DE102009036509A1 - Metal-fiber composite-shaft has hollow-cylindrical shaped shaft part made of fiber composite, where shaft part has center longitudinal axis - Google Patents

Abstract

The metal-fiber composite-shaft (1) has a hollow-cylindrical shaped shaft part (2) made of fiber composite, where the shaft part has a center longitudinal axis (5). A matrix (6) is provided, in which fibers are embedded. A part of the bearing element has a peripheral contour. An independent claim is also included for a manufacturing method for a metal-fiber composite-shaft.

Description

The invention relates to a metal-fiber composite shaft according to the preamble of claim 1. The invention further relates to a manufacturing method and a manufacturing plant for a metal-fiber composite shaft.

From the DE 29 46 530 A1 a drive shaft is known which comprises a tube made of a fiber-reinforced plastic matrix and end pieces arranged on the tube metallic end pieces. The encapsulated in the plastic matrix fibers extend in the innermost and outermost layers of the tube helically with closely spaced turns and the least possible slope. In the intermediate layers, the pitch angle of the fibers is between 30 ° and 60 °, the fibers being arranged in successive intermediate layers in counter-intersecting turns. The end pieces have a conically shaped sleeve extension, which is knurled on its surface and thus forms a toothing. The fibers are wound during the winding process of the tube over the sleeve extension and form after curing of the plastic matrix a rotationally fixed connection between the tube and the end pieces.

In order to avoid a displacement of the reversing loops to be formed when winding the counter-intersecting intermediate layers, are in the DE 30 27 432 A1 Anchoring pins arranged on the end pieces, which are screwed into threaded holes of the sleeve extension. The anchoring pins form during the winding reversal points for the fibers, so that the fibers have a defined position in the area of the reverse loops.

The invention has the object of developing a metal-fiber composite material shaft of the generic type such that their mechanical strength, in particular in the connection region of a shaft part made of fiber composite material and a metallic connection part, is improved.

This object is achieved by a metal fiber composite shaft having the features of claim 1. According to the invention, it has been recognized that the metal-fiber composite shaft has a higher mechanical strength and better force or torque transmission properties, if at least a part of the arranged on the metallic connection part and radially projecting bearing elements has a deviating from a circular peripheral contour. The bearing elements form with their circumferential contour corresponding contact surfaces for the fiber loops large-area counter bearing and allow to selectively define the fiber directions in the direction of the hollow cylindrical shaft part and adapted to the required force or torque transmission properties of the shaft. Since the non-rotatable connection between the shaft part and the connecting part is produced by the fiber loops mounted on the bearing elements, the torsional strength is increased compared to mere wrapping of the connecting part with the fibers - as is known from the prior art. Due to the large contact surfaces, load peaks on the fiber loops and the associated bearing elements are avoided. Since the fiber directions are specifically adapted to the load by the shape and arrangement of the bearing elements, an optimized force or torque transmission can be achieved. The fiber loops surround the associated bearing elements segmentally and / or completely. Preferably, all bearing elements have a deviating from the circular shape circumferential contour. The bearing elements are preferably formed integrally with the main body of the connecting part and / or arranged circumferentially at regular intervals on the base body. The connection part may be rigid or realize an axial length compensation function. For this purpose, the connecting part forms an axial sliding connection.

The metal-fiber composite shaft according to the invention represents a hybrid component which has a high specific strength. Due to their low density, fiber composites have a much higher specific strength compared to steel and additionally have material-inherent vibration-damping properties. Since the mechanical properties of fiber composites in a wide range of materials by the combination of reinforcing fibers and the surrounding plastic matrix and production technology by the fiber directions, especially within a multi-layer structure, are adaptable, these are in a special way to a weight and produce load-optimized shaft. As reinforcing fibers, for example carbon, glass and / or polyester fibers can be used, which are embedded in a thermoplastic and / or thermosetting plastic matrix. The torsional rigidity and / or the bending stiffness of the shaft can be varied considerably, for example, with the same starting materials, ie reinforcing fibers and matrix, by varying the amount of fibers lying parallel to the corresponding loading direction.

Among the thermosetting plastics, preferably polyester and / or vinyl esters and / or mixtures thereof, derivatives and / or hybrids are used as the matrix material. Furthermore, epoxy resins, their mixtures, derivatives and / or hybrids can be used. To cure the Matrix materials may be introduced radical-forming additives and / or photoinitiators.

The fiber-matrix coating can be applied, for example, as an impregnated fiber roving, ie as an impregnated bundle of single filaments. Furthermore, the fiber-matrix application can be applied as an impregnated strip of a plurality of individual filaments, which differs greatly in cross section between width and height.

The fiber-matrix coating can also be applied as a unimpregnated fiber roving or unimpregnated ribbon, the roving itself being provided with a binder which has the task of bonding the adjoining roving surfaces. The binder is applied to the surface of the rovings to ensure adhesion to adjacent rovings. In the case of dry, ligated rovings or tapes, it is necessary to impregnate and cure the fibers after the winding process by means of a matrix infiltration process, before the winding core is removed.

The binders use thermoplastic or duromer binders. Duromeric binders are usually tacky at room temperature and are cured to secure the adhesion via a temperature increase. Thermoplastic binders are not tacky at room temperature and must therefore be heated briefly after the winding process, so that the binder particles are converted from a solid to a liquid state and so an adhesion effect can be achieved. After heating, the thermoplastic binder must be allowed to cool again or cooled until it is a solid and thus has an adhesive effect.

Furthermore, the fiber-matrix application can be applied as unimpregnated fiber roving or ribbon, in which case the roving or the ribbon itself is composed of a mixture of reinforcing fibers and polymeric fibers. The polymeric fibers provide, after reflow, the amount of matrix required for impregnation.

