DE102011056415A1 - Producing fiber composite component with integrated quality control function for motor vehicle, comprises introducing reference material on fiber mat, preparing fiber composite material by adding resin material, and visually inspecting - Google Patents

Abstract

Producing a fiber composite component (7) with integrated quality control function for a motor vehicle, comprises: providing at least one fiber mat (1); introducing and/or applying a reference material in and/or on the fiber mat; preparing a fiber composite material by adding resin material; forming the fiber composite component from the fiber composite material; and visually inspecting the fiber composite component by the inserted and/or applied reference material. An independent claim is also included for a fiber mat for producing a fiber composite component, comprising weft yarns (2) and warp yarns (3), where at least one reference thread (4) is woven into the fiber mat, and the reference thread is formed at least in sections from luminescent material over its length.

Description

The present invention relates to a method for producing a fiber composite component with integrated quality control function according to the features in claim 1.

The present invention further relates to a fiber mat for producing a fiber composite component according to the features in the preamble of claim 12.

Today, motor vehicle manufacturers strive to produce fuel-efficient vehicles that also have low CO ₂ emissions. To save fuel, there are different approaches. On the one hand, new engine generations are being developed that deliver consistent performance with significantly lower fuel consumption. This is made possible, for example, by charging processes of the internal combustion engines. Alternatively, more and more hybrid vehicles are used, which also use electric drives in addition to the internal combustion engine.

In addition, there are other possibilities, for example, in the improvement of the flow characteristics of a motor vehicle, so that in driving accordingly by a better CW value also fuel is saved.

Another way of saving fuel is to reduce the dead weight of the motor vehicle itself. As a result, significantly less mass has to be moved, which leads to considerable fuel-saving potential and thus also to a lower CO ₂ emission. Here, too, there are various possibilities, on the one hand to hold light metal alloys, on the other hand, high-strength and / or ultra-high-strength steels are used in the body shop.

Also find more and more fiber composite components or hybrid components, which consist of a metallic portion and a fiber composite share, moving into the body shop. For example, hoods, doors, trunk lids, fenders or else roof panel elements or other body parts or even body structural parts are produced as a lightweight component. Due to more and more advanced manufacturing processes for the automated production of fiber composite components, their production has become more economical, so that they are not only reserved for prototype construction, supercars or the automotive upper class. Thus, the possibility of automated production of fiber composite components is nowadays also economically applicable to the automotive middle class.

However, fiber composite components are subject to some production-related features, so that a consistent quality in the production and associated strength properties must be ensured at the automated fiber composite components. On the one hand, it must be ensured that the fiber orientation of the fiber mats is oriented in accordance with the target specifications, so that the component complies with corresponding strength properties associated with the fiber orientation. On the other hand, it is important that a homogeneous distribution of matrix resin in the fiber material is set, so that the material is not weakened by air pockets or inhomogeneous distributions.

For the production control of the actually existing fiber orientation on the finished manufactured component, it is hitherto known to use optical methods which directly attempt to determine the orientation of the fiber by a feature recognition. In this example, color pigments are applied to fibers or certain points of the fiber mat and then detected by optical detection systems and performed a target-actual comparison. There are, for example, systems which enable piecewise geometry detection with the aid of line-shaped light sources and systems which determine the surface contour of the component from reference points and the full-frame images of the object from different viewing angles.

These optical systems require the use of image capture hardware and subsequent software data analysis to determine the contour. The systems themselves then supply geometry data of the component surface in different data formats or also statements about local deformations of the material on the component after the production process. However, they all have in common that surface markings must be applied to the component itself, based on a contrast difference, color difference or brightness difference from the fiber composite material to which they are applied.

The systems known from the prior art exclusively use ambient light for illumination in optical image recognition. The disadvantage here is that the applied markings are optically visible and usually the material of the marker affects the finished component in its properties, at least visually, negative.

