WO2022043632A1 - Installation and method for manufacturing brake discs - Google Patents

Installation and method for manufacturing brake discs Download PDF

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Publication number
WO2022043632A1
WO2022043632A1 PCT/FR2021/051472 FR2021051472W WO2022043632A1 WO 2022043632 A1 WO2022043632 A1 WO 2022043632A1 FR 2021051472 W FR2021051472 W FR 2021051472W WO 2022043632 A1 WO2022043632 A1 WO 2022043632A1
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WO
WIPO (PCT)
Prior art keywords
level
installation
tower
parts
station
Prior art date
Application number
PCT/FR2021/051472
Other languages
French (fr)
Inventor
Paul-André CHEVRIN
François GEBURTIG
Bérenger ROUSSEL
Original Assignee
Safran
Safran Landing Systems
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Safran, Safran Landing Systems filed Critical Safran
Publication of WO2022043632A1 publication Critical patent/WO2022043632A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2200/00—Materials; Production methods therefor
    • F16D2200/0034—Materials; Production methods therefor non-metallic
    • F16D2200/0039—Ceramics
    • F16D2200/0047—Ceramic composite, e.g. C/C composite infiltrated with Si or B, or ceramic matrix infiltrated with metal

Definitions

  • the invention relates to the field of brake discs made of composite material for aircraft, in particular for aircraft landing gear.
  • the invention relates to the field of brake discs made of carbon-carbon composite material.
  • a carbon-carbon composite material also called C-C composite, is made up of a fibrous reinforcement consisting of carbon fibers and a carbon-based matrix.
  • Such a composite material has good mechanical strength, in particular at high temperature, high thermal conductivity, a high coefficient of friction at high energy and a low density compared for example to steel. Given these properties, carbon-carbon composites find numerous applications in the aerospace field, in particular for the manufacture of brake discs for aircraft.
  • C-C composite brake discs for aircraft are manufactured according to manufacturing ranges involving different operations using different types of installation specific to the specific processes implemented.
  • the installations are generally positioned in the same manufacturing workshop in order to guarantee the continuity of the flow of parts at the different stages of their manufacture.
  • Some operations are implemented as a unit: a single part is processed during this operation in an installation capable of processing the parts one by one.
  • Other operations are implemented in batches of a large number of parts.
  • the first step is to manufacture the fibrous reinforcement.
  • This manufacturing step consists of textile operations intended to produce a part in the form of an annular carbon fiber preform, using as raw material cables made up of a large number of filaments.
  • the thick annular preform is for example made up of a stack of textile sheets bonded together by needling, sheet after sheet.
  • the chemical nature of these layers can be organic, for example if the layers are made up of tows of polyacrylonitrile or carbon fibers.
  • obtaining a carbon fiber preform requires the implementation of a carbonization operation during which the fiber of the preforms is transformed into carbon fiber. This operation is carried out by processing a batch of preforms in a dedicated thermal chamber.
  • the preforms are grouped together in stacks on trays which are transported and placed in the thermal chamber in which they undergo a densification treatment by gas to form blanks. . This is carried out at temperatures of the order of 1000°C and at low pressure, and under sweeping of a gas such as a hydrocarbon. These temperature and pressure conditions lead to the cracking of the gas and allow the filling of the porosities, thus constituting the carbon matrix of the composite material.
  • Brake disc blanks are thus formed in batches of a large number of units.
  • Densification can be carried out in several infiltration cycles between which the blanks are peeled during a unit machining operation in order to open the surface porosities again and allow good densification during the following densification cycle.
  • a heat treatment can also be carried out on a batch of blanks in a dedicated thermal chamber.
  • the manufacture of brake discs involves several transformation stations.
  • the first transformation station groups together the textile operations for the constitution of the dry preforms, peeling, and machining, and therefore performs operations on unitary elements.
  • the second transformer station which notably comprises large thermal enclosures to carry out the steps carbonization, densification and heat treatment, performs operations on batches of parts at the semi-finished stage grouped in stacks on trays.