The metal-fiber composite shaft according to the invention is adapted to the special properties of fiber-reinforced composite materials and thus optimally utilizes the properties of the reinforcing fibers. In particular, the metallic connection parts are optimally connected to the shaft part to a mechanical hybrid component. Due to the low weight and the high specific strength high forces or torques can be transmitted, the load of bearings by the rotation of the shaft is low due to the low weight. The reinforcing fibers may, for example, be applied as filaments, threads, rovings, tapes, mats, fabrics and / or mats.

The metal-fiber composite shaft can be used as a drive shaft in any drive trains, for example in drive trains of motor vehicles.

A metal-fiber composite shaft according to claim 2 has optimized power transmission characteristics for forces acting in the direction of the central longitudinal axis, such as bending forces.

A metal fiber composite shaft according to claim 3 has optimized power transmission characteristics for forces acting in a direction transverse to the central longitudinal axis, such as torsional forces.

A metal-fiber composite shaft according to claim 4 enables optimization of the power transmission characteristics in two main load directions.

A metal-fiber composite shaft according to claim 5 enables optimization of the power transmission properties in both directions of rotation of the shaft.

A metal-fiber composite shaft according to claim 6 ensures a rotationally fixed connection between the shaft part and the connection parts.

A peripheral contour according to claim 7 defines two parallel fiber directions, wherein the associated contact surface has large flat portions. The bearing elements have the shape of a tooth flank in a parallelogram-shaped circumferential contour.

A circumferential contour according to claim 8 defines two differently extending fiber directions, wherein the associated contact surface has large-area planar sections.

A circumferential contour according to claim 9 defines two differently extending fiber directions, wherein the associated Annrangfläche has large-area planar sections.

A peripheral contour according to claim 10 avoids punctiform load peaks of the fiber loops, since no sharp corners or edges are formed. The bearing elements or the fiber loops have in the rounded portion a radius in the range between 1 mm and 10 mm, in particular between 2.5 mm and 10 mm, and in particular between 5 mm and 10 mm. The rounded portion is preferably aligned symmetrically to the fiber directions.

A metal fiber composite shaft according to claim 11 enables optimization of the force transfer characteristics for any number of load directions. In the individual cascade stages, the bearing elements can be arranged according to the desired force or torque transmission characteristic, wherein two fiber directions are defined in each cascade stage, for example. By the cascade stages, the number of circumferentially distributable bearing elements is increased, so that the rotational strength of the connection between the shaft part and the connection part is improved.

A metal fiber composite shaft according to claim 12 can be easily wound during manufacture.

A metal fiber composite shaft according to claim 13 optimizes the force transfer characteristics as well as the rotational strength of the connection between the shaft member and the connector.

The invention is further based on the object of developing a production method for a metal fiber composite shaft such that it can be produced easily and with improved mechanical strength, in particular in the connection region of a shaft part made of fiber composite material and a metallic connection part.

This object is achieved by a manufacturing method having the features of claim 14. The production of the metal-fiber composite shaft is carried out in one set-up so that the production steps of applying a fiber-matrix application and of curing the fiber-matrix application proceed to form a solid structure in a production facility. Preferably, a possibly still required surface finishing of the hardened shaft part is performed without changing the clamping in the manufacturing plant. A subsequent balancing of the shaft can be avoided by their preparation in one setting. The shaft can be made in a single setup with significantly reduced rotational vibration. When applying the fiber-matrix-order on the winding core, the fiber loops are formed, which are wound against the contact surfaces of the bearing elements fitting. By hardening the fiber-matrix-order to a solid structure, so the fiber composite material, a rotationally fixed connection between the connecting part and the hardened shaft part is formed, the shaft due to the given by the peripheral contour contact surfaces and fiber directions for the respective application optimal force or torque transmission characteristics.

The winding core can be connected before and / or after clamping the connection part with this. The winding core can therefore be clamped pre-assembled or assembled in the manufacturing plant. The connection can be made non-positively and / or positively, for example by a press fit. For easier removal of the winding core from the hardened shaft part, this may be formed in the shape of a truncated cone, which has over its length a taper in the range of 0.025 ° to 0.125 °.

Preferably, in applying the fiber-matrix-order with one of the winding device a plurality of fiber rovings are wound simultaneously on the winding core, wherein the rovings are applied uniformly distributed over the winding core circumference. For this purpose, the winding device, for example, a Ringwickelkopf, are arranged on the evenly distributed over the circumference fiber guides. For fully automatic application of the fiber matrix order, the winding device may comprise a clamping unit and / or a cutting unit, so that the rovings can be clamped at the beginning of the winding process and cut at the end of the winding process.

For curing the fiber-matrix application, the winding device has an irradiation unit which, by irradiation with high-energy radiation, such as UV radiation, IR radiation, laser radiation or microwave radiation, provides the required activation energy to trigger the hardening of the matrix material, and to accelerate. Preferably, the radiation sources are attached directly to the ring winding head. The irradiation may take place during, preferably from the beginning, the continuous application process and / or after the application process.

To minimize the deflection of the winding core, this is preferably formed as a hollow profile. The hollow profile may be stiffened by reinforcing fibers, for example carbon fibers. Preferably, the winding core is constructed of a fiber composite material.

A manufacturing method according to claim 15 enables a rapid curing of the fiber matrix order, for example a thermosetting plastic matrix. The high-energy radiation can be, for example, UV radiation, IR radiation, laser radiation or microwave radiation. The Radiation intensity of the radiation can be varied between the beginning and the end of the winding process. In a continuous irradiation, for example, at the beginning of the winding process, a high radiation intensity can be adjusted to compensate for the energy flow in the winding core. This is particularly advantageous for metallic winding cores. From a certain number of winding layers then the radiation intensity can be reduced, since due to the lower thermal conductivity of the fiber composite, the energy dissipation is reduced. In the case of a thermosetting plastic matrix, if necessary, the irradiation can be adjusted since the onset of reaction heat due to the exothermic reaction is sufficient to trigger the curing of the last winding layers. In the case of a thermoplastic matrix, the radiation sources of the irradiation unit are used for heating the fiber-matrix application, for example the rovings or ribbons.

