EP2670584A1

EP2670584A1 - Method and arrangement for producing preforms

Info

Publication number: EP2670584A1
Application number: EP12700986.8A
Authority: EP
Inventors: Niccolò Pini; Daniele ROGANTINI; Giovanni Furia
Original assignee: KRINGLAN COMPOSITES AG
Current assignee: KRINGLAN COMPOSITES AG
Priority date: 2011-01-31
Filing date: 2012-01-24
Publication date: 2013-12-11
Also published as: CN103391841A; JP2014509270A; CA2826054A1; CH704406A1; US20130306233A1; WO2012104174A1; TW201249634A

Abstract

In a method for producing fiber-reinforced preforms with a thermoplastic matrix, first individual precuts (11, 25) are generated from fiber-reinforced semi-finished products such as films, panels, webs or ribbons, said precuts are transferred by means of automated transport means (13, 27) onto a storage area and then joined by means of spot welding to form preforms.

Description

METHOD AND ARRANGEMENT FOR PREPARING FORMS

The present invention relates to a method for

Production of fiber-reinforced preforms with

thermoplastic matrix according to the preamble

Claim 1, and an arrangement for automated

Manufacture of fiber-reinforced preforms.

The production of so-called preforms or preforms of fiber composite workpieces with thermoplastic matrices is known per se. First, from semi-finished products, such as

For example, fiber-reinforced films, tapes, plates, etc. blanks with the correct shape and

Cut fiber orientation and these blanks are then accurately positioned manually on appropriate tools and finally connected by small welding points.

These known manually performed methods for

Production of preforms is very time-consuming and hardly acceptable for mass production. It is also important to achieve a high repeatability of the geometric position of the fiber-reinforced blanks on the preform tool in the various layers.

It is therefore an object of the present invention to accelerate the implementation of the described method.

Accordingly proposed is a method for

Production of preforms, according to the wording of claim 1. It is proposed that first of the fiber-reinforced semi-finished products such as films, tapes, plates, etc., the individual blanks are produced and these blanks are transmitted by automated means of transport on a shelf as a preform and using

Spot welding to preforms are joined together.

According to an embodiment variant, it is proposed that blanks in predetermined shape and fiber direction are produced from the fiber-reinforced semifinished product such as films, webs, tapes, etc., and these blanks are deposited and positioned on a preforming tool by means of at least one automated transport means in an approximately exact position relative to one another and the filed

Blanks are connected by welding points.

The blanks are produced by means of so-called cutters, by punching, by means of cutting knives, etc., and according to a variant embodiment, it is proposed that the automated means of transport be one or more robots, at least comprising a gripping member for picking up or putting down the blanks produced.

According to a further embodiment variant, it is possible to provide at least one intermediate storage for temporarily storing the blanks. The intermediate storage may be

For example, to act a vertically automated circulation rack, the blanks in drawer-like

Documents are stored, either on a base similar blanks or on a pad all Blanks intended for making a preform.

The automated means of transport can be, for example, robots with one or more articulated arms, the articulated arm of the robots having grippers with adjustable suction cups and possibly one or more ultrasonic welding modules.

Further variants of the inventive

Methods are characterized in dependent claims.

The method described according to the invention is

especially suitable for the production of

rotationally symmetric or quasi rotationally symmetric preforms such as:

- Oval, rectangular, hexagonal tube shapes, conical

Tube shapes (open or closed)

- Tube shapes with varying wall thickness

- Bolt fixtures that require wall reinforcement

- branched pipe shapes

- crooked pipe shapes

- 2D components such as. Door module, cross member or the like.

- etc.

To give an example, this is the production of a wheel rim.

Further proposed is an arrangement for

automated manufacturing of fiber reinforced

Preforms according to the wording of claim 7. The arrangement has at least one two-dimensional

Cutting device for producing blanks from fiber - reinforced semifinished products such as films, tapes, plates, etc. .

at least one automated means of transport for

Picking up the blanks and optionally depositing on a preforming tool and a preforming tool on which the blanks are deposited, which is such that after production of the preform, the tool is deformable.

Further variants of the inventive

Arrangements are characterized in dependent claims.

The invention will now be explained in more detail by way of example and with reference to the accompanying drawings.

Showing:

Fig. 1 shows schematically a possible embodiment of the inventive method in three phases - cutting, interim storage and laying the

fiber-reinforced blanks

Fig. 2 shows some embodiments of

fiber-reinforced blanks,

3 shows a detail of the phase of cutting blanks from semi-finished rolls, FIG.