Another disadvantage is that the fiber composite components have an uneven surface, as z. B. in tissues or fiber materials may be the case, the image capture by locally makes different reflection properties and surface topographies difficult or error-prone.

It is therefore an object of the present invention to indicate a possibility of carrying out a production method for fiber composite components with an integrated quality control option, which can be integrated into a production process and does not influence the component produced.

The above object is achieved with a manufacturing method for producing a fiber composite component according to the features in claim 1. The aforementioned object is further achieved with a fiber mat for producing a fiber composite component according to the features in claim 12.

Advantageous embodiments of the present invention are part of the dependent claims.

• – Bereitstellen mindestens einer Fasermatte,
• – Einbringung und/oder Aufbringen eines Referenzmaterials in und/oder auf die Fasermatte,
• – Herstellen eines Faserverbundmaterials durch Hinzufügen von Harzmaterial,
• – Umformen des Faserverbundmaterials zu dem Faserverbundbauteil, optische Kontrolle des Faserverbundbauteils anhand des eingebrachten und/oder aufgebrachten Referenzmaterials.

The inventive method for producing a fiber composite component with integrated quality control function, in particular for a motor vehicle, is characterized by the following method steps:

• Providing at least one fiber mat,
• Introduction and / or application of a reference material in and / or on the fiber mat,
• Preparing a fiber composite material by adding resin material,
• - Forming the fiber composite material to the fiber composite component, optical control of the fiber composite component based on the introduced and / or applied reference material.

In the present solution of the aforementioned object, in particular a luminescent marking material, in particular a luminescent under UV light marking material, applied to the fiber material as a reference material.

However, the marking material can also be incorporated into the fiber material itself. The optical analysis then takes place under ultraviolet light, ie UV light, with an optical analysis method known from the prior art. Both linear UV light sources, such as UV lasers or UV illuminators, can be used in combination with optical detection systems and evaluation methods.

For this purpose, it is particularly preferred within the scope of the invention to use an ultraviolet-sensitive marking material which produces different colors from one another via admixtures of different additives under ultraviolet light irradiation, so that a further differentiation possibility of the marking points or reference points is possible. In this way, for example, lines marked in different colors can be detected and an additional evaluation possibility for the absolute position determination is given via a relative position determination.

In the subsequent image analysis, ie the optical control, the geometry of the reference points is detected. By means of an evaluation software, a direct comparison of the acquired reference data with those of the fiber orientation, for example from a CAE simulation, is thus possible. As a result, tissue distortions, tissue cracks or even deviations outside of the production tolerances can be detected or detected.

The overall method is particularly preferred for use in the series production process, since the deformability and / or the chemical composition of the fiber composite material are not affected during processing. The reference materials which have been incorporated, in particular as ultraviolet luminescent, or applied reference materials are not visible to the human eye under normal illumination. It is thus possible to mark not only prototypes or reference components accordingly, but to run the mark over the entire series of components. It is also possible to provide each manufactured component with a corresponding mark, so that a complete documentation and quality control is ensured.

The inventive method for producing the fiber composite component is particularly preferably characterized in that a reference thread is woven into the fiber mat. This may consist entirely of luminescent material or be coated with such material. Alternatively and / or additionally, a reference thread can likewise preferably be applied to the fiber mat. This makes it possible to follow a reference thread woven into the fiber mat during and / or after completion of the production process, and to draw conclusions about the fiber orientation in the component. The respective fibers or threads of the fiber mat adjacent to the reference thread have at least approximately the same orientation. Thus, it is possible, under certain circumstances sufficient for the trained components to introduce or apply a reference thread in the component. In the case of complex-shaped components, it is sometimes advantageous if several reference threads are introduced into the component adjacent to one another at a distance from one another. Thus, it is again possible to obtain an overall impression of the fiber orientation in the entire component to win. The intermediate spaces formed between the reference threads can be detected by interpolation of two adjacent reference threads. It is thus possible to draw a conclusion on the fibers lying between the two reference threads.

