DE102016101961A1 - Sensor device for detecting material defects and method thereof - Google Patents

Abstract

The invention relates to a sensor device for detecting material defects of a Faserendlosmaterials while depositing the Faserendlosmaterials on a tool for the production of a fiber composite component, wherein at least one sensor is provided to which the Faserendlosmaterial is continuously supplied during deposition, wherein the sensor for detecting the fiber width of is formed, which is adapted to detect a material error of the fiber endless material in dependence on the detected fiber width of the fiber endless material.

Description

The invention relates to a sensor device for detecting material defects of a Faserendlosmaterials while depositing the Faserendlosmaterials on a tool for the production of a fiber composite component. The invention also relates to a fiber laying device for laying fiber endless material with such a sensor device. Likewise, the invention relates to a method for detecting material defects of a Faserendlosmaterials while depositing the Faserendlosmaterials on a tool for the production of a fiber composite component.

Components made of a fiber composite material, in short fiber composite components, are today due to their weight-specific strength and rigidity from the air and space travel indispensable. But in other classical manufacturing areas, the application of such materials is becoming more and more popular because with constant stiffness and load capacity can be significantly reduced weight. Therefore, fiber composite materials are particularly suitable for lightweight construction.

A disadvantage of these fiber composites is the higher production costs compared to conventional, in particular isotropic materials, which makes a series production comparatively more expensive. This is ultimately due to the fact that sometimes individual process steps in the manufacture of a fiber composite component must be performed manually.

For some time, therefore, there have been efforts to automate the deposition process, ie to automate the deposition of the fiber material on the tool to form a preform for the production of a fiber composite component. For example, from the DE 10 2010 015 027 B4 such as EP 25 05 343 B1 a Faserlegevorrichtung known in which by means of robots and arranged on the robot fiber laying heads the Faserendlosmaterial can be stored on a tool for forming the component geometry, wherein the fiber endless material is provided in a ribbon or strand. In this case, the fiber endless material is guided by a relative to the laying head fixed fiber storage or fiber magazine to the fiber laying head, which then presses the fiber endless material on the tool surface and deposits there. For example, rovings are used as fiber endless materials.

In the automated production of fiber composite components, several fiber webs are deposited on the tool in different layers. It has been shown that material defects can arise in this case, which lead to a defect in the component in the subsequent production of the fiber composite component, so that the component must be repaired or completely supplied to the committee. Such material defects are, for example, the twisting of a fiber or a band by 180 degrees (so-called twists) or material folds.

In practice, the plant operator must continuously monitor the production in order to recognize the material faults mentioned above at an early stage and to be able to eliminate the cause of the fault. In addition, he must note down the current path and the number of faulty fibers so that a robot, after removal of the corresponding fibers by the plant operator, at the end of a situation again can put down. This determination is made immediately after each lane on the mold, because the faulty fibers are difficult to trace back because of the countless webs and fibers later. However, this requires a lot of concentration from the plant operator in order to be able to recognize and document all defects that occurred parallel to the plant operation. In addition, large molds prevent the direct view of deposited fibers, which is why faulty fibers are difficult to identify in places. Should it still be possible, it is not always possible to assign them over long distances to the corresponding fiber numbers, as a result of which defect-free fibers are removed from the mold and incorrect data is entered into the repair program of the robot.

It is therefore an object of the present invention to provide a way that can be automatically detected and logged with the material defects in the automated filing of fiber webs. It is a particular object of the present invention to provide such automated detection of material defects that can be easily integrated into existing investment concepts.

The object is achieved with the sensor device according to claim 1, a fiber laying device according to claim 8 and a method for detecting material defects according to claim 10 according to the invention.

According to claim 1, a sensor device for detecting material defects of a Faserendlosmaterials is proposed during the deposition of Faserendlosmaterials on a tool for the production of a fiber composite component, according to the invention, the sensor device has at least one sensor to which the Faserendlosmaterial is continuously supplied during deposition, the sensor for Detecting the fiber width of the fed Faserendlosmaterials is formed. An evaluation unit signal-connected to the sensor is set up in such a way that material errors occur of the continuous fiber material can be detected as a function of the detected fiber width of the fiber endless material.

