DE102015206858A1 - Method and device for producing flat components with fiber-reinforced plastic - Google Patents

Abstract

A device (1) for producing planar components (23) with fiber-reinforced plastic is proposed, wherein the device has at least one tool mold (5) for receiving fiber material and at least one laying head (4) for depositing and pressing fiber material in the mold ( 5) and the laying head (4) relative to the tool mold (4) translationally (7) is displaceable and the device (1) about a substantially parallel to the translation plane of the laying head (4) extending axis of rotation (11) rotatable tool mold holder (9) has at least two molds (5).

Description

The present invention relates to an apparatus for producing flat components with fiber-reinforced plastic, wherein the device has at least one tool mold for receiving fiber material and at least one laying head for depositing and pressing fibrous material in the mold and the laying head is translationally displaceable relative to the mold the preamble of claim 1.

The invention further relates to a method for the production of components with fiber-reinforced plastic, in which by means of a laying fiber material is placed in a mold and pressed and the laying head is moved to the fiber tray translationally relative to the mold, according to the preamble of claim. 9

The planar component may be, for example, a fender of a motor vehicle, which is formed by means of fiber deposition in a tool mold. In such a component, a robot is often used which has a laying head on the robot arm with which the fiber material can be deposited in the tool mold.

In this known manufacturing method, the laying head of the robot arm is translationally moved in at least two directions relative to the mold, namely in Hochachsrichtung the fender to be manufactured to store fiber material over the entire Hochachsrichtung of the fender in the mold and also across the Hochachsrichtung the fender to the prepreg in the tool shape according to the width direction of the fender to complete.

Since such a fender is a mass-produced component, multiple assembly robots are often arranged in a production line, each of which is associated with one or two tool molds. Since the robot arm with the laying head performs many process operations during the formation of the prepreg mold, the travel time of the laying head per component to be manufactured adds to a large amount with many positive and negative accelerations of the robot arm, resulting in that the productivity of this known manufacturing method is comparatively low ,

There are already known other manufacturing processes for the production of flat components.

Based on DE 10 2011 109 698 A1 has become known a method for producing a resin-impregnated fiber semi-finished, which consists of several superimposed fiber layer. Each individual fiber layer is subdivided into a plurality of underlay, which can be made parallelized by means of a storage head. The Untergelege can be connected to partial areas to form a gel layer and deposited the individual layers of gel by means of a robot and then trimmed the prepreg so created on form.

Based on DE 3226290 A1 For example, a method and apparatus for controllably depositing fibers on a mold has become known. The tool mold is arranged on a tool table and a laying head for depositing fibers on the tool mold is arranged on a movable by means of a traveling platform holder. The endless fiber is pressed by means of a pressurized gas into the mold, wherein the laying head for the layered structure of the workpiece is moved over the mold back and forth.

Based on DE 3040838 A1 For example, a method and an apparatus for producing flat components made of fiber-reinforced materials have become known. The known device has a storage unit with two fiber spools, which are each guided through a impregnating bath and are provided therein with matrix resin. The fiber-impregnated fiber slivers are then programmatically stored in four tool molds for the simultaneous production of four rotor blades via two laying heads, with two molds arranged side by side and two mold pairs in succession.

The known manufacturing methods are characterized by a high degree of complexity of the apparatus for performing the respective method, which is in the manufacture of rotor blades for helicopters of less importance, but provides an increase in the costs associated with the production of sheet-like components in The series production, for example, the automotive industry are unsustainable.

Proceeding from this, the present invention, the object of the invention to provide a device for producing flat components with fiber reinforced plastic, which allows a cost-effective and less procedural operations of a handling device-requiring production method for the sheet-like component and beyond also to be feasible with the device manufacturing process become.

The invention has to solve this problem with respect to the device to the features specified in claim 1. advantageous Embodiments thereof are described in the further claims. In addition, the invention has the features specified in claim 9 with respect to the method, wherein advantageous embodiments of the method are described in the further claims.

The invention provides a device for producing flat components with fiber-reinforced plastic, wherein the device has at least one tool mold for receiving fiber material and at least one laying head for depositing and pressing fiber material in the mold and the laying head is translationally displaceable relative to the mold, wherein the Device has a rotatable about a substantially parallel to the translation plane of the laying head axis of rotation tool mold holder with at least two molds.