  • the first transformer station is arranged on a first level of the installation, a low level.
  • the loading and unloading of the trays in the thermal enclosures is done through an entrance arranged in the upper part of the thermal enclosures, which are generally a few meters high. This entry is made through an opening system at the top of the thermal enclosures such as a pivoting lid. Consequently, the second transformer station comprising in particular the thermal enclosures is arranged on a second level of the installation.
  • the parts must be routed between transformer stations comprising entrances arranged on separate levels of the installation.
  • Such a configuration of the installation requires dedicated means such as goods lifts, and generally leads to load breaks between the two levels.
  • the processing of parts individually for certain operations, and in batches for other operations also leads to load breaks between the two areas.
  • the flow of parts at the semi-finished stage between the different stations is not homogeneous, causing bottlenecks that generate cycle times and intermediate manufacturing stocks, leading to significant additional production costs.
  • the invention proposes an installation for the manufacture of brake discs for an aircraft, formed from a composite material comprising a matrix and a fibrous reinforcement, the installation comprising:
  • a second part transformation station having a second entrance arranged on a second level of the installation, the second level being raised with respect to the first level; and - a tower for storing and transferring parts capable of moving between the first station and the second station, the tower comprising:
  • At least one swing able to move in the support structure to receive the parts of the first station from the first level and transfer them to the second station by the second level.
  • the installation for the manufacture of brake discs therefore comprises a tower for storing and transferring parts between the various transformation stations, which makes it possible to easily transport these parts from one station to another.
  • the storage tower comprises according to the invention at least one swing for receiving the parts.
  • the balancelle according to the invention moves in the support structure of the tower in order to receive the parts by one or the other level.
  • the first transformer station on the first level the tower is loaded and then moved to the second transformer station placed on the second level.
  • the swing is then moved in height according to, for example, a rotation-translation movement in order to align it with the second level where the parts are unloaded in order to be transferred to the second transformation station.
  • the parts leaving the second transformation station can be recovered at the level of the second level to be loaded onto the swing of the storage tower then transported by this mobile tower to the first manufacturing station where they are unloaded at the level of the first level, with a view to machining the parts.
  • the storage tower makes it possible to distribute the flow of parts between the various stations, which limits load breaks and improves manufacturing speed.
  • the tower comprises a plurality of swings.
  • the number of swings in a tower can be chosen so as to allow simultaneous storage of a full load and a full unloading of a thermal chamber.
  • a load of parts from the first station is loaded onto the tower, which is routed opposite the second station.
  • the parts treated in the second station are first unloaded onto the available swings of the tower, then the untreated parts brought by the tower are immediately loaded into the second station. This minimizes the waiting time for the second workstation between two processing cycles.
  • the installation according to the invention may comprise one or more of the following characteristics, taken separately from each other or in combination with each other:
  • the storage and transfer tower comprises an interface arranged on the support structure and capable of cooperating with a guided autonomous vehicle to move the tower;
  • an electric control device capable of controlling the movement of the storage tower and the movement of the swing
  • the storage and transfer tower comprises wheels on which the support structure is mounted;
  • the storage and transfer tower comprises a first parts passage giving access to the first level and a second parts passage giving access to the second level;
  • the distance between the first passage and the second passage is between 2 m and 20, preferably between 5 m and 10 m;
  • the storage and transfer tower comprises a plurality of rows of swings superimposed and distributed over two columns, each of the swings being able to be placed in the support structure;
  • the support structure has a width comprised between 2 m and 20 m, preferably comprised between 5 m and 10 m and a depth less than the width of the support structure, for example comprised between comprised between 2 m and 8 m.
  • the invention also relates to a method for manufacturing brake discs for an aircraft comprising the following steps:
  • a storage and transfer tower comprising a support structure and at least one movable swing in the support structure
  • the swing is rotatable in the support structure.