In a further particularly preferred embodiment variant of the present invention, the reference thread is formed from luminescent material, in particular from material which is luminescent under UV light. In this case, the UV light is absorbed by the reference material and emitted light of a different wavelength after a certain time. If the emission is instantaneous, it is called fluorescence, and in the case of persistence, it is minutes or hours of phosphorescence.

According to the invention, the reference material preferably glows in the optically visible, that is, in the wavelength range recognizable by the human eye. However, it can also luminesce in another wavelength range that can not be detected by the human eye.

In particular, the ultraviolet light has the advantage that the method is approximately independent of daylight feasible. It is thus possible, for example, to stochastically introduce the reference fibers, which are woven into the fiber mat and luminescent under UV light, into components in series production or else to introduce them into each component of series production. An optical and / or aesthetic impairment of the component due to reference marks does not occur, since the exclusively luminescent under UV light reference marks in the form of reference threads for the human eye are not visible in daylight. An impairment of the manufactured component, for example by a diminishing quality impression, is thereby avoided.

In a further preferred embodiment of the present invention, a luminescent material, in particular a material that is luminescent under UV light, is applied to the fiber mat. Here, for example, by a spraying process or by a tactile application method, a luminescent, in particular under ultraviolet light luminescent material, are applied to the fiber mat or on the resin-enriched fiber composite mat. The material can be applied, for example, in a line, punctiform or other form. This also makes it possible, in turn, to close the fiber orientation after application of the essentially flat fiber mat by firstly following the production process of the fiber mat without defects in the fiber orientation after the fiber mat has been formed. The applied reference points or marking points or markings, for example in continuous lines, allow a conclusion on the fiber orientation within the fiber composite component to be produced or produced during or after the deformation of the fiber composite material into the fiber composite component. It is thus possible, by detecting the reference points during the manufacturing process or on the manufactured component, to optically detect the fiber orientation in the component in the course of a quality control. Thus, conclusions about the fiber orientation can be drawn on the production quality and the adjusting itself in the component strength can be monitored.

In particular, during and / or after the manufacture of the fiber composite component, optical control by means of ultraviolet light is carried out for this purpose, the luminescent material being used to control the fiber orientation of the fibers in the fiber mat during and / or after the deformation. Any manufacturing error occurring here and / or a deviation of the component nominal geometry and / or leaving the fiber orientation of the production tolerance limits are thus recognizable on the basis of the optical control. A fast, direct and time-efficient detection of any production deviations and / or production errors is thus ensured.

Further preferably, the luminescent under UV light exposure material is applied to the fiber mat with a spray process. In a further preferred embodiment variant of the present invention, the luminescent material, in particular the material which is luminescent under the action of UV light, is applied at least in sections to a blank in a winding process.

In a further embodiment of the present invention, it is also conceivable that during the manufacturing process itself luminescent material is at least partially applied to the fiber mat or the fiber composite material. In this case, the fiber mat is not already identified by means of luminescent material prior to integration into the production process, but the luminescent material is applied after the beginning of the production process. For example, it is conceivable to apply correspondingly luminescent material to the resin-enriched fiber mat shortly before reshaping or even during the forming process. In this way, a particulate control of the production process can then be detected in a directly downstream detection step.

It is likewise conceivable within the scope of the invention for luminescent material to be applied at least partially to the fiber mat during the production process. This makes it conceivable, for example, that the luminescent material is applied in regions on the fiber mat, so that a corresponding critical during the manufacturing process area can be specifically monitored. This is, for example, an area with locally high degrees of deformation, in which it may be conceivable that, due to production fluctuations, the fiber orientation deviates correspondingly from the specified nominal fiber orientation. As a result, it is not necessary to monitor the entire component, but only the partial corresponding, previously defined and possibly critical area. As a result, the initial cost of a production line or a corresponding monitoring device for the production line are significantly lower, since no total acquisition system, but only a system for partial areas must be purchased and operated.

