各个层在其整个长度上在工作过程中被压到型芯上,因此成型工具必须在整个型材长度上延伸,其中,应当考虑的是,由于型芯沿着空间曲线的延伸,成型工具必须依照成型面的由此形成的延伸走向。针对成型工具具有两个能够弹性地分岔、通过边缘缝隙分为成型指的板条,板条在放置区域的两侧加载相应的层的情况,这种补偿通过在确定的区域中分别能够针对自身变形的指部确保,然而存在的缺点为,通过这些指部无法实现层或者加固型材的预设的压实。
为了借助超声波至少部分地固化由以多个层贴靠在型芯上的、预浸渍的纤维料幅构成的加固型材,还已知的是(EP 2 873 517 A1),将悬浮地支承的超声震荡单元在重叠的周向分布中压到型材表面上并且将型芯与贴靠的纤维料幅相对于超声震荡单元沿着型材纵向移动。通过超声震荡单元的压力加载使相叠的纤维料幅能够附加地共同地被压实。如果不考虑假设纤维料幅已经无折叠地贴靠在型芯上,那么由于超声震荡单元与纤维料幅之间的沿型材纵向的相对运动而产生的风险是,纤维料幅彼此移动并且尤其随着超声震荡单元的调节压力的升高而堆积在超声震荡单元前面。出于该原因在超声震荡单元和加固型材之间导引的缓冲膜仅能降低该风险,然而无法排除该风险,这同样适用于超声震荡单元上的滑动层。
发明内容
因此本发明所要解决的技术问题在于,提供一种方法,借助所述方法能够将待成型的加固型材的层的至少一个纤维料幅渐进地沿型材纵向无折叠地压到型芯上并且在应用预设压力的情况下被压实。
所述技术问题按照本发明从前述类型的方法出发如此解决,即,借助既沿型芯的周向也沿型芯的纵向相互错开地布置的、能够朝型芯的成型面施加作用的多个成型冲头将所述层沿着所述型芯的纵向逐步地渐进地成型地压到所述型芯上。
由于成型冲头由于该措施在成型工作行程之间从层的分别由成型冲头成型的、贴靠在型芯上的区段上抬起并且相对于放置在型芯上的层针对新的变形步骤沿着型芯的纵向以输送步进移动,该层在避免在型芯和成型装置之间产生造成折叠的相对运动的情况下逐步地被压到型芯上,从而由于成型冲头相互错开以及沿着型材纵向的渐进的输送步进使该纤维层以固持的放置区域为出发点横向于型材纵向渐进地成型地被压到型芯上直至到达型材纵向边缘。由于在变形过程中应当防止成型冲头相对于型芯沿着型材纵向发生相对运动,因此型芯例如可以在输送步进之间停止。然而也可行的是,成型装置在成型冲头加载期间与型芯同步地共同运动,这使得能够连续地输送型芯。针对连续的型芯输送也足够的是,为成型冲头配设沿着型材纵向弹性地弯曲的托架,所述托架在工作行程中补偿随着型芯运动的层和支承在位置固定地固持的成型装置上的成型冲头之间的相对运动。纤维料幅的在此无法避免的剪切载荷不会导致层运行时产生任何不允许的不规则性,因为由此产生的纤维层的任何纵向翘曲都会由于在工作行程之间释放层而被构成层的纤维料幅的固有弹性恢复。由于在纤维料幅成型期间消除了型芯与成型冲头之间沿着型材纵向的相对运动,因此避免了由这种相对运动带来的缺点,这使得纤维料幅层能够沿着型芯渐进地成型,即使在挤压压力较高的情况下也不存在纤维料幅起皱或翘曲的风险。
为了制造多层的加固型材,除了被直接成型地压在所述型芯上的第一层之外,每个从预浸渍的纤维料幅上切割出来的另外的层都以类似的方式放置在先前成型的层上并且固持在所述放置区域中并且随后借助既沿型芯的周向也沿型芯的纵向相互错开地布置的多个成型冲头从所述放置区域直至型材纵向边缘成型地渐进地被压到先前成型的层上。各个层自身能够在此在其变形过程中被压实。在层的长度上均匀地被压实的前提条件是,输送步进的长度与成型冲头的长度适配,成型冲头由此在每个输送步进之后使与层的先前变形的纵向区段连接的区域变形,或者变形区域相互重叠。
为了由多个从预浸渍的纤维料幅上切割出来的层制造加固型材,可以通过以下设备实现,所述设备具有确定型材形状的型芯、将这些层固持在所述型芯的放置区域上的压紧装置和用于将这些层成型地压到所述型芯的成型面上的成型装置。所述成型装置能够朝着所述型芯的成型面的方向施加作用,并且所述成型装置具有既沿型芯的纵向也沿型芯的轴向彼此错开地布置的成型冲头,由此如果所述成型装置和型芯能够沿型芯的纵向逐步地相对彼此位移,便产生了用于将各个纤维料幅层逐步地连续地压到型芯上或者上一个施加到型芯上的纤维料幅层上的设计方面的前提条件。