A manufacturing method according to claim 16 ensures a low rotational vibration of the metal-fiber composite shaft, since their production takes place in a single clamping. The post-processing may be, for example, a grinding, milling and / or turning operation.

The invention is further based on the object to provide a manufacturing plant, with a metal fiber composite material shaft easily and with improved mechanical strength, in particular in the connection region of a shaft part made of fiber composite material and a metallic connection part, can be produced.

This object is achieved by a manufacturing plant with the features of claim 17. By means of the rotary spindle and the thrust bearing, the connecting part and the winding core connected thereto are clamped, wherein these are rotationally driven by means of the first spindle drive motor for the winding process. The winding device is arranged between the rotary spindle and the anvil and can be moved in the x direction by means of the first x drive motor, so that the fiber matrix application can be applied over the entire length of the winding core. The winding core extends to apply the fiber matrix order through the passage opening of the winding device. The passage opening is preferably formed by a ring winding head, on which distributed over its circumference a plurality of fiber guides are arranged, which serve as a feed unit for applying the fiber-matrix order. Irradiation with high-energy radiation can take place during and / or after the application of the fiber-matrix coating by the irradiation unit, so that the curing of the matrix material can be triggered and / or accelerated at an early stage. The application of the fiber-matrix-order, so the fiber-matrix layers, and curing takes place accordingly in one setting. In order to form the fiber loops resting on the bearing elements of the connecting part, the control unit is designed such that the spindle drive motor for driving the rotary spindle and the x-drive motor for moving the winding device can be correspondingly driven. The control unit controls the spindle drive motor and the x-drive motor in such a way that the bearing elements of the connection part spanned in the rotary spindle can be wrapped with the fibers by means of the winding device and thus the desired fiber loops are formed.

A manufacturing plant according to claim 18 allows automatic application of the fiber matrix order at the beginning of the application process. By means of the clamping unit, the fibers can be clamped at the beginning of the winding process to the winding core and even wrapped, so that the fibers are fixed to the winding core. Preferably, the clamping unit is designed as a pressure pliers. A fiber catcher holds the fiber ends, which are then clamped by means of Andruckbändern the Andruckzange on the winding core.

A manufacturing plant according to claim 19 enables an automatic termination of the application of the fiber matrix order. The cutting unit preferably also serves as a fiber catcher.

A manufacturing plant according to claim 20 enables a two-sided Drehantreiben of the winding core.

A manufacturing plant according to claim 21 enables the clamping of hubs of different lengths and thus the production of waves of different lengths.

A manufacturing plant according to claim 22 allows an immediate reworking of the shaft part after curing. The shaft part is accordingly produced in a single clamping and reworked.

A manufacturing plant according to claim 23 allows a simple clamping of the connection part and the winding core, in which the handling device receives the connection part and the winding core and supplies the clamping.

A manufacturing plant according to claim 24 has a high flexibility in the handling of the connecting parts and the winding core.

Further features, advantages and details of the invention will become apparent from the following Description of several embodiments. Show it:

1 a schematic representation of a metal-fiber composite shaft according to a first embodiment,

2 a perspective view of a metallic connection part of the metal-fiber composite shaft in 1 .

3 FIG. 4 is a perspective view of a metallic connection part of a metal-fiber composite shaft according to a second embodiment, FIG.

4 FIG. 2 is a perspective view of a metallic connection part of a metal-fiber composite shaft according to a third embodiment, FIG.

5 FIG. 2 is a perspective view of a metal connection part of a metal-fiber composite shaft according to a fourth embodiment, FIG.

6 FIG. 4 is a perspective view of a metal connection part of a metal-fiber composite shaft according to a fifth embodiment, FIG.

7 a side view of a metallic connection part of a metal-fiber composite shaft according to a sixth embodiment,

8th an axial section through the connection part in 7 .

9 FIG. 2 is a schematic view of a metal-fiber composite shaft according to a seventh exemplary embodiment with a length compensation function. FIG.

10 a perspective view of a metallic connector with the length compensation function of the metal-fiber composite shaft in 9 .

11 a schematic representation of a manufacturing plant for the metal-fiber composite shafts according to the 1 to 10 .

12 a schematic representation of a processing device for processing a fiber matrix order,

13 a schematic diagram of a winding device of the manufacturing plant in 11 for applying the fiber matrix order,

14 an axial section through the winding device according to 13 in a holding state of the fibers,

15 a perspective view of serving as a fiber catcher cutting unit of the winding device in 13 .

16 an axial section through the winding device in 13 in a clamping state with means of a clamping device formed as a clamping unit to a winding core pressed fibers, and

17 a perspective view of a trained as Andruckzange clamping unit for the fibers in a closed position according to 16 ,

The following is with reference to the 1 and 2 a first embodiment of the invention described. A metal fiber composite shaft 1 has a hollow cylindrical shaft part 2 made of a fiber composite material and two metal connecting parts 3 on, at the wave dividing ends 4 with the shaft part 2 are connected. The shaft part 2 has a central longitudinal axis, with corresponding central longitudinal axes of the connecting parts 3 a common central longitudinal axis 5 the metal fiber composite shaft 1 form. The metal fiber composite shaft is hereinafter referred to as shaft.

The trained from the fiber composite shaft part 2 has a matrix 6 plastic and fibers embedded therein 7 or fiber rovings on the shaft dividing ends 4 several, in the direction of the central longitudinal axis 5 extending fiber loops 8th form. The fiber loops 8th are evenly distributed over the circumference of the shaft part 2 arranged. The matrix 6 and the fibers embedded therein 7 are in 1 only shown schematically.