  • Figure 1 is a schematic view of an installation for manufacturing brake discs for an aircraft
  • FIG.2 Figure 2 is a schematic perspective view of an element of the installation
  • Figure 3 is a longitudinal sectional view of another element of the installation
  • Figure 4 is a perspective view of an example of a storage tower according to the invention.
  • Figure 5 is a schematic view of a method according to the invention.
  • the brake discs are intended to be mounted in the braked wheels which equip an aircraft landing gear.
  • Brake discs are made of a fibrous reinforcement and a matrix.
  • the fibrous reinforcement is in particular densified by the matrix.
  • the matrix is for example a carbon matrix and the fibrous reinforcement comprises for example carbon fibers.
  • the composite material is commonly referred to in the field of the invention as carbon-carbon (C-C) composite.
  • Installation 1 comprises a first station 3 for converting parts 2 having a first inlet 30 arranged on a first level Z0 of the installation 1.
  • the parts 2 are semi-finished brake discs and thus represent, according to the present invention, the partially developed brake discs.
  • the first processing station 3 comprises, for example, a textile cell 31, carrying out textile operations to form parts 2 in the form of fiber preforms, possibly a peeling cell 32 intended to form parts 2 in the form of blanks and possibly a machining cell 33 intended to form the brake discs in their final shape.
  • the installation 1 further comprises a second station 4 for transforming the parts 2.
  • the second station 4 has a second entrance 40 arranged on a second level Z1 of the installation 1.
  • the second station 4 generally comprises one or more enclosures 41 capable of at least one carbonization operation, and/or at least one densification operation, and/or at least one heat treatment operation.
  • the second level Z1 is raised with respect to the first level Z0.
  • the distance D, measured along the Z axis, separating the first and the second level Z0, Z1 is of the order of a few meters, for example between 2 m and 20 m.
  • the installation 1 further comprises a tower 5 for storing and transferring the parts 2 capable of moving between the first station 3 and the second station 4 for processing.
  • the installation 1 can comprise a plurality of storage and transfer towers 5.
  • the storage and transfer tower 5 has a height measured along the Z axis, equal to the distance D.
  • the parts 2 are manufactured individually within the textile cell 31 in the form of annular preforms.
  • the manufacture of the annular preforms within the textile cell 31 comprises textile operations intended to produce an annular carbon fiber preform, using as raw material cables formed from a plurality of filaments, in particular a large number of filaments.
  • the thick annular preform is formed from a stack of textile layers bonded together, for example by needling, layer after layer.
  • the chemical nature of these plies can be organic, for example if the plies are formed from tows of polyacrylonitrile fibers or from carbon in the case of tows of carbon fibers.
  • the parts 2 are grouped by lot 20 shown by way of example in Figure 2.
  • a plurality of lots 20 are generally formed.
  • the batch 20 of coins 2 thus comprises a plurality of stacks 21 of coins 2 grouped together on a plate 22.
  • the plate 22 is circular and has a diameter comprised for example between 1 m and 5 m, for example 3 m.
  • the plate 22 comprises a plurality of orifices allowing the passage of gases and a standardization of the temperature in the parts 2 within the enclosure 41.
  • the parts 2 comprise an identification member making it possible to position the parts 2 in the installation 1.
  • the identification member is for example an RFID chip, an engraving or a machining of the parts 2.
  • the member identification is integrated directly on the parts 2 or on the tray 22.
  • Tower 5 includes a support structure 51 and at least one swing 52.
  • the support structure 51 is preferably made of steel.
  • the support structure 51 is preferably a mechanically welded structure.
  • the support structure 51 has for example a rectangular base and extends vertically along the Z axis.
  • the support structure 51 has for example a width L, measured along the Y axis and perpendicular to the Z axis, comprised between 2 m and 20 m, preferably between 5 m and 10 m, for example 8 m.
  • the depth P of the support structure 51, measured along the X axis, is for example less than its width L.
  • the depth P is for example between 2 m and 8 m, for example 4 m.