The present invention further relates to a fiber mat for producing a fiber composite component, wherein the fiber mat may be a woven fabric, a scrim, a knitted fabric, a non-woven or any other type of fiber textile. The fiber mat can also already be preimpregnated with resin. It can be used in a production method already mentioned, wherein the fiber mat is characterized in particular by the fact that at least one reference thread is woven into the fiber mat, wherein the reference thread is at least partially formed of luminescent material over its length or coated with luminescent material. This means that, for example, a weft thread or even a warp thread or else an additional thread as a reference thread is woven into the fiber mat itself.

The reference thread itself is at least partially formed over its length of luminescent material. This means that sections that are luminescent in accordance with in particular UV light exposure, respectively followed by sections that are formed accordingly from conventional materials. The reference thread itself can be designed, for example, such that it is formed from the same material from which the remaining fibers of the fiber mat are formed. The sections which are formed from luminescent material are accordingly to be understood in the context of the invention as meaning that a luminescent agent is applied to the reference thread, is introduced into it or else the entire respective section of luminescent material is formed. For example, the sections may be a few millimeters long, followed by sections that may be several centimeters long that are not luminescent.

In the context of the invention, the reference thread, particularly preferably over its entire length, is formed entirely from luminescent material. The reference thread formed overall from luminescent material offers the particular advantage that it can be rotated relative to the fiber mat and / or to the adjacent fibers within the production process in the fiber composite component to be produced, without any loss of optical control. For example, only applied reference points themselves would protrude, for example, by twisting into the interior of the component and would no longer be visually recognizable. With the fully formed luminescent reference thread, this danger does not exist. Even if sections of the reference thread itself are covered by resin or adjacent fibers during the production process, at least parts of the reference thread are still recognizable on the surface and a corresponding optical recognition can be carried out.

In particular, even in the case of the fiber mat, the luminescent material is a material which is luminescent under the action of ultraviolet light radiation. It is made possible according to a luminescent luminosity and / or reflection. Again, this results in the advantage that reference threads in the fiber mat can also remain in series components, without representing a visual impairment of the component itself.

In the context of the invention, it is conceivable in particular that two different materials are used, wherein the different luminescent materials differ from one another under the action of ultraviolet light. This results in the ability to detect and control not only the absolute fiber orientation on the finished component or during the production process, it can also relative distances are identified accordingly. For example, two reference threads with mutually different luminescent materials can be introduced directly next to one another in the fiber mat. During the forming process, it is therefore possible to ascertain a possible expansion or a distance between the two initially adjacent reference threads with differently luminescent colors.

In the context of the invention, a plurality of reference threads can be woven into the fiber mat for the relative and / or absolute position determination; in particular, two reference threads are woven, which are at a defined distance from each other exhibit. The distance itself is preferably constant over the length of the reference threads. This makes it possible to equip the fiber mat according to during the manufacturing process in a planar alignment with two adjacent reference threads, which have a constant distance from each other. During or after the forming process to the fiber composite component, it is thus possible to determine the absolute position of the reference threads and to control corresponding component target geometries. In addition, it is possible to check the relative values of the fiber orientations or fiber displacements by the distances which change during the forming process, so that any shearing or excessively high strains can also be monitored.

Depending on the application, it is also conceivable that the distance over the length of the reference threads is increasingly and / or decreasing and / or alternately formed. Depending on the component geometry of the fiber composite component to be produced, it may be advantageous if the reference fibers are initially arranged in a kind of funnel shape relative to each other in the fiber mat, so that corresponding reference measurements of relative positions to each other can be made in the manufactured fiber composite component.

In the context of the invention, it is also possible to weave the reference thread meandering in the fiber mat. Here, it is again conceivable that due to the deformation occurring a corresponding stretching of the meandering shape by evaluating the frequency and / or amplitude and / or period of the meandering shape allows a conclusion on the corresponding occurring in the component fiber orientations, changes in length or similar values of the fibers.