For connection to the shaft part 2 have the metallic connection parts 3 each a hollow cylindrical body 9 on, at the uniformly distributed over the circumference a plurality of radially projecting bearing elements 10 are arranged in one piece. The bearing elements 10 serve for the storage of fiber loops 8th , so that their number and arrangement of the number and arrangement of fiber loops 8th equivalent. The bearing elements 10 are at one of the shaft part 2 facing the end of the body 9 educated. At one of the shaft part 2 opposite end of the body 9 this one has a ring collar 11 on, on the two opposite connection elements 12 are attached axially projecting. The connection elements 12 serve to fasten the shaft 1 with a designated Part of a drive train, for example, to form a propeller shaft.

Each of the bearing elements 10 has a deviating from a circular peripheral contour U in the form of a parallelogram. Due to this peripheral contour U have the bearing elements 10 the shape of tooth flanks of a gear. The bearing elements 10 Form along their peripheral contour U extending contact surfaces A, against which the fiber loops 8th abut and so the shaft part 2 with the respective connection part 3 connect. The contact surfaces A run along the respective peripheral contour U and substantially radially to the central longitudinal axis 5 ,

Due to the parallelogram-shaped circumferential contour U, the contact surfaces A each form two parallel and substantially planar, long sections A ₁ and A ₂ . The long sections A ₁ and A ₂ are interconnected by two short sections A ₃ and A ₄ , wherein the shaft part 2 opposite section A _{3 is} rounded and the shaft part 2 facing section A ₄ not to rest the respective fiber loop 8th serves. By the parallel sections A ₁ and A ₂ defines the respective bearing element 10 for the fibers 7 the fiber loop 8th two parallel fiber directions F ₁ and F ₂ . The fiber directions F ₁ and F ₂ close with the central longitudinal axis 5 two identical winding angles α ₁ and α ₂ a. The winding angles α ₁ and α ₂ are, for example, 35 °, so that the fiber directions F ₁ and F _{2 are} a component transverse to the central longitudinal axis 5 and a component in the direction of the central longitudinal axis 5 to have.

The following is with reference to 3 A second embodiment of the invention described. The bearing elements 10a have a circumferential contour U in the form of a drop. The drops are formed axially symmetrical and parallel to the central longitudinal axis 5 oriented. As a result, the planar sections A ₁ and A _{2 form} the contact surfaces A for the fibers 7 two symmetrical to the central longitudinal axis 5 extending fiber directions F ₁ and F ₂ , which form with this a winding angle α ₁ and a corresponding negative winding angle α ₂ . The winding angles α ₁ and α ₂ are for example ± 35 °. The part of the shaft 2 facing away section A _{3 of} the respective contact surface is rounded. With regard to the further construction, reference is made to the preceding embodiment.

The following is with reference to 4 a third embodiment described. The bearing elements 10b have a circumferential contour U in the form of a rhombus. The bearing elements 10b are formed axially symmetrical and parallel to the central longitudinal axis 5 oriented. The planar sections A ₁ and A _{2 of} the respective contact surface A form for the fibers 7 two to the central longitudinal axis 5 symmetrically extending fiber directions F ₁ and F ₂ off. The winding angle α ₁ corresponds to the negative winding angle α ₂ due to the symmetry. The winding angles α ₁ and α ₂ are for example ± 35 °. The part of the shaft 2 facing away section A _{3 of} the respective contact surface A is formed substantially triangular with rounded corners or edges. With regard to the further construction, reference is made to the preceding embodiments.

The following is with reference to 5 a fourth embodiment described. The main body 9c of the respective connection part 3 has several cascade stages. A first cascade stage 13 with a first diameter D ₁ is the shaft part 2 whereas a second cascade level 14 with a larger diameter D ₂ the connection elements 12 is facing. The bearing elements 10 the cascade stages 13 and 14 are the same and formed according to the first embodiment. Alternatively or additionally, the bearing elements can also be designed according to the second and / or third embodiment. The circumferential contour U _{1 of} the bearing elements 10 the first cascade level 13 and the peripheral contour U _{2 of} the bearing elements 10 the second cascade stage 14 have the shape of a parallelogram. According to the first embodiment, the contact surfaces are denoted by A ₁₁ to A ₁₄ and A ₂₁ to A ₂₄ , wherein the first digit denotes the cascade stage and the second digit the portion of the contact surface A. The same applies to the fiber directions F ₁₁ and F ₁₂ and F ₂₁ and F ₂₂ and for the associated winding angle α ₁₁ and α ₁₂ and α ₂₁ and α ₂₂ . Through the cascade stages 13 and 14 becomes an associated first fiber layer 15 and a second fiber layer 16 formed according to the shape and arrangement of the bearing elements 10 in the respective cascade stage 13 respectively. 14 oriented fibers 7 identify. With regard to the further construction, reference is made to the preceding embodiments.

The following is with reference to 6 a fifth embodiment described. The main body 9d of the respective connection part 3 has several cascade stages. The bearing elements 10 the first cascade level 13 are formed according to the first embodiment in the form of a parallelogram. The circumferential contour U _{1 of} these bearing elements 10 defines two parallel fiber directions F ₁₁ and F ₁₂ which are parallel to each other and transverse to the central longitudinal axis 5 run. The corresponding winding angles α ₁₁ and α ₁₂ are for example 35 °. The bearing elements 10 the second cascade stage 14 are also in the form of a parallelogram, but in the reverse direction to the bearing elements 10 the first cascade level 13 oriented. The bearing elements 10 the second cascade stage 14 define due to their circumferential contour U ₂ two mutually parallel fiber directions F ₂₁ and F ₂₂ , relative to the central longitudinal axis 5 run symmetrically to the fiber directions F ₁₁ and F ₁₂ . The corresponding winding angles α ₂₁ and α ₂₂ are for example -35 °. With regard to the further construction, reference is made to the preceding embodiments. In particular, the bearing elements 10 be formed according to the second and / or third embodiment, wherein in each case a cascade stage 13 or 14 same bearing elements 10 are arranged, but in the different cascade stages 13 or 14 same or different bearing elements 10 can be arranged.