  • the support structure 51 comprises a first passage 50a and a second passage 50b of the parts 2 and in particular, the batches 20.
  • the first passage 50a gives access to the first level Z0 of the installation 1 and the second passage 50b gives access to the second level Z1 of the installation 1.
  • the distance H separating the first passage 50a and the second passage 50b is equal to the distance D. It is for example between 2 m and 20 m, preferably between 5 m and 10m. The distance H is for example 7 m.
  • tower 5 is capable of receiving and transferring 2 coins, in the form of 20 batches, both from the first level Z0 and from the second level Z1.
  • the support structure 51 defines an internal space 53 in which the swing 52 is arranged.
  • the tower 5 comprises a plurality of swings 52.
  • the tower 5 comprises swings 52 in a quantity twice the number of trays 22 loaded in the enclosure 41 .
  • rows of swings 52 are superimposed and distributed mainly on two columns and arranged in the internal space 53.
  • the first and last row respectively located at the level of the first and second passage 50a, 50b only comprises a swing 52 centered in the internal space 53. This configuration allows facilitate the entry and/or exit of parts 2.
  • the swings 52 are formed of a steel frame comprising two side walls 54 mounted on two slides 55 transverse to the side walls 54 and secured to the support structure 51.
  • the swings 52 further comprise a bottom 56 d tray support 22.
  • the swings 52 according to the invention are able to move in the support structure 51 .
  • the displacement of the swings 52 within the support structure 51 makes it possible to reduce the size of the tower 5.
  • the swings 52 are mounted mobile in rotation and possibly in translation in the support structure 51 .
  • the system making it possible to drive the swings 52 in rotation comprises, for example, an electric control device and a means for driving all of the swings 52, such as a belt or a chain. This thus allows the swings to move in the support structure to distribute the flow of parts 2.
  • a first batch 20 is loaded on a first swing 52 via the first passage 50a located at the first level Z0.
  • the tower 5 advantageously comprises an interface (not shown) arranged on the support structure and capable of cooperating with an autonomous guided vehicle (AGV, for Automatic Guided Vehicle in English).
  • AGV autonomous guided Vehicle
  • the tower 5 also comprises wheels (not shown), preferably articulated.
  • the support structure 51 is mounted on wheels, preferably four wheels mounted on the rectangular base of the support structure 51.
  • the wheels facilitate the movement of the tower 5 between the first station 3 and the second station 4 of transformation.
  • the tower 5 can, according to the invention, move in translation in the installation 1 at level Z0 in the plane defined by the axes X and Y.
  • the articulated wheels facilitate such movement.
  • the installation 1 comprises the electrical control device (not shown) making it possible to control the movement of the swings 52 and advantageously of the tower 5.
  • the tower 5 is moved from the first station 3 to the second station 4 of transformation over a distance for example of 200 m, so as to position itself for example opposite the enclosure 41 of densification to be unloaded then reloaded .
  • the heat-treated parts 2 are unloaded from the densification chamber 41 and transferred through the second passage 50b to tower 5 at level Z1.
  • the first empty swing 52 located at the level of the second passage 50b is loaded with a heat-treated batch 20, then the system of swings 52 is rotated in the support structure 51 to position the empty swing 52 following at the level of the second passage 50b.
  • An additional batch 20 is thus loaded into tower 5, then another, until the densification enclosure 41 is completely unloaded.
  • the batches 20 loaded with non-heat-treated parts 2 are then unloaded from their swing 52 towards the densification enclosure 41 at the level of the passage 50b, until the enclosure 41 is completely loaded.
  • the installation 1 comprises for example a conveyor and a positioning system at the level of the first passage 50a.
  • the tower 5 comprises for example a traveling crane connecting the second passage 50b and the second entrance 40.
  • An articulated arm or a hook makes it possible to apprehend and position the parts 2 in or outside the tower 5.
  • the densification enclosure 41 is for example represented in FIG. 3.