In the context of the invention, a further advantageous embodiment is to be seen in that two reference threads are woven into the fiber mat, wherein the reference threads are arranged at an angle to each other. Preferably, the reference threads intersect within the fiber mat. Most preferably, the reference threads themselves are arranged at right angles to each other.

Again, it is in turn advantageous for a variety of applications, if correspondingly arranged at an angle to each other two reference threads are arranged in the component. For example, this can be a weft thread and a warp thread. Again, it is possible to draw conclusions about the fiber orientation and the length changes, stresses and strains prevailing in the component via the absolute determination of the reference threads or else the relative determination of the reference threads.

The aforementioned features are within the scope of the invention arbitrarily combinable with the associated advantages.

Further advantages, features, characteristics and aspects of the present invention will become apparent from the following description. Preferred embodiments are shown in the schematic figures. These are for easy understanding of the invention. Show it:

1 a fiber mat according to the invention with reference threads;

2 the fiber mat off 1 after forming;

3 a fiber mat according to the invention with two reference threads and

4 a fiber mat according to the invention with different reference threads

In the figures, the same reference numerals are used for the same or similar components, even if a repeated description is omitted for reasons of simplicity.

1 shows a fiber mat according to the invention 1 , The fiber mat 1 has weft threads 2 and warp threads 3 on, with the warp threads 3 in the X direction and the weft threads 2 oriented in the Y direction. In each case a reference thread is in the X-direction and also in the Y-direction 4 in the fiber mat 1 woven in. The two reference threads 4 intersect at a node 5 and have an angle of substantially 90 ° to each other. The reference threads 4 each run parallel to the weft threads 2 or warp threads 3 , In the embodiment shown here are the reference threads 4 over the side edges 6 the fiber mat 1 formed overhanging, so that they can be found faster immediately. In the context of the invention, however, these can also only within the mat, so not to the side edge 6 reaching or be set back against this. In the figures, both thicker and thinner threads are shown.

2 shows the fiber mat according to the invention 1 after forming into a fiber composite component 7 , In turn, the reference threads can be seen 4 , which is the shape of the fiber composite component 7 have adapted and thus a possibility of controlling the fiber flow of the weft 2 as well as warp threads 3 allows. This can be used to determine whether a shearing or a correct fiber course can be produced in the component itself. In the embodiment shown here is the node 5 on an outer dome of the fiber composite component 7 arranged. The side edges 6 are accordingly toward the fiber composite component 7 fed back pointing, which is due to a change in length due to the degree of deformation.

In 3 also shown is a fiber mat according to the invention 1 , at the two reference threads 4 woven in one direction, running parallel to one another. The reference threads 4 have a distance a to each other. Due to the relative distance a of the reference threads 4 To each other in the initial state, a conclusion can be drawn on how the fibers are in an intermediate region after completion of the forming or even during the forming process 8th between the two reference threads spaced at the distance a 4 Behavior or how its course is oriented.

In 4 is again a fiber mat according to the invention 1 shown in the various reference threads 4 woven in. Related to the image plane is a lower alternating reference thread 9 represented, whose course follows a sinusoid. The course of the amplitude A or the frequency f can be used to determine during or after the transformation, to what extent the weft 2 and warp threads 3 have stretched from each other or in which direction they are oriented. Due to the alternation, it is possible to focus only on one area 10 to lay so that only critical areas 10 are locally monitored. Shown on the image plane above are two reference threads 4 at an angle α to one another in the fiber mat 1 woven in. For special applications, it is also possible to determine a positional deviation of the course of the fiber orientation.