The following is with reference to the 7 and 8th a sixth embodiment of the invention described. The main body 9e of the respective connection part 3 has three cascade stages. The part of the shaft 2 facing first cascade stage 13 has a first diameter D ₁ . The downstream second cascade stage 14 has a larger diameter D ₂ and another downstream third cascade stage 17 has a turn larger diameter D ₃ . In the first cascade stage 13 no bearing elements are arranged. In the second cascade stage 14 and the third cascade level 17 are bearing elements 10 arranged according to the first embodiment, a circumferential contour U ₂ and U ₃ in the form of a parallelogram. The bearing elements 10 the second cascade stage 14 are oblique to the central longitudinal axis 5 arranged so that these fiber directions F ₂₁ and F ₂₂ define, which are parallel to each other and transverse to the central longitudinal axis 5 run. The fiber directions F ₂₁ and F ₂₂ close with the central longitudinal axis 5 for example, winding angle α ₂₁ and α ₂₂ of 35 °. The sections of the contact surfaces A are referred to in accordance with the preceding embodiments with A ₂₁ to A ₂₄ . The bearing elements 10 the third cascade stage 17 are parallel to the central longitudinal axis 5 aligned so that the fiber directions F ₃₁ and F ₃₂ parallel to this. The associated winding angles α ₃₁ and α ₃₂ are thus 0 °. The sections of the contact surfaces A of the third cascade stage 17 are designated according to the preceding embodiments with A ₃₁ to A ₃₄ .

The first cascade stage 13 is with the fibers 7 wrapped, with no in the direction of the central longitudinal axis 5 extending fiber loops are formed. The fiber direction F _{1 of} the first fiber layer 15 runs essentially in a plane perpendicular to the central longitudinal axis 5 is oriented. The associated winding angle α ₁ is approximately 90 °, for example 88 °. The through the second cascade stage 14 formed second fiber layer 16 has, for example, winding angle of 35 °, whereby torsional forces are optimally absorbed. The third cascade stage 17 formed third fiber layer 18 has a winding angle of 0 ° and is suitable for absorbing bending forces. In addition to the three fiber layers 15 . 16 and 18 can more peripheral fiber layers 19 be provided, the winding angle is approximately 90 °. With regard to the further construction, reference is made to the preceding embodiments.

The following is with reference to the 9 and 10 A seventh embodiment of the invention is described. The wave 1 has an axial length compensation function. For this is the main body 9f one of the connecting parts 3f as a separate sliding outer sleeve 20 educated. In the sliding outer sleeve 20 is a sliding inner sleeve 21 arranged axially in the sliding outer sleeve 20 is relocatable. The sliding inner sleeve 21 is one-piece with the ring collar 11 and the attached connection elements 12 educated. At the base body 9f are according to the first embodiment bearing elements 10 educated. With regard to the further construction, reference is made to the preceding embodiments.

In principle, the bearing elements 10 , the cascade stages 13 . 14 and 17 as well as the axial length compensation function can be combined with each other. The shape and arrangement of the bearing elements 10 can be selected depending on the forces to be absorbed or torques, so that the desired fiber directions F result. Basically, the fibers 7 in the respective fiber direction F are the strongest load.

The following is with reference to the 11 to 17 a manufacturing plant 22 for the metal fiber composite shafts 1 according to the 1 to 10 described. The manufacturing plant 22 has a subordinate 23 on, at the in a horizontal x-direction and parallel x-guide rails 24 are arranged. On the x-guide rails 24 is a winding device 25 by means of a first x drive motor 26 arranged movable in the x-direction. At a first end of the undercarriage 23 is a first turning spindle 27 attached, for clamping and Drehantreiben a first metallic connector 3 serves. The first turning spindle 27 has a first chuck 28 on, by means of a first spindle drive motor 29 around a rotation axis 30 is rotationally drivable, which runs parallel to the x-direction.

A second turning spindle 31 trained counter bearing is at a second end of the undercarriage 23 on the x-guide rails 24 arranged. The second turning spindle 31 has a second chuck 28 on, by means of a second spindle drive motor 33 with the first turning spindle 27 common axis of rotation 30 is rotary drivable. The second turning spindle 31 serves to tension and Drehantreiben a second connector 3 that has a winding core 34 with the first connection part 3 connected is. The winding device 25 is between the rotary spindles 27 and 31 arranged. The rotary spindle 31 is by means of a second x drive motor 35 movable in the x-direction, so that hubs 34 different length in the rotary spindles 27 and 31 are receivable.

For preparing and providing a fiber-matrix order 36 indicates the manufacturing plant 22 a processing facility 37 on, attached to the winding device 25 connected. As a fiber matrix order 36 serve impregnated fiber rovings, which are short fibers 7 are designated. The fibers 7 be in a creel 38 from single filaments 39 formed and through a sink 40 guided. In the tub 40 is one as a matrix 6 serving liquid for impregnation. The unimpregnated fibers 7 be over several rolls 41 and a wiper unit 42 through the tub filled with the liquid for impregnation 40 guided, so after the wiper unit 42 as a fiber matrix order 36 serving impregnated fiber rovings or fibers 7 to be provided.