  • the enclosure 41 is preferably cylindrical. It comprises a wall 42, for example made of steel, which extends vertically and delimits an interior space 44 in which the batches 20 of parts 2 are arranged.
  • the enclosure 41 further comprises a series of valves 43 allowing the densification gases to be introduced.
  • the plates 22 having orifices, the gases can effectively reach the parts 2.
  • the parts 2 are also subjected to a heat treatment in the enclosure 41 at a temperature between 800°C and 2500°C depending on the type of heat treatment desired.
  • the second input 40 of the second processing station 4 is provided at level Z1 opposite the enclosure 41.
  • each enclosure 41 comprises a second entry 40.
  • the tower 5 loaded with the densified and heat-treated parts 2 is moved again to return to the first transformation station 3.
  • the heat-treated parts 2 are then deposited within the peeling cell 32.
  • the parts 2 are individually subjected to machining making it possible to open the porosities of the composite material of the parts 2 in order to fill the porosities at the very heart of the material. Then the parts 2 are again grouped into batches 20 to be subjected to heat treatment within the densification chamber 41. Tower 5 is used as before to ensure the transfer of parts 2 into enclosure 41 . Subsequently, the 2 parts are transferred via the 5 lathe into the 33 machining cell to form the brake discs.
  • a first step (a) of the method the parts 2 of brake discs made of composite material as described above are provided within the first processing station 3 as described above. More particularly, in step (a) the parts 2 are provided in the textile cell 31 . The parts 2 provided in step (a) are called in the technical field of the invention annular preforms.
  • the method then preferably comprises a step (a1) of forming batches 20 of coins 2, each batch 20 comprising a plurality of stacks 21 of coins 2, the stacks 21 being arranged on a tray 22 as described above.
  • the tower 5 is then moved during a step (c) to the second station 4 of transformation.
  • the second station 4 comprises in particular one or more enclosures 41 for densification or heat treatment, the second inlet 40 being arranged opposite the upper wall of the enclosure 41 .
  • the swing 52 is then moved in a step (d) to reach the second level Z1 of the installation 1.
  • the swing 52 is preferably moved in rotation and possibly in translation in the support structure 51 .
  • the parts 2 are then transferred in a step (e) to the second processing station 4 from the second level Z1, for example through the second passage 50b of the tower 5.
  • the parts 2 are then transformed in a step (f) to provide brake discs.
  • Step (f) optionally comprises a step (f1) of heat treatment in the enclosure 41, then a step (f2) of loading the parts 2 into the tower 5 from the second level Z1, followed by a step (f3) of moving the tower 5 towards the first transformation station 3, for example towards the peeling cell 32. Then, a step (f4) of moving the swing 52 to reach the first level Z0 is carried out. The parts 2 are then transferred in a step (f5) to the first station 3 to undergo a peeling operation. Optionally after step (f5), steps (b), (c), (d), (e) and (f) are repeated until the brake discs are obtained in their final shape.
  • the manufacture of the brake discs is carried out continuously without break in load between the first station 3 and the second manufacturing station 4.
  • the tower 5 according to the invention makes it possible to distribute the flow of parts 2 in ensuring their storage and transfer between the first level Z0 and the second level Z1.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Braking Arrangements (AREA)

Abstract

The invention relates to an installation (1) for manufacturing brake discs for an aircraft that are formed of a composite material comprising a matrix and a fibrous reinforcement, the installation (1) comprising: - a first station (3) for converting workpieces (2) and having a first inlet (30) arranged on a first level (Z0) of the installation (1); - a second station (4) for converting workpieces (2) and having a second inlet (40) arranged on a second level (Z1) of the installation (1), the second level (Z1) being elevated in relation to the first level (Z0); and - a tower (5) for storing and transferring the workpieces (2) that is able to move between the first station (3) and the second station (4), the tower (5) comprising: - a support structure (51) and - at least one swing tray (52) able to move in the support structure (51) for receiving the workpieces (2) from the first station (3) from the first level (Z0) and for transferring them to the second station (4) via the second level (Z1).