In the apparatus according to the invention, the laying head can be translationally displaced relative to the tool shape, so that the translational displacement movement, for example, the width direction of the manufactured fiber-reinforced plastic component can be covered with the laying head, while the relative movement necessary for fiber deposition in the direction transverse to the width direction of the component to be produced between the laying head and the tool mold can be implemented by a rotary actuation of the tool mold holder and thus the tool mold. As a result, by the rotary actuation of the tool mold holder, the fiber deposition over the entire necessary distance to cover the extension of the component to be produced in Hochachsrichtung be performed and it is no longer necessary to move the laying head in Hochachsrichtung of the manufactured component. But it is also possible to perform the rotational actuation of the tool mold holder so that passes through the rotary actuator another tool shape in the detection range of the laying head and the laying head is also viewed in Hochachsrichtung of the component for fiber storage.

Due to the fact that the rotatable tool mold holder has at least two tool molds, the fiber deposit for two components to be produced can be realized by turning the tool mold holder with a stationary laying element releasing the fiber material by a rotation angle range corresponding to the extent of the component to be produced in the high axis direction and the fiber deposit is carried out as long as the tool shape is in the detection range of the laying head, whereupon then the tool mold holder is rotated about such a rotation angle range around the axis of rotation that the second tool shape comes into the detection range of the laying head and then over one of the extension in the Hochachsrichtung of in the second tool shape to be produced component corresponding rotational actuation of the tool mold holder the fiber deposit is performed while still standing laying head for the second component.

Thereafter, it is only necessary to translate the laying head translationally relative to the tool mold holder in only one axial direction by a predetermined amount, which corresponds approximately to the width of the fiber to be deposited and by a corresponding Faserablage and rotational actuation of the tool mold holder one of the first deposited fiber adjacent second fiber in store both molds.

This process is repeated until the fiber deposit has been carried out in accordance with the total component width of the components to be produced. In this case, the laying head has to be displaced translationally relative to the two molds only in one direction and on the one hand results in a significant reduction in the processing operation to be performed by the laying head and on the other hand, the handling device which moves the laying head in only this one direction can be designed cost-effectively compared to a mounting robot.

It is also provided according to a development of the invention that the tool mold holder is provided with at least two largely flat outer surfaces body and the outer surfaces are designed for the arrangement of molds. Thus, the tool mold holder can be inexpensively formed, since it only has to have one degree of freedom of movement, namely rotatable about an axis of rotation substantially parallel to the translation plane of the laying head. For example, in the case of two tool molds, a box-shaped tool mold holder with two largely flat outer surfaces is sufficient.

It is also provided according to a development of the invention that the tool mold holder is provided with six largely flat outer surfaces body and the outer surfaces are designed for the arrangement of molds. The tool mold holder can thus have the shape of an elongated column with hexagonal base, which has six largely flat outer surfaces, which are thus designed to accommodate six molds, so that by a corresponding rotation of the hexagonal column, the fiber deposit with only one laying head for six flat Components is possible.

It is also provided according to a development of the device according to the invention that the Tool mold holder An elongate body is provided with at least two largely planar outer surfaces, which are designed for the arrangement of tool molds and at least one outer surface in Axiallängsrichtung of the body is provided with at least two mutually spaced tool molds. In other words, the elongate body has flat outer surfaces which have a plurality of tool molds spaced apart from each other on an outer surface, so that a plurality of laying heads are also associated with the plurality of tool molds spaced apart in the longitudinal direction of the elongated body by the rotational actuation of the elongated body several tool shapes are loaded simultaneously with fiber material and the respective laying head has to be moved translationally in each case only in one direction.

When in the axial longitudinal direction of the elongated body each on an outer surface four spaced tool shapes can be provided in this way at a tool mold holder with six outer surfaces a total of 24 tool molds of four laying heads with fiber material, the four laying heads each four molds on an outer surface at the same time Equip fiber material.

It is also provided according to a development of the invention that at least one tool mold are rotatably mounted on the tool mold holder about a substantially perpendicular to the axis of rotation tool mold axis. By the rotational actuation of the tool mold, it is possible to deposit at an angle to each other extending fiber sections on the tool mold, so that a component can be created which has a multiaxial load corresponding multi-axial fiber deposit.