The winding device 25 includes a feeder unit 43 for applying the fiber matrix order 36 , a clamping unit 44 for clamping the fibers 7 at the beginning of the winding process, a cutting unit 45 for cutting the fibers 7 at the end of the winding process and an irradiation unit 46 for curing the fiber matrix order 36 during the winding process. The feeder unit 43 is designed as a ring winding head, at the circumferentially evenly distributed more guide holes 47 are arranged. The guide holes 47 break through the ring winding head 43 and serve to guide the fibers 7 , The ring winding head 43 is on a retaining plate 48 attached, as x-carriage of the winding device 25 serves and on the x-guide rails 24 is movable. The ring winding head 43 forms together with the retaining plate 48 a passage opening 49 for the winding core 34 out. The irradiation unit 46 is in the ring winding head 43 integrated. These are a variety of radiation sources 50 For example, UV lamps, annular in the ring winding head 43 arranged. The radiation sources 50 are in two axially offset rows and over the circumference of the ring winding head 43 evenly distributed in this arranged.

The clamping unit 44 is designed as a pressure pliers and on the second rotating spindle 31 attached. The pressure forceps 44 has a first pliers half 51 and a second pair of pliers connected thereto 52 on. The pliers halves 51 and 52 are by means of a closing drive 53 around a locking axis running parallel to the x-direction 54 pivotable against each other. In addition, the pressure forceps 44 by means of a first y-drive 55 in a horizontal and perpendicular to the x-direction extending y-direction movable and to the winding core 34 can be delivered. The y-drive 55 can be electrical, hydraulic or pneumatic. The pliers halves 51 and 52 are hook-shaped and have a hook shape such that the winding core 34 by means of the pressure forceps 44 can be grasped on both sides. On the pliers halves 51 and 52 is each a pressure belt 56 respectively. 57 stored in such a way that this on the respective pliers half 51 . 52 can run around. For this purpose, the pliers halves 51 . 52 several rotatably mounted guide rollers 58 on. One of the leadership roles 58 is by means of a spring in a linear guide 59 slidably mounted and serves as a length compensation for the Andruckbänder 56 and 57 when embracing the winding core 34 , 13 shows the pressure forceps 44 in an open position, whereas 17 this shows in a closed position.

The cutting unit 45 is also designed as a fiber catcher. For this purpose, the cutting unit 45 an outer sleeve 60 and an inner sleeve 61 on, by means of a cutting drive 62 around the axis of rotation 30 are rotatably mounted in each other. The cutting unit 45 is at the second turning spindle 31 attached and by means of an x-drive 63 displaceable in the x direction. The x-drive 63 can be designed electrically, pneumatically or hydraulically. The outer sleeve 60 indicates one of the pressure pliers 44 facing side axially extending longitudinal recesses 64 in their number and arrangement the guide holes 47 for the fibers 7 are adjusted. Each of the longitudinal recesses 64 is a slanted recess 65 assigned to the corresponding side in the inner sleeve 61 are formed. The oblique recesses 65 run obliquely to the associated longitudinal recesses 64 and expand in the direction of the pliers 44 , In a partial area, the oblique recesses 65 one cutting edge each 66 such that by turning the outer sleeve 60 and the inner sleeve 61 to each other by the longitudinal and oblique recesses 64 . 65 running fibers 7 are severable. For this purpose, the inner sleeve 61 relative to the outer sleeve 60 in the direction of rotation 67 twisted.

For reworking the shaft part 2 indicates the manufacturing plant 22 a processing device 68 on, on the underframe 23 between the first turning spindle 27 and the winding device 25 is arranged. The processing device 68 includes an x-slide 69 which by means of a third x drive motor 70 in the x-direction on the x-guide rails 24 is movable. At the x-slide 69 is a tool turret 71 arranged by means of a y-drive motor 72 in the y-direction to the shaft part 2 is deliverable. The tool turret 71 includes a turret drive motor 73 , by means of a revolver disc 74 with tools 75 is rotatable.

For handling the connection parts 3 as well as the hubs 34 is a handling device 76 provided as an industrial robot with a gripper 77 is trained. The handling device 76 allows a displacement of the connecting parts 3 and hubs 34 in the x, y and vertical z directions. The handling device 76 is on second x-rails 78 arranged and by means of a fourth x-drive motor 79 movable in the x-direction.

The manufacturing plant 22 also has a control device 80 on, by means of the production of the metal-fiber composite shaft 1 is controlled. The control device 80 is via signal lines 81 with the drive motors 26 . 29 . 33 . 35 . 53 . 70 . 72 . 73 and 79 as well as with the drives 55 and 64 connected. The control device 80 is in particular designed such that when applying the fiber-matrix order 36 in the direction of the central longitudinal axis 5 or the axis of rotation 30 extending fiber loops 8th can be generated. These are the spindle drive motors 29 . 33 and the x drive motor 26 for the winding device 25 accordingly controllable and movable.

The following is the manufacturing process of the metal-fiber composite shaft 1 described. With the handling device 76 First, a first connection part 3 gripped and to the first rotary spindle 27 method. The connection part 3 is spanned in this. Subsequently, a second connection part 3 gripped and to the second rotary spindle 31 procedure and there spanned. The connecting parts 3 are now using a hub 34 connected with each other. For this purpose, the handling device engages 76 a winding core 34 and moves this to the one in the first spindle 27 tensioned connection part 3 , The winding core 34 gets into the connection part 3 introduced and held there for example by means of a press fit. Subsequently, the winding device 25 as well as the second turning spindle 31 in the direction of the first turning spindle 27 procedure, so that the winding core 34 through the duct opening 49 guided and into the connection part 3 the second rotary spindle 31 is introduced. The winding core 34 is in this connector part 3 for example, held by a press fit. The connecting parts 3 and the winding core 34 are now in the manufacturing plant 22 clamped.

The fiber matrix order 36 is from the processing facility 37 provided and over the ring winding head 43 fed. For this purpose, the fibers or fiber rovings impregnated with the matrix material run 7 in the direction of the axis of rotation 30 through the guide holes 47 , The fibers 7 are now using the cutting unit 45 , which also serves as a fiber catcher, gripped. For this purpose, the outer sleeve 60 and the inner sleeve 61 together in the direction of the ring winding head 43 shifted so that the ends of the fibers 7 in the longitudinal recesses 64 and the oblique recesses 65 be introduced. Subsequently, the inner sleeve 61 relative to the outer sleeve 60 in the direction of rotation 67 twisted, with the fibers 7 between the outer sleeve 60 and the inner sleeve 61 be clamped. Then the outer sleeve 60 and the inner sleeve 61 back towards the second spindle 31 proceed so that the cutting unit 45 and the ring winding head 43 are spaced apart in the axial direction.