Description

DESCRIPTION DESCRIPTION
INSTALLATION ET PROCEDE DE FABRICATION DE DISQUES DE FREIN INSTALLATION AND METHOD FOR MANUFACTURING BRAKE DISCS
Domaine technique de l’invention Technical field of the invention
L’invention concerne le domaine des disques de frein en matériau composite pour aéronefs, notamment pour les trains d’atterrissage d’aéronefs. The invention relates to the field of brake discs made of composite material for aircraft, in particular for aircraft landing gear.
En particulier, l’invention concerne le domaine des disques de frein en matériau composite carbone-carbone. In particular, the invention relates to the field of brake discs made of carbon-carbon composite material.
Etat de la technique State of the art
L’état de la technique est illustré par les documents US-A-3 178 041 et « Manufacture and examination of carbon ceramic brakes », Rancso Bence, Novembre 2015. The state of the art is illustrated by documents US-A-3 178 041 and “Manufacture and examination of carbon ceramic brakes”, Rancso Bence, November 2015.
Un matériau composite carbone-carbone, appelé aussi composite C-C est formé d’un renfort fibreux constitué de fibres de carbone et d’une matrice à base de carbone. Un tel matériau composite présente une bonne tenue mécanique, notamment à température élevée, une conductivité thermique élevée, un coefficient de frottement élevé à haute énergie et une faible densité comparé par exemple à l’acier. Compte tenu de ces propriétés, les composites carbone-carbone trouvent de nombreuses applications dans le domaine aérospatial, notamment pour la fabrication de disques de frein pour aéronefs. A carbon-carbon composite material, also called C-C composite, is made up of a fibrous reinforcement consisting of carbon fibers and a carbon-based matrix. Such a composite material has good mechanical strength, in particular at high temperature, high thermal conductivity, a high coefficient of friction at high energy and a low density compared for example to steel. Given these properties, carbon-carbon composites find numerous applications in the aerospace field, in particular for the manufacture of brake discs for aircraft.
Les disques de frein pour aéronefs en composite C-C sont fabriqués suivant des gammes de fabrication impliquant différentes opérations utilisant différents types d’installation propres aux procédés spécifiques mis en œuvre. Les installations sont généralement positionnées dans un même atelier de fabrication afin de garantir la continuité des flux de pièces aux différents stades de leur fabrication. Certaines opérations sont mises en œuvre de façon unitaire : une seule pièce est traitée au cours de cette opération dans une installation capable de traiter les pièces une par une. D’autres opérations sont mises en œuvre par lot d’un grand nombre de pièces. C-C composite brake discs for aircraft are manufactured according to manufacturing ranges involving different operations using different types of installation specific to the specific processes implemented. The installations are generally positioned in the same manufacturing workshop in order to guarantee the continuity of the flow of parts at the different stages of their manufacture. Some operations are implemented as a unit: a single part is processed during this operation in an installation capable of processing the parts one by one. Other operations are implemented in batches of a large number of parts.
La première étape consiste à fabriquer le renfort fibreux. Cette étape de fabrication consiste en des opérations textiles destinées à produire une pièce sous la forme d’une préforme annulaire en fibres de carbone, en utilisant comme matière première des câbles constitués d’un grand nombre de filaments. La préforme annulaire épaisse est par exemple constituée d’un empilement de nappes textiles liées entre elles par aiguilletage, nappe après nappe. La nature chimique de ces nappes peut être organique par exemple si les nappes sont constituées de câbles de fibres en polyacrylonitrile ou en carbone. Dans le cas des fibres en polyacrylonitrile, l’obtention d’une préforme en fibres de carbone nécessite la mise en œuvre d’une opération de carbonisation au cours de laquelle la fibre des préformes est transformée en fibre de carbone. Cette opération est réalisée par un traitement d’un lot de préformes dans une enceinte thermique dédiée. The first step is to manufacture the fibrous reinforcement. This manufacturing step consists of textile operations intended to produce a part in the form of an annular carbon fiber preform, using as raw material cables made up of a large number of filaments. The thick annular preform is for example made up of a stack of textile sheets bonded together by needling, sheet after sheet. The chemical nature of these layers can be organic, for example if the layers are made up of tows of polyacrylonitrile or carbon fibers. In the case of polyacrylonitrile fibers, obtaining a carbon fiber preform requires the implementation of a carbonization operation during which the fiber of the preforms is transformed into carbon fiber. This operation is carried out by processing a batch of preforms in a dedicated thermal chamber.