It is also provided according to a development of the device according to the invention that the laying head has a thread feed and a Fadenandrückrolle and a thread cutting device and the Fadenandrückrolle is designed to be spring loaded. By this configuration can be pressed in accordance with the example of three-dimensional shape of the tool shape following contour-right in the mold and the thread cutting device of the fiber material or thread or roving are then cut off each of the Fadenandrückrolle the deposited thread or sliver when the tool form holder performs a rotational movement, the brings a arranged on another outer surface tool shape in the detection range of the laying head.

It is also provided according to a development of the invention that the laying head is designed to be rotatable relative to the mold. In this way, a thread rest take place on the tool mold, in which the deposited thread follows in sections a multiaxial loading direction.

Finally, it is also provided according to a development of the device according to the invention that the device has at least two laying heads, which are arranged opposite each other with interposed tool mold holder. Thus, for example, a gel layer can be applied with a thread orientation by a laying head in the mold and from the opposite laying head another gel layer with a different thread orientation, so that a further reduction of the production time for a sheet-like component can be realized.

The invention also provides a method for the production of components with fiber-reinforced plastic, in which by means of a laying fiber material is placed in a mold and pressed and the laying head is moved to the fiber tray translationally relative to the mold, wherein the method according to the laying head fiber material in at least two Laying head deposits alternately supplied tool molds.

In this way, a laying head can provide at least two molds with fiber material, wherein the laying head first introduces the fiber material into a first mold and presses and then introduces fiber material into the second mold after a corresponding displacement movement of the mold relative to the laying head and presses and then again the first tool mold is fed to the laying head, which then deposits and presses on the first tool mold further fiber material, wherein this can take place, for example, at an angle to the first fiber layer of the first tool mold. By repeating the fiber tray, a laying head can thus introduce fiber material into more than one tool mold and press it there by moving a respective tool shape relative to the laying head through a displacement movement.

The displacement movement may be a rotary actuation of a tool mold receiver which has a plurality of tool molds on the outer circumference, each of which is fed alternately to the laying head for fiber deposition.

For fiber deposition over the width direction of the tool shape of the laying head can be moved in translation relative to the mold, but it is also possible, the tool shape translational relative to a stationary arranged laying head and thereby implement a fiber tray in the widthwise direction of the tool mold, while the fiber tray in the direction transverse to the width direction of the tool mold is implemented by a rotational angle actuation of the tool mold.

Finally, it is also provided by the method according to the invention that the fiber material is fed to the laying head during fiber deposition on the tool mold and the fiber feed to the laying head is otherwise interrupted. In this way, it is achieved that the fiber tray from the laying head takes place on the tool shape only when a provided for fiber deposition portion of the mold is the laying head opposite, while when the tool holder is currently in rotational actuation, so a mold from the Detection range of the laying head is moved out and the next tool shape has not yet been brought into the detection range of the laying head, the laying head no thread is fed, the thread feeder is thus interrupted.

The invention also provides for the use of the above-described method for producing a fiber-reinforced plastic component for producing prepregs with dry fiber material and / or for depositing fiber material provided with thermosetting or thermoplastic resin material in the tool mold.

The invention will be explained in more detail below with reference to the drawing. This shows in:

1 a schematic representation of an embodiment of an apparatus according to the present invention;

2 a representation similar to that after 1 ;

3 a schematic plan view of a tool mold holder;

4 an enlarged view of the detail "A" after 3 ;

5 a representation similar 3 showing the arrangement of two opposing bobbin creels with laying heads.

1 The drawing shows in the upper half of a schematic, slightly perspective embodiment of a device shown 1 according to the present invention.

The device 1 has a schematically illustrated creel 2 for receiving provided on rollers or coils fiber material in the form of, for example, dry fiber ribbons 3 on. The slivers 3 Become closer by means of a 4 the drawing shown laying head 4 in a mold 5 inserted and there by means of a Fadenandrückrolle or pressure roller 6 pressed.

The laying head 4 can be in the direction of the double arrow 7 be moved translationally, so that he a displacement movement relative to a component plane 8th executes in a translation plane. In the tool mold holder 9 In the illustrated embodiment, it is an elongated roller 10 that makes a rotational movement about a rotation axis 11 can perform. The roller 10 owns, as this is closer to 3 the drawing is shown, six component levels, ie six outer surfaces 12 , so that on the six outer surfaces six tool shapes 5 can be arranged.