LIST OF REFERENCE NUMBERS

1

fiber mat

2

wefts

3

warp

4

reference thread

5

junction

6

side edges

7

Fiber composite component

8th

intermediate area

9

alternating reference thread

10

Area

X

direction

Y

direction

a

distance

A

amplitude

f

frequency

Claims (22)

Method for producing a fiber composite component with integrated quality control function, in particular for a motor vehicle, characterized by the following method steps: - providing at least one fiber mat ( 1 ) - introducing and / or applying a reference material in and / or on the fiber mat ( 1 ) - Producing a fiber composite material by adding resin material - Forming the fiber composite material to the fiber composite component ( 7 ) - Optical control of the fiber composite component ( 7 ) based on the introduced and / or applied reference material. Method according to claim 1, characterized in that a reference thread ( 4 ) in the fiber mat ( 1 ) is woven. Method according to claim 1 or 2, characterized in that a reference thread ( 4 ) on the fiber mat ( 1 ) is applied. Method according to claim 2 or 3, characterized in that the reference thread ( 4 ) is formed of luminescent material, in particular of luminescent material under UV light. A method according to claim 1 to 3, characterized in that the reference thread is coated with luminescent material, in particular with luminescent under UV light material. Method according to one of claims 1 to 5, characterized in that a luminescent material, in particular under UV light luminescent material on the fiber mat ( 1 ) is applied. Method according to one of claims 1 to 6, characterized in that during and / or after the production of the fiber composite component ( 7 ) an optical control is carried out by means of UV light, wherein the luminescent material is used to control the fiber orientation of the fibers in the fiber mat ( 1 ) during and / or after forming. Method according to one of claims 1 to 7, characterized in that a manufacturing error occurring and / or a deviation of the component target geometry and / or leaving the production tolerance limits due to the optical control is detected. Method according to one of claims 1 to 8, characterized in that the luminescent material with a spray process on the fiber mat ( 1 ) is applied. Method according to one of claims 1 to 9, characterized in that luminescent material is applied in the winding process on a roving. Method according to one of claims 1 to 10, characterized in that during the production of the fiber composite mat on the weft threads ( 2 ) and / or warp threads ( 3 ) is applied at defined intervals luminescent material. Method according to one of claims 1 to 11, characterized in that during the manufacturing process luminescent material at least partially on the fiber mat ( 1 ) or the fiber composite material is applied. Fiber mat for producing a fiber composite component, wherein the fiber mat ( 1 ) from weft threads ( 2 ) and warp threads ( 3 ) and is used in a production method according to at least one of claims 1 to 12, characterized in that at least one reference thread ( 4 ) in the fiber mat ( 1 ), the reference thread ( 4 ) is formed at least partially luminescent over its length, preferably of luminescent material. Fiber mat according to claim 13, characterized in that the reference thread ( 4 ) is formed over its entire length of luminescent material. Fiber mat according to claim 13, characterized in that the reference thread ( 4 ) is coated with luminescent material. Fiber mat according to claim 13 to 15, characterized in that the luminescent material is formed under UV light luminescent. Fiber mat according to one of claims 13 to 16, characterized in that at least two different materials are used, wherein the colors of the luminescent material differ from each other under the action of ultraviolet light. Fiber mat according to one of claims 13 to 17, characterized in that a plurality of reference threads ( 4 ) in the fiber mat ( 1 ), in particular two reference threads ( 4 ), which have a defined distance (a) to each other. Fiber mat according to claim 18, characterized in that the distance (a) over the length of the reference threads ( 4 ) is constant. Fiber mat according to claim 18 or 19, characterized in that the distance (a) over the length of the reference threads ( 4 ) is formed increasingly and / or decreasing and / or alternating. Fiber mat according to one of claims 13 to 20, characterized in that the reference thread ( 4 ) meandering into the fiber mat ( 1 ) is woven. Fiber mat according to one of claims 13 to 21, characterized in that two reference threads ( 4 ), the reference threads ( 4 ) are arranged at an angle to each other, in particular the reference threads intersect ( 4 ), particularly preferred are the reference threads ( 4 ) arranged at right angles to each other.

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