Les préformes annulaires - souvent désignées par le terme préformes sèches - subissent ensuite une étape de densification durant laquelle les porosités entre les fibres sont comblées par la matrice carbonée pour former des ébauches. Dans le cas d’une densification par voie gazeuse (Chemical Vapor Infiltration), les préformes sont regroupées en piles sur des plateaux qui sont acheminés et placés dans I’ enceinte thermique dans laquelle elles subissent un traitement de densification par voie gazeuse pour former des ébauches. Celui-ci est réalisé à des températures de l’ordre de 1000°C et à basse pression, et sous balayage d’un gaz tel qu’un hydrocarbure. Ces conditions de température et de pression entraînent le craquage du gaz et permettent le remplissage des porosités, constituant ainsi la matrice en carbone du matériau composite. Les ébauches de disques de freins sont ainsi formées par lot d’un grand nombre d’unités. The annular preforms - often referred to by the term dry preforms - then undergo a densification step during which the porosities between the fibers are filled with the carbon matrix to form blanks. In the case of densification by gas (Chemical Vapor Infiltration), the preforms are grouped together in stacks on trays which are transported and placed in the thermal chamber in which they undergo a densification treatment by gas to form blanks. . This is carried out at temperatures of the order of 1000°C and at low pressure, and under sweeping of a gas such as a hydrocarbon. These temperature and pressure conditions lead to the cracking of the gas and allow the filling of the porosities, thus constituting the carbon matrix of the composite material. Brake disc blanks are thus formed in batches of a large number of units.
La densification peut être effectuée en plusieurs cycles d’infiltration entre lesquels les ébauches sont écroutées lors d’une opération d’usinage unitaire afin d’ouvrir à nouveau les porosités en surface et permettre une bonne densification lors du cycle de densification suivant. Densification can be carried out in several infiltration cycles between which the blanks are peeled during a unit machining operation in order to open the surface porosities again and allow good densification during the following densification cycle.
Entre les cycles de densification et lorsque l’ébauche est à la densité finale requise, un traitement thermique peut également être réalisé sur un lot d’ébauches dans une enceinte thermique dédiée. Between densification cycles and when the blank is at the required final density, a heat treatment can also be carried out on a batch of blanks in a dedicated thermal chamber.
Enfin, un usinage final des ébauches incluant un dressage des faces de frottement et l’usinage de tenons, est réalisé au sein d’une cellule d’usinage pour former les disques de frein selon leur forme finale. Finally, final machining of the blanks, including dressing of the friction faces and machining of tenons, is carried out within a machining cell to form the brake discs according to their final shape.
Ainsi, la fabrication des disques de frein implique plusieurs postes de transformation. Le premier poste de transformation regroupe les opérations textiles de constitution des préformes sèches, l’écroutage, et l’usinage, et assure donc des opérations sur des éléments unitaires. A l’inverse, le second poste de transformation qui comprend notamment des enceintes thermiques de grande dimension pour réaliser les étapes de carbonisation, de densification et de traitement thermique, assure des opérations sur des lots de pièces au stade semi-fini regroupées par piles sur des plateaux. Thus, the manufacture of brake discs involves several transformation stations. The first transformation station groups together the textile operations for the constitution of the dry preforms, peeling, and machining, and therefore performs operations on unitary elements. Conversely, the second transformer station which notably comprises large thermal enclosures to carry out the steps carbonization, densification and heat treatment, performs operations on batches of parts at the semi-finished stage grouped in stacks on trays.