The opened pressure tool 44 will now be in the direction of the winding core 34 procedure, whereby the fibers 7 and the winding core 34 through the pressure belts 56 . 57 be seized. Then the pressure pliers 44 by means of the closing drive 62 in the in 17 shown closed position, wherein the fibers 7 by means of the pressure belts 56 . 57 at the hub 34 be clamped. This is in 16 shown.

The cutting unit 45 releases the clamping of the fibers 7 and drive back completely in the direction of the second spindle 31 , By driving the spindles 27 . 31 begins the winding process, with the ends of the fibers 7 first be wrapped by this themselves, so that the fibers 7 at the hub 34 being held. Through the circulating pressure belts 56 . 57 become the fibers 7 kept constantly during this wrapping process. Will the pressure pliers 44 no longer needed, so this is opened and in the y-direction of the winding core 34 move away. Now the actual winding process begins.

The winding core 34 and the connecting parts 3 be - depending on the training of the wave 1 - in several fiber layers 15 . 16 . 18 wrapped, in particular fiber loops 8th are formed, which at the contact surfaces A of the bearing elements 10 abut and so the non-rotatable connection between the shaft part 2 and the connection parts 3 produce. Through the ring winding head 43 be simultaneously a variety of impregnated fibers or fiber rovings 7 on the winding core 34 applied. During the winding process, this fiber matrix job 36 by means of the irradiation unit 46 irradiated so that even during the winding process on or curing of the fiber-matrix order 36 he follows.

At the end of the winding process, the cutting unit 45 in the direction of the ring winding head 43 proceed until the fibers 7 again in the longitudinal recesses 64 and the oblique recesses 65 are introduced. Subsequently, the cutting unit 45 something from the ring winding head 43 spaced. The inner sleeve 61 becomes relative to the outer sleeve 60 in the direction of rotation 67 twisted so that the cutting edges 66 the fibers 7 cut. By the spacing before cutting is the secure gripping of the fibers 7 guaranteed for the execution of a subsequent winding process.

The hardened shaft part 2 is by means of the processing device 68 - If necessary - reworked so that imbalances generated during the winding process can be reduced. For this purpose, the shaft part 2 by means of the turning spindles 27 . 31 rotatably driven. The tool 75 the processing device 68 is delivered in the y-direction and the shaft part 2 reworked. The post-processing can be, for example, a grinding, milling and / or turning operation. The winding, curing and reworking of the shaft part 2 takes place in one setting.

After completion of the reworking handles the handling device 76 the shaft part 2 , The connecting parts 3 Now be through the chucks 28 . 32 Approved. The winding device 25 and the second rotating spindle 31 be from the first turning spindle 27 Move away, leaving the corrugated part 2 no longer through the duct opening 49 extends. The of the handling device 76 held metal fiber composite shaft 1 can now be stored, with the hub 34 still located in this. In a subsequent step, the winding core 34 away. The conical design of the winding core 34 facilitates removal.

By winding, curing and reworking the shaft 1 in a single clamping and by the formation of the control device 80 wrapping the fiber loops 8th around the corresponding bearing elements 10 allows, the shaft can 1 be produced in a simple manner and with respect to the prior art improved force or torque transmission properties and a significantly reduced Rotationsunwuchtigkeit. Depending on the design of the control device 80 as well as the connecting parts 3 Any of those in the 1 to 10 described metal-fiber composite shafts 1 getting produced.

QUOTES INCLUDE IN THE DESCRIPTION

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Cited patent literature

• DE 2946530 A1 [0002]
• DE 3027432 A1 [0003]

Claims (24)