As the lower illustration in 1 The drawing shows are at the component level 8th or outer surface 12 the three visible of the six tool shapes 5 already partially with slivers 3 provided, this by a rotary actuation of the roller 10 around the axis of rotation 11 takes place around and whenever there is a tool shape 5 in the detection area of the laying head 4 located, the filing of sliver 3 on the mold 5 takes place and then when fiber material after rotation of the roller 11 360 ° at a cross-sectional plane in the longitudinal direction of the roller 10 at all on the outside surface 12 existing tool shapes 5 took place, the laying head 4 in the direction of the double arrow 7 is moved by the amount of a sliver width translationally in the plane of the drawing in the direction from right to left.

1 The drawing also makes it clear that on the outer surfaces 12 the roller 10 in the longitudinal direction of the arrow 13 a plurality of spaced tool molds 5 are possible, so that in the illustrated embodiment of the device 1 a total of 24 molds 5 on the outer surfaces 12 may be arranged, each mold plane in the longitudinal direction of the roller 10 a laying head 4 can be assigned so that 24 flat components with the device 1 can be made during a complete work cycle.

2 The drawing shows a representation similar to the upper half of 1 the drawing, with the four on the outer surface 12 ' arranged tool shapes 5 around a tool axis of rotation shown only schematically 14 in the direction of the arrow 15 have been rotated by an angle of 45 °, so that with the laying heads 4 a fiber deposit at a 45 ° angle can be performed to produce a sheet member which intended to receive a multiaxial burden.

3 The drawing shows a schematic plan view of the roll 10 to 1 the drawing from the front.

As will be readily apparent, in this embodiment, there are three exterior surfaces 12 a total of three molds 5 arranged so that over the laying head 4 In this embodiment, three flat components can be produced. The laying head 4 can be in the direction of the arrow 16 be designed pivotable or rotatable, so that an additional degree of freedom for the movement of the laying head 4 relative to the mold 5 is possible.

4 The drawing shows a schematic representation of the laying head 4 on a positive mold section 17 the mold 5 , The laying head 4 has a thread feeder or fiber feed 18 , via which the sliver shown schematically 3 the application site in the mold 5 is supplied and there by means of a pressure roller 6 into the mold 5 is pressed, wherein the pressure roller 6 via a spring device 19 biased, so that the pressure roller 6 positive mold sections of the mold 5 , such as the section 20 and negative mold sections of the mold 5 can follow and the sliver 3 always directly on the mold surface of the mold 5 comes to the plant. With the double arrow 21 This degree of freedom is achieved by the spring balance on the contour of the mold 5 shown.

5 The drawing shows two laying heads 4 Opposite arranged with the roller 10 in the space. This configuration is made possible by an independently proceeding displacement movement of the two laying heads 4 in the direction of the direction of movement 7 the sections of filing of sliver material 3 on the mold 5 , so that it is thereby possible to create a planar component which requires, for example, only at one section in the width direction an additional reinforcement layer. The flat component produced in this way 23 can then in the direction of the arrow 22 from the mold 5 be removed and supplied, for example, another processing station.

By means of the duplication of the molds and their mounting on a rotating drum or revolving drum, the device according to the invention enables the depositing speed of the fiber deposit to be kept constant. A constantly recurring stop and re-acceleration of a mounting robot, as is necessary according to the known manufacturing processes, is eliminated. The location of the fiber tray on the tool holder can be duplicated, and the ability to freely rotate the tool mold on the tool holder around the tool axis allows the invention to adjust any fiber angle. The angle of the fiber tray by the laying head relative to the roller or drum does not change thereby.

This makes it possible to perform the laying head relatively relatively rigid with its additional equipment, such as the fiber feed and the creel, since the laying head does not have to perform complicated Verfahroperationen. With the device according to the invention and the method according to the invention, dry fibers for producing a preform can be deposited on the tool mold, it is also possible to deposit impregnated prepregs, ie prepregs which have been impregnated, for example, with a thermosetting or thermoplastic resin material and it is also possible to wet fiber material store the mold. Due to the omission of complex procedural operations of the laying head high speeds can be realized in the fiber deposition, the angle of the fiber tray can be adjusted freely by the rotation of the molds, the fiber feed is significantly simplified and due to the elimination of large acceleration components in the process operations is compared with the known manufacturing processes reduces the production time per flat component.