Fig. 4 in fragmentary form of Figure 1 and schematically the transfer of the blanks in an intermediate storage and then the removal of the blanks by means of a robot Fig. 5 shows a schematic detail of Figure 1, the transferring the blanks from the intermediate storage for

Preforming tool and producing the preform by spot welding,

6a and 6b a possible embodiment of the preforming tool in side view and in cross section, using a so-called turret rotation system,

Fig. 7 shows schematically in cross section a preforming tool for producing a rim preform for

motor vehicles

Fig. 8 shows schematically a further embodiment of the inventive method without the use of an intermediate storage, and

Fig. 9 shows schematically another

Embodiment of the inventive method for the parallel production of two 2-dimensional preforms.

Figure 1 shows schematically a possible embodiment of the method in three phases, namely cutting of

Semi - finished rolls, storage of fiber - reinforced blanks and finally laying and welding of the

Preforms.

In phase I, as shown in particular in Figure 3, the process starts on an example

two-dimensional cutting machine (cutter) 9, where

for example, carbon fiber reinforced blanks (KFZ) 11 of one or more carbon fiber ribbons

(Semi-finished rolls) 7 are cut out. To the process too There is the possibility to mount an additional cutting tool module on the cutter 9. The cut car are sorted by a robot 13 to shape and placed in an intermediate storage 23 (Phase II) The choice of the robot 13 is based on the movement requirement between cutting machine 9 and intermediate storage 23, which indicates, for example, 2D linear movements and a Z-stroke. That's why the selection has been reduced to, for example, two different robot models, such as Scara or Portal robots. For example, if the Scara model is selected, it is mounted on a running device with transverse track 17 in order to increase the mobility and range.

In Figure 2, some examples of possible blanks IIa to llle are shown, which by means of the cutter, respectively. the cutting machine 9 from the semi-finished rolls. 7

can be cut out. This is just a selection and the possible cutting forms are no limits. Of course, it is also possible to produce differently thick blanks by using semi-finished rolls of different thickness. Instead of semi-finished rolls and bands ode plates can be used, which have different thicknesses.

As already mentioned, the vehicles are cut with the cutter 9 from the semifinished rolls or plates, etc., then they are pushed further by the cutter with a conveyor belt until a robot 13 receives them with a gripper 15. The recording or picking coordinates are taken from the Cutting machine directly to a robot controller

passed on.

In the second phase according to Figure 4 gets the

Robot controller the position of the storage spaces 19 in

Interim storage communicated from a warehouse control, so that he can store the car 21 at the desired locations. The intermediate storage can be a vertical automated

Circulating rack (eg with paternoster system). This solution provides good space utilization in the cell where

For example, drawers 19 can be stacked. The different vehicle molds 21 can be used in pre-cut blister molds with rectangular outer geometries. In this case, the depositing and pecking of vehicles is much easier, due to the same picking position. The intermediate bearing 23 is provided with a control to the rolling movement of the drawers and the

Check the position of the car, etc. For picking the car from the cutter, a gripper 15 on the robot

attached, which is equipped for example with adjustable Saugnäpfen.

As shown schematically in particular in FIG. 4, the first robot 13 stores the motor vehicle 21 in the intermediate storage 23, for example in position 19. On the

opposite side of the intermediate bearing 23, the vehicle are removed by means of another robot 27.

Schematically illustrated is the wiederentnehmbare car in the opposite position 25th

The third phase begins with one or more

Knickarmrobotern 27, which the individual vehicle 25 from Bring intermediate bearing to Preformwerkzeug 39 and secured in the correct orientation by welding on the tool or on the underlying layers, such as

schematically shown in Figure 5. The robot controller learns the position of the respective motor vehicle 25 in the intermediate bearing 23 from the bearing control. The positioning of the vehicle is preferably carried out in three dimensions, and also the simultaneous movement of a robot mounted on a linear axis 31, for example six-axis robot

carried out. Also in this case, grippers 29 are mounted for picking the vehicle on the two articulated robots, which are equipped with adjustable suction cups and one or more ultrasonic welding modules. The two robots 27 can work together or be independent. One possibility is that the first robot brings the blanks onto the preforming tool, as shown schematically in FIG. 5 and the second welds them together, or that the two robots make the same process individually. Again, the robots can be mounted on a track 31 to improve their mobility. That in FIG. 5 and also with reference to FIG. 6

