FR2865156A1 - Apparatus for making fibre-reinforced composition materials includes machine with mobile gantry to deliver reinforcing filaments to mould - Google Patents

Abstract

The apparatus includes a mould and a machine with a mobile gantry (1) above it to deliver reinforcing fibres of glass, carbon, synthetic or vegetable material with a resin matrix to the mould. The apparatus includes a mould and a machine with a mobile gantry (1) above it to deliver reinforcing fibres of glass, carbon, synthetic or vegetable material with a resin matrix to the mould. The machine has a turret (5) for storing the filaments (8) that provide the reinforcing fibres, and a dispensing arm (4) for the matrix material. It also has a conveyor to deliver the fibres to an interface unit (6), a tensioner, a nacelle (3) that is fixed to the gantry and moves the turret and distribution arm in a direction perpendicular to the axis of the gantry's travel, and a system for impregnating the fibres with the matrix material.

Description

DEVICE FOR REMOVING FLOOR OR WIRES IN A MOLD FOR

  THE MANUFACTURE OF PARTS IN COMPOSITE MATERIALS.

  The present invention relates to the field of facilities for the manufacture of composite materials having high mechanical properties. The present invention relates more particularly to a device and its automated manufacturing process of large parts in composite materials with high mechanical performance.

  The prior art already knows devices for making sophisticated textiles, including in particular a plurality of different material. Nevertheless, materials that are still textile materials.

  Indeed, at present, there is no automated process for manufacturing long-fiber composite parts, which makes it possible to obtain high mechanical characteristics in the context of a severely constrained operating environment. This finding applies in particular to manufacturers of wind turbines and wind turbine blades who have invested heavily for several years to control their own blade manufacturing and improve yields.

  Thus, there is no on the market of devices for the manufacture of large composite materials, all automating the production line so that a very limited number of operators is necessary, the composite material retaining all its mechanical qualities.

  The present invention intends to remedy the shortcomings of the prior art by proposing a system for depositing long fiber composite materials in a mold, identical to the work performed by human operators. This automated system for manufacturing composite materials is capable of producing large-scale composite materials, such as for the production of parts in molds of left-hand shapes of mats or the like.

  To do this, the present invention relates to a device for manufacturing composite materials with high mechanical performance, comprising at least one mold in which is deposited the material for the manufacture of said composite material, a machine tool comprising a mobile gantry, located above said mold, carrying at least one wire storage turret, said machine tool comprising a reel arm for deposition of the matrix of the composite material, and a deposition interface, managed by a control means, for the removal and cutting of the son forming the reinforcement of the composite material, characterized in that it comprises means for conveying said son for the routing of said son in the aforesaid deposition interface to an application means in the mold, said conveying means being adapted to distribute the driving force by contact with said son.

  Advantageously, the device according to the invention will comprise means for tensioning the wires.

  According to a preferred embodiment, the device of the invention will comprise at least one nacelle, fixed on the gantry, for translating the aforesaid storage turret and the reel arm.

  Advantageously, the device of the invention will include means for impregnating the wires with the matrix.

  According to one embodiment of the invention, the impregnation means will comprise a hot depositor nozzle for conveying the matrix material, the son coming into the resin during their passage through the depositing interface. .

  According to another embodiment of the invention, the impregnation means will comprise a sealed tank having at least one slot calibrated to the section of the son, said sealed tank comprising the matrix material.

  Preferably, the application means, fixed to the application interface, will consist of a deposition roller capable of acting in pressure on the deposited wires.

  According to a preferred embodiment of the invention, the wire storage turret may comprise a plurality of rotary mounted pylons comprising a plurality of rolls son.

  Advantageously, the device of the invention will comprise a son collector from each of the wire rolls.

  Preferably, the yarns will be fiberglass and / or carbon fiber, aramid or any other synthetic and / or vegetable fiber.

  Thanks to the invention, the device makes it possible to carry out all the following steps: 2865156 4 - deposit of a ply or fibers of glass fiber (carbon, aramid or any other synthetic and / or vegetable fiber), deposit or spraying gelcoats and mold release agents, defining points on the surface of the mold, machining (cutting, deburring, etc.) in two molds of concave shape, for example a bottom mold and a mold extrados to form a mold. pale 10 wind turbine.

  the present invention also allows: - the removal of pre-impregnated fiberglass son, - the cutting of pre-impregnated fiberglass sheets, - the filament winding on a mandrel (spar mold) or any other form of revolution.