In particular, it is determined whether the fiber width of the fiber endless material changes, in particular whether the fiber width is reduced, so that when the fiber width is changed starting from a fiber width without material defects, a material defect of the fiber endless material is inferred. For example, if the material defect is a twist, the fiber width of the continuous fiber material in the area of the twist is significantly reduced relative to the normal fiber width, which can be detected by continuously detecting the fiber width of the fiber endless material and analyzing the fiber width. If the fiber width now changes from a normal fiber width without material defects to a significantly reduced fiber width, then a material defect of the fiber endless material can be deduced. The evaluation unit will then detect a material error and, if appropriate, transmit a corresponding message to the system control, so that it can then initiate appropriate measures for error correction.

The inventors have recognized that, based on a continuous monitoring of the fiber width of the fiber endless material, material defects during the laying down of the fiber endless material can be detected quickly and, above all, reliably. In particular, it has been recognized that the monitoring of the fiber width is sufficient in order to be able to infer corresponding material defects of the fiber endless material when depositing the fiber material.

Thus, the fiber width of the fiber endless material can be monitored continuously, for example by means of an optical sensor, for example an imaging optical sensor. With the aid of an image processing program, the fiber width can then be detected on the basis of the recorded image data, whereby deviations from the normal fiber width can then also be detected here and then conclusions can be drawn about material defects.

Advantageously, the evaluation unit is set up to determine whether the fiber width of the fiber endless material falls below a predetermined threshold value or limit value. If the fiber width falls below a predetermined threshold value or limit value, then a material defect is concluded and a corresponding material defect is detected in the fiber endless material. This can improve the detection of material defects and reduce the likelihood of false alarms.

In a particularly advantageous embodiment, the sensor has at least two light barriers arranged at a distance from one another which are smaller than the fiber width of the fiber endless material without material defects (normal fiber width), the light barriers being arranged so that the light barriers are interrupted when the fiber endless material of the sensor device is supplied are when the Faserendlosmaterial does not have the fiber width conditional material defects. If, however, the fiber endless material has a material defect which causes the fiber width, for example a twist or a material fold, at least one light barrier is not interrupted, which can be detected by the evaluation unit. In this case, a material error is detected by the evaluation unit.

With the aid of the light barriers and the arrangement such that the distance between the light barriers to each other is smaller than the normal fiber width of Faserendlosmaterials, reducing the fiber width can be detected below a predetermined threshold (defined by the distance between the light barriers) by the previously interrupted light barriers are not interrupted in the area of the material defect (at least one of them), so that the material defect is then detectable.

The light barriers are in each case arranged in the edge region of the fiber endless material and emit a light barrier signal transversely to the conveying direction and transversely to the fiber plane, i. in the direction of fiber thickness.

Due to the very small size of such a sensor based on at least two light barriers, such a sensor device can be integrated into existing fiber guides of casual robots so that all fiber strands of the fiber endless materials can be monitored independently there. In this way, eliminating the detection and documentation of faulty fibers by the plant operator, since such information can be transferred from the sensor to a higher-level control from then on.

Advantageously, the evaluation unit is set up in such a way that it recognizes a characteristic change in the fiber width and then, depending on the characteristic change in the fiber width, then concludes that there is a material defect. Thus, for example, in the case of a twist (twisting a fiber through 180 degrees), the characteristic deviation of the fiber width is such that, starting from the normal fiber width, a continuous, constant decrease of the fiber width is first to be detected until a minimum fiber width has been reached, whereupon the fiber width is restored continuously increases steadily until it has reached the normal fiber width. Such a Fiber width profile, which is characteristic of a particular material defect, can be determined by the evaluation unit on the basis of the continuously determined fiber width, whereupon the material defect can then be deduced.

In an advantageous embodiment, the light barriers are designed so that the distance of the light barriers is mutually variable, so that the sensor device can be adapted to the type of fiber endless material used, in particular the normal fiber width. In addition, the sensitivity of the detection can be adjusted by changing the distance of the light barriers from one another, as this makes it possible to adapt the predetermined threshold value.

In a further advantageous embodiment, the sensor of the sensor device has two fork light barriers, each fork light barrier having a first leg and a second leg, which are connected to one another by means of a web. In this case, a light barrier emitter is arranged on the first leg of the fork light barriers, while a light barrier receiver is arranged on the second, opposite leg. The first leg, the web and the second leg of the fork light barrier thereby form a U-shaped detection region through which the fiber endless material is passed.