所述成型装置和型芯相对彼此位移的步进长度等于或小于所述成型冲头的沿型芯的纵向测量的长度,由此将各个成型冲头分别无间距地依次相续地使用或者在纤维料幅层的搭叠的纵向区段中使用,从而在与变形装置的长度对应地进给纤维料幅所需的多个输送步进之后,使纤维料幅局部地变形为由型芯确定的型材形状。通过其它的输送步进使纤维料幅层的完全地被压到型芯上或者上一个施加的纤维料幅层上并且由此完成变形的纵向区段延长。
为了能够针对不同的型材形状简单地改装成型装置,在必要时可更换的成型冲头本身可以分别围绕沿型芯的纵向延伸的轴线可枢转地支承在横向于型芯的纵向可移动的滑座上。由此,使成型冲头在其距离和定向方面可以与待制造的加固型材的相应型材形状相适配。与之相关地,所述成型冲头与伺服缸构成可枢转地支承在所述滑座上的构造单元,由此产生特别简单的设计条件。
所述成型装置有利地配设所述压紧装置,然而这并非是必须的。
附图说明
根据附图详细阐述按照本发明的方法。在附图中:
图1在横向剖切型芯得到的剖面中示出按照本发明的具有用于制造加固型材的成型装置的设备,
图2在沿箭头II的方向观察的侧视图中示出所述设备,和
图3在成型装置的范围内示出型芯的俯视图,然而仅在成型冲头的分布中示出所述成型装置的可加载的成型冲头。
具体实施方式
所示的用于通常由多个层1、2、3、即所述实施例中的承载层2和两个覆盖层1和3制造加固型材的设备具有型芯4,所述型芯确定了型材形状、例如帽罩形型材以及型材的纵向延伸走向,从预浸渍的纤维料幅切割出来的层1、2、3借助成型装置5依次成型地被压到所述型芯的成型面上。该成型装置5一方面包括用于将层1、2、3固持在型芯4的放置区域6上的压紧装置7并且另一方面包括成型冲头8,所述成型冲头8面对型芯4的成型面定向并且通过伺服驱动器9被加载。成型冲头8既沿着型芯4的纵向也沿着型芯的周向彼此错开地布置,以便能够将层1、2、3依次逐步成型地压到型芯4上或者上一次施加的层1、2上。成型冲头8由于很大程度上的型材对称性而成对地布置在放置区域6的两侧。为了使成型冲头8能够自动地面对型芯4的成型面定向,所述成型冲头8能够有限地自由枢转地支承或者具有弹性地弯曲的托架。
伺服驱动器9优选设计为与成型冲头8构成构造单元的伺服缸,所述伺服缸能够围绕沿着型芯4的纵向构成的轴线10枢转地支承在滑座11中并且能够借助枢转驱动器12枢转调节。滑座11本身在支架14中的横向于型芯4的纵向延伸的导引件13上可移动地导引并且能够通过驱动器15沿着导引件13被调节。成型装置5能够通过例如操作机械的万向接头16相对于型芯4的纵向延伸走向定向,以便沿着静止的型芯4移动或者相对于沿纵向可移动的型芯4被静止地固持。
为了制造加固型材,在成型装置5面向型芯4定向并且成型冲头8面向型芯4的成型面定向之后,第一层1对准型芯4的放置区域6地放置并且通过针对压紧装置7对应地控制伺服驱动器17借助压紧装置7面向型芯4固持。如果在该初始位置控制沿型芯4的周向与放置区域6相接的成对的成型冲头8,则由伺服驱动器9加载的成型冲头8在从帽罩形型材的底部向侧壁过渡的过渡区域中将层1压到型芯4上,其中,所述层1在第一变形步骤中从图1中由点划线表示的初始位置弯曲到围绕型芯4的纵向棱边的由虚线所示的中间位置上,所述纵向棱边确定了该过渡区域。
在图3中,第一层1的导入成型装置5中的、位于第一对成型冲头8的区域中的、尚未变形的起始部18以实线表示。借助压紧装置7固持在放置区域6中的起始部18的由第一对成型冲头8进行的变形由点划线表示。随着每一个输送步进,型芯4连同第一层1在压紧装置7和成型冲头8抬起时移动距离,所述距离选择为小于成型冲头8沿型材纵向测量的长度,以便在每个输送步进之后通过第一对成型冲头使层1实施变形,从而使层1在依次相续的变形步骤中在由第一对成型冲头确定的周向区段的区域中在应用相应压力的情况下在其长度上连续地变形。