  The invention will be better understood by means of the description, given purely for explanatory purposes, of one embodiment of the invention, with reference to the appended figures: FIG. 1 illustrates a sectional view of the device according to the invention with its gantry, the nacelle, the turret 25 and the reel arm; - Figure 2 illustrates a partial sectional view of the deposition interface according to one embodiment; - Figure 3 illustrates a partial sectional view of the deposition interface according to a second embodiment; and - Figure 4 illustrates a partial sectional view of the removal interface according to a third embodiment.

  As can be seen in FIG. 1, the device according to the invention comprises a gantry 1 having the shape of an inverted flared U. This gantry 1 comprises, of course, a central slot 2 for the passage in particular of the reel arm 4, said gantry 1 being placed overhanging, or above, a mold, not shown in the accompanying figures, necessary to achieve a composite material. Indeed, the present invention is intended to apply to processes for producing a composite material using at least one mold. For example, in the case of the realization of a pale large, it will be necessary to have a mold for the intrados and a mold for the extrados.

  The gantry 1 will carry on either side of the central slot 2 a nacelle 3 for operating the direction of the reel arm 4 along the central slot 2. Finally, on the nacelle 3 is the circular turret 5 having a plurality of pylons 5 'each comprising a plurality of wire coils for forming the core or the reinforcement of the composite material.

  In a particular embodiment, the gantry 1 performs a longitudinal displacement perpendicularly, or transversely, to the axis of the linear slot 2 over a length of 55 meters. Of course, this length can be much higher and exceeded 100 meters. The weight on board of this gantry 1 will be between 7 and 8 tons, while the width between the two guide rails, not visible in the accompanying figures, will be between 5 and 8 meters.

  Gantry 1 has the function of presenting the reel arm 4 and the deposition interface 6 in the different positions: working, - maintenance, - testing and control.

  This gantry 1 must be able to move in two speeds: a working speed Vt (250mm / s), a speed Vr return (2 to 4 x Vt).

  A scale and a platform to the standards in force allows the operator to climb on the nacelle 3.

  A plurality of elements is fixed to the gantry 1, in particular: the turret 5 storing the filament (son forming the reinforcement or the core of the composite material), the nacelle 3 supporting the robot 7 actuating the deposition interface 6, the turret 5 and the reel arm 4, - the reel arm 4 which conveys the filaments to the deposition interface 6 managed by the robot 7.

  The turret 5 comprises a reel of fiber yarns. The fiber store is made up of different elements 5 'to unwind fiber son packaged in coils.

  Each wire starts from a reel in use to a collector, not shown in the appended figures, placed in the center of the turret 5.

  The coils have a unit mass of approximately 24 kilos and the following dimensions 310 x 165 x 260 (millimeters). Of course, these dimensions and this weight reflect only one embodiment and do not constitute a limiting criterion.

  The coils are threaded on rotating pylons to prevent the winding of the wire. The number of 5 'pylons corresponds to the number of fiberglass son constituting the final tablecloth.

  The circular arrangement of the pylons 5 'on the floor of the turret 5 allows a rectilinear path without returning each wire to the central collector.

  On each pylon 5 'several coils are threaded on each other to limit the stopping phases for reloading the system. The reels are unwound on each pylon 5 ', level by level. The first unwound reels are those which are placed at the top of each stack, the bottom reel supporting the mass of the other reels.

  As the reels are emptied, the wire coming from the pylon changes level (1st level, 2nd level, 3rd level). The position of the wire depends on the position of the reel unwound. A mechanical and automatic system must ensure a return of the wire down. This system always limits the angular deviations between the coil axis and the wire (90 +/15) before it goes down into the central manifold.

  The fiber yarn of the empty spool is tied to the next spool yarn to ensure continuity of the fiber yarn feed. The junction (or splicing) son of two different coils must withstand the efforts of conveying. This junction is done by gluing almost instantaneously. This junction does not make the son rigid and does not increase the width of the wire flat.