If such a forked light barrier is now arranged at both edge regions of the fiber endless material, then the fiber width can be separately monitored for each side of the fiber endless material, the respective light barrier not being interrupted if the fiber width falls below a certain threshold value, which is detected by the evaluation unit and then due to a material defect is closed.

The two fork light barriers are arranged so that the respective open sides of the U-shaped detection areas are opposite, whereby a passage is created by the fiber endless material is to be passed.

With regard to the fork light barriers, it is particularly advantageous if these fork light barriers are arranged to be movable relative to one another, so that the distance of the fork light barriers from one another is variable. Thus, the detection range can be adapted to the normal fiber width of the fiber endless material used.

According to claim 8, a fiber laying device is proposed which is designed for laying fiber endless material on a tool. The fiber laying device generically has an automatic handling machine, at one end of which a fiber laying head for depositing the fiber endless material is arranged as the end effector. Furthermore, a fiber storage device fixed in relation to the fiber laying head is provided, which is designed to provide the fiber endless material to be deposited. The fiber storage for this purpose, the fiber material, usually wound up on coils. With the help of a fiber feeder, the provided fiber endless material is then guided from the fiber storage to the fiber laying head. According to the invention, it is now provided that the fiber-laying device has a sensor device as described above in order to be able to continuously monitor the fiber width and, if necessary, be able to detect material defects.

Advantageously, the sensor of the sensor device is arranged on the fiber feed device or on the fiber lay head, so that the fiber endless material can be supplied to the sensor. If a plurality of webs of fiber endless material fed to the fiber laying head, so it is particularly advantageous if a separate sensor is provided for each fiber web, so that the fiber width of each fiber web can be monitored independently of the others.

According to claim 10, a method for detecting material defects of a Faserendlosmaterial during the deposition of Faserendlosmaterials on a tool for the production of a fiber composite component proposed, during the deposition of the fiber material continuously detects the fiber width of the fiber endless material by means of a sensor and a material error of the fiber endless material in dependence the detected fiber width of the fiber endless material is detected by means of an evaluation unit.

Advantageous embodiments of the method can be found in the subclaims.

The invention will be explained by way of example with reference to the attached figures. Show it:

1 - Schematic representation of a fiber-laying device;

2 - Schematic representation of the principle of action of the sensor device;

3 - Exemplary representation of detectable material defects.

1 schematically shows a fiber laying device 10 holding an automatic handling machine 11 in the form of an industrial or articulated robot. As the end effector of the handling machine 11 is a fiber laying head 12 provided, which is a pressure roller 13 has, with which the supplied fiber endless material on a tool (not shown) can be stored. With the help of the handling machine 11 is the fiber laying head 12 while freely movable in space, in particular in the three translational and three rotational axes of motion.

Opposite the freely movable fiber laying head in the room 12 has the fiber laying device 10 Furthermore, a fixed fiber storage 14 on, in which the fiber endless material to be deposited 15 provided. The fiber endless material 15 is strand or web-shaped on coils 16 is wound up and then a feeder 17 supplied, which is the Faserendlosmaterial 15 to the fiber laying head 12 promotes. The promotion of fiber endless material 15 takes place preferably along the kinematic chain of the handling machine 11 ,

In the embodiment of 1 is at the fiber laying head 12 in the feeder 17 a sensor device 20 arranged to detect material defects of the fiber endless material 15 during the laying of the fiber endless material 15 with the help of the fiber laying head 12 is trained. In this case, the sensor device 20 designed so that they each individual fiber strand of Faserendlosmaterials 15 separately and individually monitored so as to be able to determine exactly which fiber strand of the fiber endless material has a material defect.

2 shows the functional principle in a schematic representation of the sensor device 20 , The sensor device 20 has a sensor 21 on top of that with an evaluation unit 22 connected is. With the help of the sensor 21 can be the fiber width b of the fiber endless material 15 monitor to change the fiber width b of the fiber endless material 15 to be able to detect a material defect.

In the embodiment of 2 the sensor points 21 two forked light barriers 23 each having a lateral edge region of the fiber endless material 15 enclose. A fork light barrier 23 has a first leg 24a on, opposite a second leg 24b is arranged. Both thighs are over a bridge 24c connected with each other.

On the first leg 24a a fork light barrier 23 is a light barrier emitter 25a arranged while on the opposite second leg 24b a corresponding light barrier receiver 25b is provided.