按照所示的实施例,由第一对成型冲头围绕型芯4的纵向棱边在帽罩形型材的底部和侧壁之间弯曲的起始部18在对应于箭头19的三个输送步进之后到达如细虚线所示的第二对成型冲头8的区域。在该起始位置中,起始部18可以在第二变形步骤中借助第二对成型冲头被压到由型芯4定义的帽罩形型材的侧壁上,这由起始部18的较粗的点划线轮廓形状表示。
由于成型冲头对彼此间沿着型材纵向的均匀的间隔,分别在三个另外的输送步进之后使用在型芯4的周向上错开地布置的另一对成型冲头8,直至通过终止变形过程的最后一个成型冲头对使第一层1在成型装置5的出口处具有由型芯4预设的型材形状。
随着每一个另外的输送步进,第一层1的完全成型的纵向区段延长,直到在完全地完成之后第二层2能够以类似的方式施加到成型地贴靠在型芯4的成型面上的第一层1上。当在必要时在经过对预浸渍的纤维料幅的至少局部地固化之后将成型的加固型材从型芯4上取下之前,重复施加层直至最后的层3。
由于与将各个单独的层1、2、3压到型芯4或者之前施加的层1、2上相关地通过压紧装置7和成型冲头8对层1、2、3进行压力加载,各个单独的层1、2、3能够符合相应要求地被压实,其中,通过使用伺服驱动器9或者17能够检测相应的层的厚度。为了提高压实效果,可以通过振动驱动器加载压紧装置7和成型冲头8。
Claims (7)
1.一种由至少一个从预浸渍的纤维料幅上切割出来的层(1)制造加固型材的方法,将所述层放置在确定型材形状的型芯(4)上并且固持在型芯(4)上的放置区域(6)中,并且从所述放置区域(6)开始横向于型材纵向地渐进地将所述层压到所述型芯(4)上直至到达型材纵向边缘,其特征在于,借助既沿型芯(4)的周向也沿型芯(4)的纵向相互错开地布置的、能够朝型芯(4)的成型面施加作用的多个成型冲头(8)将所述层(1)沿着所述型芯(4)的纵向逐步地渐进地成型地压到所述型芯(4)上。
2.根据权利要求1所述的方法,其特征在于,为了制造多层的加固型材,除了被直接成型地压在所述型芯(4)上的第一层之外,每个从预浸渍的纤维料幅上切割出来的另外的层(2、3)都以类似的方式放置在先前成型的层(1、2)上并且固持在所述放置区域(6)中并且随后借助既沿型芯(4)的周向也沿型芯(4)的纵向相互错开地布置的多个成型冲头(8)从所述放置区域(6)直至型材纵向边缘成型地渐进地被压到先前成型的层(1、2)上。
3.一种用于由多个从预浸渍的纤维料幅上切割出来的层(1、2、3)制造加固型材的设备,所述设备具有确定型材形状的型芯(4)、将这些层(1、2、3)固持在所述型芯(4)的放置区域(6)上的压紧装置(7)和用于将这些层(1、2、3)成型地压到所述型芯(4)的成型面上的成型装置(5),其特征在于,所述成型装置(5)能够朝着所述型芯(4)的成型面的方向施加作用,并且所述成型装置具有既沿型芯(4)的纵向也沿型芯的轴向彼此错开地布置的成型冲头(8),并且所述成型装置(5)和型芯(4)能够沿型芯(4)的纵向逐步地相对彼此位移。
4.根据权利要求3所述的装置,其特征在于,所述成型装置(5)和型芯(4)相对彼此位移的步进长度最多等于所述成型冲头(8)的沿型芯(4)的纵向测量的长度。
5.根据权利要求3或4所述的装置,其特征在于,在必要时可更换的成型冲头(8)本身分别围绕沿型芯(4)的纵向延伸的轴线(10)可枢转地支承在横向于型芯(4)的纵向可移动的滑座(11)上。
6.根据权利要求5所述的装置,其特征在于,所述成型冲头(8)与伺服缸构成可枢转地支承在所述滑座(11)上的构造单元。
7.根据权利要求1至6之一所述的装置,其特征在于,所述成型装置(5)具有所述压紧装置(7)。
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