Metal fiber composite shaft comprising - a hollow cylindrical and a central longitudinal axis ( 5 ) having wave part ( 2 ) of a fiber composite material with - a matrix ( 6 ) and - in the matrix ( 6 ) embedded fibers ( 7 ), whereby the fibers ( 7 ) at a shaft end ( 4 ) several in the direction of the central longitudinal axis ( 5 ) extending fiber loops ( 8th ), - one with the shaft part ( 2 ) connected metallic connection part ( 3 ; 3f ) with - a hollow cylindrical basic body ( 9 ; 9c ; 9d ; 9e ; 9f ) and - several peripherally on the main body ( 9 ; 9c ; 9d ; 9e ; 9f ) and radially projecting bearing elements ( 10 ; 10a ; 10b ) for storing the fiber loops ( 8th ), characterized in that - at least a part of the bearing elements ( 10 ; 10a ; 10b ) has a peripheral contour (U) deviating from a circular shape and forms abutment surfaces (A) running along the circumferential contour (U), and - the fiber loops ( 8th ) for transmitting power between the shaft part ( 2 ) and the connection part ( 3 ; 3f ) abut against the contact surfaces (A). Metal fiber composite shaft according to claim 1, characterized in that at least one of the contact surfaces (A) in the direction of the shaft part ( 2 ) one parallel to the central longitudinal axis ( 5 ) extending fiber direction (F) defined. Metal fiber composite shaft according to claim 1 or 2, characterized in that at least one of the contact surfaces (A) in the direction of the shaft part ( 2 ) one transverse to the central longitudinal axis ( 5 ) extending fiber direction (F) defined. Metal fiber composite shaft according to one of claims 1 to 3, characterized in that at least one of the contact surfaces (A) in the direction of the shaft part ( 2 ) defines two differently extending fiber directions (F). Metal-fiber composite shaft according to claim 4, characterized in that the fiber directions (F) symmetrical to the central longitudinal axis ( 5 ). Metal fiber composite shaft according to one of claims 1 to 5, characterized in that at least one of the contact surfaces (A) has a substantially planar portion (A ₁ , A ₂ ). Metal-fiber composite shaft according to one of claims 1 to 6, characterized in that at least one of the bearing elements ( 10 ) has a peripheral contour (U) in the form of a parallelogram. Metal fiber composite shaft according to one of claims 1 to 7, characterized in that at least one of the bearing elements ( 10a ) has a peripheral contour (U) in the form of a drop. Metal-fiber composite shaft according to one of claims 1 to 8, characterized in that at least one of the bearing elements ( 10b ) has a peripheral contour (U) in the form of a rhombus. Metal fiber composite shaft according to one of claims 1 to 9, characterized in that in at least one of the bearing elements ( 10 ; 10a ; 10b ) the contact surface (A) in a shaft part ( 2 ) facing away from section (A ₃ ) is rounded. Metal-fiber composite shaft according to one of claims 1 to 10, characterized in that the bearing elements ( 10 ; 10a ; 10b ) in several cascade stages ( 13 . 14 . 17 ) are arranged. Metal-fiber composite shaft according to claim 11, characterized in that the bearing elements ( 10 ; 10a ; 10b ) in each case in a cascade stage ( 13 . 14 . 17 ) are the same. Metal-fiber composite shaft according to claim 11 or 12, characterized in that the bearing elements ( 10 ; 10a ; 10b ) in different cascade stages ( 13 . 14 . 17 ) are formed differently. Manufacturing method for a metal-fiber composite shaft, comprising the steps: - providing a metallic connection part ( 3 ; 3f ) with - a hollow cylindrical basic body ( 9 ; 9d ; 9e ; 9f ) and - several peripherally on the main body ( 9 ; 9d ; 9e ; 9f ) and radially projecting bearing elements ( 10 ; 10a ; 10b ), wherein at least a part of the bearing elements ( 10 ; 10a ; 10b ) has a peripheral contour (U) deviating from a circular shape and forms abutment surfaces (A) running along the peripheral contour (U), - clamping the connecting part ( 3 ; 3f ) and a winding core connected thereto ( 34 ), - application of a fiber matrix order ( 36 ) on the winding core ( 34 ) to form a hollow cylindrical shaft part ( 2 ), - wherein against the contact surfaces (A) adjacent and in the direction of a central longitudinal axis ( 5 ) of the shaft part ( 2 ) extending fiber loops ( 8th ), - whereby the fiber loops ( 8th ) the shaft part ( 2 ) with the connection part ( 3 ; 3f ) connect, - curing the fiber matrix order ( 36 ) to a fiber composite material, - unclamping the connection part ( 3 ; 3f ) and the winding core ( 34 ), and - removing the winding core ( 34 ). Manufacturing method according to claim 14, characterized in that the curing during the application of the fiber matrix order ( 36 ), wherein the curing by irradiation of the fiber-matrix order ( 36 ) with an irradiation unit ( 46 ) emitted radiation is initiated. Manufacturing method according to claim 14 or 15, characterized in that a reworking of the hardened shaft part ( 2 ) takes place before relaxing. Manufacturing plant for a metal-fiber composite shaft with - a subframe ( 23 ), - a first rotary spindle ( 27 ) for tensioning a metallic connection part ( 3 ), which - on the undercarriage ( 23 ) is arranged and - about an axis of rotation parallel to an x-direction ( 30 ) by means of a first spindle drive motor ( 29 ) is rotationally drivable, - one on the subframe ( 23 ) arranged abutment ( 31 ) for storing one with the connecting part ( 3 ) connected winding core ( 34 ), - a winding device ( 25 ), which - on the undercarriage ( 23 ) between the rotary spindle ( 27 ) and the counter bearing ( 31 ) is arranged, in the horizontal x-direction by means of a first x-drive motor ( 26 ), - an opening ( 49 ) for the winding core ( 34 ), - a feed unit ( 43 ) for applying a fiber matrix order ( 36 ) on the winding core ( 34 ) and - an irradiation unit ( 46 ) for curing the fiber matrix order ( 36 ) to a shaft part ( 2 ) comprises a fiber composite material, and - a control device ( 80 ), which is designed such that when applying the fiber matrix order ( 36 ) in the direction of a central longitudinal axis ( 5 ) of the shaft part ( 2 ) extending fiber loops ( 8th ) are producible. Manufacturing plant according to claim 17, characterized in that the winding device ( 25 ) a clamping unit ( 44 ) for clamping fibers ( 7 ) of the fiber matrix order ( 36 ) on the winding core ( 34 ) having. Manufacturing plant according to claim 17 or 18, characterized in that the winding device ( 25 ) a cutting unit ( 45 ) for cutting the fibers ( 7 ) after application of the fiber matrix order ( 36 ) having. Manufacturing plant according to one of claims 17 to 19, characterized in that the abutment ( 31 ) is designed as a rotary spindle, which is about the axis of rotation ( 30 ) by means of a second spindle drive motor ( 33 ) is rotary drivable. Manufacturing plant according to one of claims 17 to 20, characterized in that the abutment ( 31 ) in the x direction by means of a second x drive motor ( 35 ) is movable. Manufacturing plant according to one of claims 17 to 21, characterized in that a processing device ( 68 ) for reworking the shaft part ( 2 ) provided on the subframe ( 23 ) and by means of a third x-drive motor ( 70 ) is movable in the x-direction. Manufacturing plant according to one of claims 17 to 22, characterized in that a handling device ( 76 ) for handling the connection part ( 3 ) and the winding core ( 34 ) is provided. Manufacturing plant according to claim 23, characterized in that the handling device ( 76 ) by means of a fourth x drive motor ( 79 ) is movable in the x-direction.

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