The photocell emitter 25a sends a light cabinet signal 26 off, in the uninterrupted state of the light barrier of the light barrier receiver 25b is receivable. If the light barrier is interrupted, then the light barrier signal 26 , For example, a laser light or infrared light from the light barrier receiver 25b not received.

As in the embodiment of 2 can be seen, the two edge regions of Faserendlosmaterials 15 by a fork light barrier 23 monitored left and right. 2 shows a section across the device, so that the promotion of fiber endless material 15 out of the viewing plane.

In the embodiment of 2 has the fiber endless material 15 In this case, a normal fiber width b, ie a fiber width without material defects, so that both the left and the right fork light barrier are interrupted. Here is the distance between the two fork light barriers 23 is selected so that the distance between the emitted light barrier signals is smaller than the normal fiber width b of the fiber endless material 15 ,

In the embodiment of 2 are the two light barrier receivers 25b the two forked light barriers 23 with the evaluation unit 22 connected so that it can be determined by applying a simple electrical signal, whether the fork light barrier is interrupted or not. In the example of 2 in which the fiber endless material 15 has a flawless normal fiber width b, both are fork light barriers 23 interrupted. If the fiber width changes and this leads to an uninterrupted light barrier, a corresponding signal from the light barrier receivers will accordingly be produced 25b to the evaluation unit 22 Posted.

Now receives one of the two fork light barriers, the light barrier signal, as in 3 is shown, it can be assumed that the fiber width b of the fiber endless material 15 falls below a predetermined limit of the fiber width, so it must be assumed that due to the reduced fiber width of the fiber endless material 15 has a material defect. Now if one of the two light barriers has no interruption, the light barrier receiver will detect 25b the light barrier signal 26 received, so that a corresponding signal to the evaluation 22 is transmitted, which then registers the signal change of the light barrier.

In 3 is exemplary in the upper figure, a continuous fiber material 15 is shown to have a fiber width b1 which is smaller than the fiber width b in the normal state due to a rotation of the fiber 180 degrees about its own longitudinal axis. In In this case, both the left and the right fork light barrier 23 no interruption to what is done by the evaluation unit 22 is then registered for this fiber strand of the fiber endless material 15 Issues a corresponding material error.

In the example below 3 the case is shown that on one side of the fiber endless material 15 a material fold has been created, whereby the fiber material is unilaterally changed in its geometry. This is detected by one of the two fork light barriers 23 is not interrupted, while the other fork light barrier (in this case right) is still interrupted. Also in this case the evaluation unit will detect a material error and issue a corresponding message.

The combination of several sensors 21 allows a modular design of a compact sensor, which can be integrated into existing systems of different manufacturers. As a result, any number of fiber strands can be monitored independently of each other. Incidentally, another advantage is that the monitoring takes place without contact, so that there is no impairment or damage to the fiber material at any time.

In addition, the distance between the fork light barriers can be 23 (see. 2 ), so that the sensitivity of the sensor 21 can be adjusted. The greater the distance between the forked light barriers 23 (And thus the closer the distance of the light barrier signals 26 to the normal fiber width b), the more sensitive the sensor reacts 21 for possible material defects or deviations from the normal or standardized fiber width b.

The light barrier signal 26 For example, it may be an emitting infrared light emitted by a transmitter (IR-LED) and received by a receiver (phototransistor).

LIST OF REFERENCE NUMBERS

10

Fiber laying device

11

handling machines

12

Fiber laying head

13

pressure roller

14

fiber storage

15

Fiber endless material

16

Do the washing up

17

feeding

20

sensor device

21

sensor

22

evaluation

23

Slotted Optical Switches

24a

First leg

24b

Second thigh

24c

web

25a

Photoelectric emitter

25b

Light barrier receiver

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 102010015027 B4 [0004]
• EP 2505343 B1 [0004]

Claims (13)