For example, shown preforming tool 39 is mounted on a rotating shaft 47 so that a

Positioning at a certain angle is possible, such that the mounting position of the vehicle is arranged in each case on the upper tool surface. This axis 47 is controlled as the eighth movement axis of the robot. Another variant would be to mount the preforming tool on another articulated arm robot. For example, the preform tool assembly 37 illustrated with reference to FIGS. 5 and 6, comprising a so-called turret rotation system, is divided into two parts; both (identical) parts consist of one or more

Single preforming tools 39, which can be mounted in series. While one page is in progress,

shown in Figures 5 and 6 as position A, the other (position B) can be unloaded to remove the preform from the tool and to be loaded again. The rotation of the two Vorformwerkzeuganordnungen carried by means of a rotatable about the axis 45 connecting element 43, which in turn is held by a stand member 41. The number of used

Single preforming tools depends on the cutting strategy; When automobiles are cut at one go for multiple tools, such as rims, multiple individual preform tools are assembled together in series. For example, Figure 5 shows arrangements of Vorformwerkzeugen, each having 5 tools. In FIG. 6, the arrangement or the revolver rotation system is shown in a side view in FIG. The rotation of the two

Preform tooling arrangements are achieved by means of the turret rotation system 37. The whole process is

completely controlled by control software. The

Cutting geometry is calculated for each vehicle and passed on to the cutting machine controller. The

Cutting position on the tape is also pre-calculated and determined with optimization algorithms for maximum material utilization. Figure 7 shows the example of a

Car Wheel Tool 39 How a preform tool can be opened by the tool for preform removal. The tool 39 is divided into two and separable along the dashed line 51. For preforming of the preform, the preforming tool 39 is separated along the dashed line 51 and so the two parts 53 and 55 can each be removed laterally from the preform (not shown).

FIG. 8 schematically shows a further embodiment variant of the method according to the invention, having only two phases. In contrast to the illustration in Figure 1, no intermediate storage is used. Thus, for example, an additional cutting tool on the cutter is not necessary. It may also be possible that only one

Semi-finished roll 7 is used. The articulated robot 13 takes with a gripper 15, equipped with suction cups and ultrasonic welding head, the blanks 11 from the conveyor belt and brings them directly to the preforming tool 39 for the welding process. The preforming tool 39 mounted on a rotating axle 47 is positioned at a certain angle such that the mounting position of the automobile is on the upper tool surface. This axis 47 is controlled as the seventh movement axis of the robot.

Finally, FIG. 9 shows another one

Embodiment of the inventive method for the production of different types of preforms. In the plant, shown in Figure 9, are parallel produced side by side two different preforms, in the left lane, starting from so-called unidirectional bands 4 which are fed by rollers 2 on a revolver bearing a shearing shear 6. On the right side are used as semifinished GMT

Used plates 7, which are cut in a punching machine 8. The further promotion takes place each on a conveyor belt 12, wherein the blanks 11 analogously to the previously described method by means of, for example, scara robots 13, arranged on a linear axis 17 in a second phase (3) an automated circulation rack 23 are supplied. In the feed zone blanks 21 are stored and lie on the opposite side

Blanks 25 ready for transfer to a backing for making the final preform. The

Blanks are in the illustration according to FIG. 9

for example, either rectangular or trapezoidal.

Of course, these can also be bent. Depending on the plate thickness or thickness of the band, the blanks have different thickness. For example, the thicker the UD tape, the fewer blanks need to be used, and this shortens the lay time.

Even with the GMT plates of different sizes can be expected with a blend of about 2.5%.

The blanks stored in the interim storage are

finally by means of two juxtaposed

Placed parallel robots 61 on each one Preformingtisch 62, each having a welding plotter 63, wherein the welding finally by means of a respective welding head 65th he follows. The preforming table represents the preform tool and is designed as a plotter and takes over the

Task of clinging and welding

(For example, ültraschlallschweissen) of the blanks.

In the illustrated in Figures 1 to 9

Movements and arrangements are concerned

Of course, only examples that are suitable to explain the present invention better.

Of course it is possible one or more

Provide robot, the blanks of one or more semi-finished rolls, plates, belts, or the like

cut, provide several cutting elements on the cutter, etc., etc. Also, it is possible, if provided, that form interim storage differently or

stored intermediate blanks differently organized.