With regard to the above in detail not explained in detail features of the invention, reference is expressly made to the claims and the drawings.

LIST OF REFERENCE NUMBERS

1

contraption

2

creel

3

sliver

4

laying head

5

mold

6

capstan

7

double arrow

8th

component level

9

Mold recording

10

roller

11

axis of rotation

12

outer surface

12 '

outer surface

13

arrow

14

Mold rotation axis

15

arrow

16

arrow

17

Positive mold section

18

thread feed

19

spring means

20

section

21

double arrow

22

removal direction

23

flat component

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102011109698 A1 [0007]
• DE 3226290 A1 [0008]
• DE 3040838 A1 [0009]

Claims (12)

Contraption ( 1 ) for the production of flat components ( 23 ) with fiber-reinforced plastic, the device comprising at least one tool mold ( 5 ) for receiving fiber material and at least one laying head ( 4 ) for depositing and pressing fiber material in the mold ( 5 ) and the laying head ( 4 ) relative to the tool shape ( 4 ) translationally ( 7 ) is displaceable, characterized in that the device ( 1 ) one about a largely parallel to the translation plane of the laying head ( 4 ) extending axis of rotation ( 11 ) rotatable tool mold receiver ( 9 ) with at least two molds ( 5 ) owns. Contraption ( 1 ) according to claim 1, characterized in that the tool mold holder ( 9 ) with at least two largely flat outer surfaces ( 12 ) and the outer surfaces ( 12 ) for arranging tool molds ( 5 ) are formed. Contraption ( 1 ) according to claim 1 or 2, characterized in that the tool mold holder ( 9 ) with six largely flat outer surfaces ( 12 ) and the outer surfaces ( 12 ) for arranging tool molds ( 5 ) are formed. Contraption ( 1 ) according to one of the preceding claims, characterized in that the tool mold holder ( 9 ) an elongated body is provided with at least two substantially flat outer surfaces ( 12 ), which are used to arrange tool molds ( 5 ) are formed and at least one outer surface ( 12 ' ) in the axial longitudinal direction of the body with at least two mutually spaced tool shapes ( 5 ) is provided. Contraption ( 1 ) according to one of the preceding claims, characterized in that at least one tool mold ( 5 ) on the tool mold holder ( 9 ) about a largely perpendicular to the axis of rotation ( 11 ) running tool rotational axis ( 14 ) is rotatably arranged. Contraption ( 1 ) according to one of the preceding claims, characterized in that the laying head ( 4 ) a thread feed ( 18 ) and a Fadenandrückrolle ( 6 ) and a thread cutting device and the Fadenandrückrolle ( 6 ) is designed spring loaded. Contraption ( 1 ) according to one of the preceding claims, characterized in that the laying head ( 4 ) relative to the tool shape ( 5 ) is rotatably formed. Contraption ( 1 ) according to one of the preceding claims, characterized by at least two laying heads ( 4 ), which are opposite each other with interposed tool mold holder ( 9 ) are arranged. Process for the production of components with fiber-reinforced plastic, in which by means of a laying head ( 4 ) Fiber material into a mold ( 5 ) is introduced and pressed and the laying head ( 4 ) for fiber deposition translationally relative to the mold ( 5 ), characterized in that the laying head ( 4 ) Fiber material in at least two laying heads ( 4 ) alternately supplied tool shapes ( 5 ). Method according to claim 9, characterized in that the tool molds ( 5 ) during fiber deposition relative to the laying head ( 4 ) in a direction substantially transverse to the translation direction ( 7 ) of the laying head ( 4 ) are moved. A method according to claim 9 or 10, characterized in that the fiber material during fiber deposition on the tool mold ( 5 ) the laying head ( 4 ) is supplied and the fiber feed to the laying head ( 4 ) is interrupted otherwise. Use of the method according to one of Claims 9 to 11 for producing prepregs with dry fiber material and / or for depositing fiber material provided with thermosetting or thermoplastic resin material in the tool mold ( 5 ).

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