  Stores having the plurality of wire spools have lifting points to be deposited and grounded for re-loading reels by an operator.

  All the mechanics and motorization of the turret are protected by sealing against small pieces of glass thread, or carbon, which are scattered in the air.

  The nacelle 3 is mounted on a transverse axis relative to the longitudinal axis of movement of the gantry 1, which allows the robot 7 to access the entire width of the gantry 1. This transverse axis makes it possible to avoid the extreme positions of the axes. 7. The nacelle supports the load of the robot 7, the turret 5, the filament coils, the reel arm 4 and various equipment (hydraulic, electrical, pneumatic ...).

  The reel arm 4 is composed of several elements: - the arm body, - the wire drive system, - the end tensioner.

  The body of the reel arm 4 is secured to the turret 5 and follows the angular displacements of the turret 5. The body of the reel arm 4 incorporates, by its geometry, the drive system of the son from the collector.

  The wire drive system is a key element of the present invention. It is composed of different sets: - a motorized treadmill, - a crazy treadmill (free of rotation), - a tension adjustment of the mats, - a pressure adjustment between the mats, a system for quick access to the threads between the carpets.

  The yarn drive system, at the outlet of the manifold, is placed in the part of the body of the reel arm 4 located under the turret 5.

  The wire drive system is flat. Each wire must be guided to the input and output of the system so that all wires run parallel. A sensor must make it possible to detect any overvoltage of the wires at the input of the drive system of the fiber wires.

  The end tensioner ensures the tension of the threads regardless of the position of the robot, so each wire 15 corresponds to a tensioning guide (flexible part equipped with eyelets). The son removal interface comprises a plurality of elements, not shown in the anexed figures: - a set of eyelet perches equipped with son passes receives the son coming from the wire reel 4 (same principle as the wire feeder arm), - a first conveyor belt which drives the fiber threads coming from the reel arm 4; - a mechanical assembly ensures the cutting of the web; - a second treadmill of reinforcement after cutting; - a matrix impregnation system, in 30 l. the occurrence of the epoxy resin, - a mechanical assembly ensures the reinforcement of the reinforcement, or the sheet, after cutting, Optionally, it may also provide a set of thermoplastic sizing (assembly son for cutting).

  The interface receives the wires by a collector; the flexible rods equipped with eyelets (fishing rod type) taking the principle used on the end tensioner of the reel arm 4.

  The son are received and repositioned in the form of a sheet (placement of the edge son aboard the son laid flat and parallel) and the son are then driven by a first set of treadmill 12 elastomer. The sheet of son passes between two treadmills 13 flasqué to ensure the driving of the web (belts made of elastomer type toothed belt). In an accessory manner, it will be possible for the sheet to be bonded during its assembly by a thermoplastic wire deposited at 70/90 relative to the direction of the fiber.

  In an embodiment shown in Figure 2, the dry fiber son arriving at the entrance of the interface conveyor (interface conveyor) come into contact with the resin film 9 semi-liquid, or pasty.

  The resin 9 is conveyed in the liquid phase (viscous) by heated pipes 10 to the dispensing nozzle 11. The dispensing nozzle 11 is heated and calibrates the film resin of rectangular section (extrusion). The temperature of the nozzle 11 must be continuously regulated to maintain the good consistency of the resin 9 (consistency of the calibrated wax).

  The section of the film is determined by the width of the web on the one hand and by the desired impregnation rate on the other hand. The fiber threads 8 arranged parallel and edge to edge during their passage through the interface conveyor sink slightly into the resin film. The cohesion of the son 8 between them at the exit of the interface conveyor is provided by the resin film 9. The unwinding of the web controls the supply of resin 9 of the system.

  According to another embodiment of the impregnation of fiber threads 8, shown in FIG. 3, it will be possible for the dry fiber threads to enter a tray 14 through a slot calibrated at the section of the dry fiber threads 8 .

  In this case, the tray 14 contains the matrix (epoxy resin and hardener), which is regulated (temperature, level, pressure ...). The impregnated sheet comes out of a calibrated slot. The impregnation of the sheet is directly a function of: - the dimensions of the exit slot, - the pressure in the tank, - the temperature of the epoxy system (or other).