Sensor device ( 20 ) for detecting material defects of a fiber endless material ( 15 ) during the laying of the fiber endless material ( 15 ) on a tool for the production of a fiber composite component, characterized in that at least one sensor ( 21 ), to which the continuous fiber material ( 15 ) is continuously feedable during deposition, wherein the sensor ( 21 ) for detecting the fiber width of the fiber endless material supplied to it ( 15 ), and an evaluation unit ( 22 ) is provided for detecting a material defect of the fiber endless material ( 15 ) as a function of the detected fiber width of the fiber endless material ( 15 ) is set up. Sensor device ( 20 ) according to claim 1, characterized in that the evaluation unit ( 22 ) to determine whether the fiber width of the continuous fiber material ( 15 ) falls below a predetermined threshold value, wherein falls below the threshold value, a material error of the fiber endless material ( 15 ) is detected. Sensor device ( 20 ) according to claim 1 or 2, characterized in that the sensor ( 21 ) has at least two spaced-apart light barriers whose distance from one another is smaller than the fiber width of the fiber endless material ( 15 ) without material defects, wherein the light barriers are arranged such that when feeding the fiber endless material ( 15 ) of the sensor device ( 20 ) the light barriers are interrupted when the fiber endless material ( 15 ) has no material defects due to the fiber width, and that at least one light barrier is not interrupted when the fiber endless material ( 15 ) has a fiber width conditional material error, wherein the evaluation unit ( 22 ) is designed for detecting a material error based on at least one uninterrupted light barrier. Sensor device ( 20 ) according to claim 3, characterized in that the light barriers are formed so that the distance of the light barriers is mutually variable. Sensor device ( 20 ) according to claim 3 or 4, characterized in that the sensor ( 21 ) two fork light barriers ( 23 ), each forked light barrier ( 23 ) on a first leg ( 24a ) a light barrier emitter ( 25a ) and on a second, opposite leg ( 24b ) a light barrier receiver ( 25b ), wherein the first and the second leg ( 24b ) over a bridge ( 24c ) are joined together so that a U-shaped detection area is created, through which the fiber endless material ( 15 ) is passed. Sensor device ( 20 ) according to claim 5, characterized in that the two fork light barriers ( 23 ) are arranged so that the respective open sides of the U-shaped detection areas are opposite each other. Sensor device ( 20 ) according to claim 5 or 6, characterized in that the fork light barriers ( 23 ) are formed so that the distance between the fork light barriers is mutually variable. Fiber-laying device ( 10 ) for laying fiber endless material ( 15 ) on a tool with an automatic handling machine ( 11 ), at one end of which a fiber-laying head ( 12 ) for depositing the fiber endless material ( 15 ), with respect to the fiber laying head ( 12 ) fixed fiber storage ( 14 ) for providing the fiber endless material to be deposited ( 15 ) and a fiber supply device ( 17 ) for feeding the fiber endless material ( 15 ) from the fiber storage ( 14 ) to the fiber laying head ( 12 ), characterized in that the fiber laying device ( 10 ) a sensor device ( 20 ) according to one of claims 1 to 7. Fiber-laying device ( 10 ) according to claim 8, characterized in that the sensor ( 21 ) of the sensor device ( 20 ) at the fiber supply device ( 17 ) on the fiber laying head ( 12 ) or in the fiber laying head ( 12 ) is arranged so that the fiber endless material ( 15 ) the sensor ( 21 ) can be fed. Method for detecting material defects of a continuous fiber material ( 15 ) during the laying of the fiber endless material ( 15 ) on a tool for the production of a fiber composite component, characterized in that during the laying of the fiber endless material ( 15 ) continuously the fiber width of the fiber endless material ( 15 ) by means of a sensor ( 21 ) and a material defect of the fiber endless material ( 15 ) as a function of the detected fiber width of the fiber endless material ( 15 ) by means of an evaluation unit ( 22 ) is detected. Method according to claim 10, characterized in that by means of the evaluation unit ( 22 ) determines whether the fiber width of the continuous fiber material ( 15 ) falls below a predetermined threshold value, wherein falls below the threshold value, a material error of the fiber endless material ( 15 ) is detected. A method according to claim 10 or 11, characterized in that the fiber width by means of at least two spaced light barriers as a sensor ( 21 ) is detected, wherein the distance of the spaced light barriers is smaller than the fiber width of the Faserendlosmaterials ( 15 ) without material defect. A method according to claim 12, characterized in that the light barriers of the Faserendlosmaterial ( 15 ) when the continuous fiber material ( 15 ) does not have the fiber width conditional material defects, or at least one of the light barriers is not interrupted when the fiber endless material ( 15 ) has a fiber width conditional material error, wherein by means of the evaluation unit ( 22 ) then a material error on the basis of the least one uninterrupted light barrier is detected.

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