Also, for arranging the blanks finally on one or more preforming tools, one or more robots of different design may be provided, one or more tools may be provided, etc. etc. Also, the inventive method is by no means limited to carbon fiber reinforced materials, also other reinforcing materials such as Glass fibers, aramid fibers, PE fibers, basalt fibers, etc. can be used.

The fiber content in the semifinished product can be selected as desired according to the requirements. For example, the proportion may be 30-60% by volume. The fiber geometry can be unidirectional. Tional be present as tissue or scrim, be configured as a fiber mat, etc.

The choice of the matrix system such as the selected thermoplastic polymer is carried out according to the requirements of the preform or to the component.

Examples are polypropylene, HD polyethylene, polyamide 6, 11 or 12, PET, PEEK, PES, PEI, POM, PPS, etc.

The described robots are also examples and, of course, differently designed robots can be used instead of, for example, a six-axis articulated robot. The same applies to the gripper organs where

For example, welding modules can be arranged, with the possibility of welding at several points simultaneously.

Turning back to the preforming tool, the preforming tool described with reference to FIGS. 5 and 6 is merely an example. Finally, as far as possible, the control of the entire arrangement should be as far as possible

automated, so that the individual devices can communicate with each other.

Claims

claims

Process for the production of fiber-reinforced preforms with thermoplastic matrix, characterized in that individual blanks are first produced from fiber-reinforced semifinished products such as films, sheets, webs, tapes, these

Blanks are transferred by automated means of transport on a shelf and are joined together by means of spot welding to preforms.

Method according to claim 1, characterized in that

- From the fiber-reinforced semi-finished products such as films, webs, tapes, plates or the like

Blanks are produced in predetermined shape and fiber direction,

- This on a preform tool means

at least one automated means of transport are positioned, and

- The individual stored blanks are connected by small welding points.

Method according to one of claims 1 or 2, characterized in that the blanks by means of a so-called cutter, by means of punching, by means of knives, by means of cutting tools, laser cutting, IS

Water jet cutting, etc. are produced from the fiber-reinforced semifinished product.

4. The method according to any one of claims 1 to 3, characterized in that the blanks are first transferred to at least one intermediate storage and stored there and then the

intermediately stored blanks are transferred to the preforming tool.

5. The method according to any one of claims 1 to 3, characterized in that the transfer of the blanks of the cutting device optionally takes place via at least one intermediate storage for Vorformwerkzeug by means of at least one robot, comprising at least one gripping member for receiving the

Cutting and finally for storing the

Cut to the preforming tool.

6. The method according to any one of claims 4 or 5, characterized in that the intermediate storage is a vertically automated circulation rack, wherein the blanks are stored in drawer-like documents, either on a base similar blanks or on a base, the blanks for

Generating a preforming tool.

7. Arrangement for the automated production of

so-called fiber-reinforced preforms,

marked by:

an at least two-dimensional cutting or punching device for producing blanks,

ADJUSTED SHEET (RULE 91)

ISA / EP - At least one automated means of transport for receiving the blanks and optionally depositing on a preforming tool, and

a preforming tool on which the blanks can be placed and which is in the form that after the preform has been produced, the tool can be shaped.

8. Arrangement according to claim 7, characterized in that at least one intermediate storage is provided, and at least one robotic means of transport between cutting or punching device and

Interim storage, and at least one robotic means of transport between interim storage and

Preforming tool.

9. Arrangement according to one of claims 7 or 8,

characterized in that at least one automated means of transport is a parallel, Scara- or portal robot, which is controlled by a robot controller.

10. Arrangement according to one of claims 7 to 9, characterized in that the at least one

automated transport means a robot with at least one gripper element, with adjustable suction cups, ice gripper, needle gripper and

optionally one or more

Ultrasonic welding modules is.

11. Arrangement according to one of claims 7 to 10,

characterized in that the at least one automated means of transport is a so-called Knickarm robot is, which is mounted on a linear axis and which at least one

six-axis robot is.

12. Arrangement according to one of claims 8 to 11,

characterized in that the intermediate storage is a so-called circulation rack.

13. Arrangement according to one of claims 7 to 12,

characterized in that the one or more preforms or preforming tools on a so-called

Revolverrotation system are arranged, comprising two positions with preforming tools, a

Position provided for laying and welding blanks to preform and the other

Position for unloading the finished

Preforms.

14. Use of the method according to one of claims 1 to 6 or an arrangement according to one of

Claims 7 to 13 for the manufacture of

Motor vehicle rims.