  The last mode of impregnation chosen to illustrate the invention, and represented in FIG. 4, consists of the deposition of a liquid epoxy film on one of the faces of the sheet: the objective here is to make the epoxy system electrostatic ( negatively charged) using an electrode 15. This electrode 15 is placed in an extruder nozzle which produces the matrix film 9. This nozzle can heat the matrix 9.

  The cutting of the fiber threads forming the reinforcement or the core of the composite material is performed by shearing with a cutting blade 16.

  In the impregnating variants of the fiber threads 8 shown in FIGS. 2 and 3: the interlocking of the threads 8 in the resin film 9 makes it possible to make clear cuts. The resin 9 ensures the maintenance of the son 8 between them. The fiber threads 8 remain attached to the film 9 after cutting and can thus be driven towards the second interface conveyor to be placed under the applicator roll 17.

  In the impregnating variant of the fiber yarns shown in FIG. 4: it is necessary to take account of the absence of connection between the fiber yarns. This is because the cut takes place before the gluing phase with the resin 9.

  Optionally and in order to ensure a perfect cut, it is expected to impregnate the web of a bead of thermoplastic polymer disposed upstream of the conveyor belt 12. The latter will apply a pressure on the molten bead making it migrate into the fiber 8. The bead will solidify during the course of the web between the two mats 12. The cutting is performed by shearing the web to the right of the gluing of the thermoplastic. The location of the cutout is located after the carpet 12, that is to say before the threads 8 are impregnated with matrix 9.

  A mechanical rebooting system allows this web to be positioned between the mold and the applicator roll 17. In one embodiment, the moving-axis system follows an elliptical trajectory (crank-handle) and in another embodiment, a plate bent to the radius of the roll that comes to press the web on the roller 17 (rotational movement), the robot 7 will adopt an inclined position at the start of the path to pinch the fall.

  The invention is described in the foregoing by way of example. It is understood that the skilled person is able to realize different variants of the invention without departing from the scope of the patent.

2865156 14

Claims (10)

  1. Device for the manufacture of composite materials with high mechanical performance, comprising at least one mold in which is deposited the material for the manufacture of said composite material, a machine tool comprising a gantry (1) mobile, located above said mold, carrying at least one wire storage turret (5) (8), said machine tool comprising a reel arm (4) for the deposition of the matrix (9) of the composite material, as well as a removal interface ( 6), managed by a control means (7), for the removal and then the cutting of the son (8) forming the reinforcement of the composite material, characterized in that it comprises a conveying means (12, 13) of said son for conveying said yarns in the aforesaid deposition interface (6) to a conveying means (12, 13) in the mold, said conveying means (12, 13) being able to distribute the training force by contact with said wires (8).   2. Device according to claim 1, characterized in that it comprises means for tensioning the son.   3. Device according to claim 1 or claim 2, characterized in that it comprises at least one nacelle (3), fixed on the gantry (1), for translating the aforesaid turret (5) storage and the reel arm (4) perpendicular to the axis of movement of the gantry (1).   4. Device according to any one of the preceding claims, characterized in that it comprises a means for impregnating (11, 14 or 15) son (8) by the matrix (9).   2865156 15 5. Device according to claim 4, characterized in that the impregnating means (11) comprises a hot depositor nozzle for conveying the matrix material (9), the son (8) sinking into the resin (9) during their passage in the removal interface (6).   6. Device according to claim 4, characterized in that the impregnation means (14) comprises a sealed tank having at least one slot calibrated to the section of the son (8), said tank (14) sealed comprising the material forming matrix (9).   7. Device according to any one of the preceding claims, characterized in that the application means, fixed to the removal interface (6), consists of a removal roller (17) able to act in pressure on the son (8) deposited.   8. Device according to any one of the preceding claims, characterized in that the turret (5) for storing the son comprises a plurality of rotatably mounted pylons (5 ') having a plurality of son rollers (8).   9. Device according to claim 8, characterized in that it comprises a son collector from each of the son rollers (8).   10. Device according to any one of the preceding claims, characterized in that the son (8) are fiberglass and / or carbon fiber, aramid or any other synthetic fiber and / or plant.