Aussi, le premier poste de transformation est agencé sur un premier niveau de l’installation, un niveau bas. A l’inverse, le chargement et le déchargement des plateaux dans les enceintes thermiques se fait par une entrée aménagée dans la partie supérieure des enceintes thermiques, qui ont généralement une hauteur de quelques mètres. Cette entrée se fait par un système d’ouverture au sommet des enceintes thermiques tel qu’un couvercle pivotant. Par conséquent, le second poste de transformation comprenant notamment les enceintes thermiques est agencé sur un second niveau de l’installation. Also, the first transformer station is arranged on a first level of the installation, a low level. Conversely, the loading and unloading of the trays in the thermal enclosures is done through an entrance arranged in the upper part of the thermal enclosures, which are generally a few meters high. This entry is made through an opening system at the top of the thermal enclosures such as a pivoting lid. Consequently, the second transformer station comprising in particular the thermal enclosures is arranged on a second level of the installation.
Ainsi, lors de la fabrication, les pièces doivent être acheminées entre des postes de transformation comprenant des entrées agencées sur des niveaux distincts de l’installation. Une telle configuration de l’installation nécessite des moyens dédiés tels que des monte-charges, et entraine généralement des ruptures de charge entre les deux niveaux. Par ailleurs, le traitement des pièces de manière unitaire pour certaines opérations, et par lots pour d’autres opérations, entraine également des ruptures de charge entre les deux zones. Le flux de pièces au stade semi-fini entre les différents postes n’est pas homogène, causant des goulots d’étranglement générateurs de temps de cycle et de stocks intermédiaires de fabrication, entraînant des surcoûts de production importants. Thus, during manufacture, the parts must be routed between transformer stations comprising entrances arranged on separate levels of the installation. Such a configuration of the installation requires dedicated means such as goods lifts, and generally leads to load breaks between the two levels. In addition, the processing of parts individually for certain operations, and in batches for other operations, also leads to load breaks between the two areas. The flow of parts at the semi-finished stage between the different stations is not homogeneous, causing bottlenecks that generate cycle times and intermediate manufacturing stocks, leading to significant additional production costs.
Il existe ainsi un besoin de fournir une installation et un procédé de fabrication permettant une fabrication en grande série de disques de frein minimisant ces ruptures de charge afin de réduire les coûts de production. There is thus a need to provide an installation and a manufacturing method allowing mass production of brake discs minimizing these breaks in load in order to reduce production costs.
Divulgation de l’invention Disclosure of Invention
A cet effet, l’invention propose une installation pour la fabrication de disques de frein pour un aéronef, formés d’un matériau composite comprenant une matrice et un renfort fibreux, l’installation comprenant : To this end, the invention proposes an installation for the manufacture of brake discs for an aircraft, formed from a composite material comprising a matrix and a fibrous reinforcement, the installation comprising:
- un premier poste de transformation de pièces présentant une première entrée agencée sur un premier niveau de l’installation; - a first part transformation station having a first entrance arranged on a first level of the installation;
- un second poste de transformation des pièces présentant une seconde entrée agencée sur un second niveau de l’installation, le second niveau étant surélevé par rapport au premier niveau; et - une tour de stockage et de transfert des pièces apte à se déplacer entre le premier poste et le second poste, la tour comprenant : - A second part transformation station having a second entrance arranged on a second level of the installation, the second level being raised with respect to the first level; and - a tower for storing and transferring parts capable of moving between the first station and the second station, the tower comprising:
- une structure de support et - a support structure and
- au moins une balancelle apte à se déplacer dans la structure de support pour recevoir les pièces du premier poste à partir du premier niveau et les transférer au second poste par le second niveau. - At least one swing able to move in the support structure to receive the parts of the first station from the first level and transfer them to the second station by the second level.
Selon l’invention, l’installation pour la fabrication de disques de frein comprend donc une tour de stockage et de transfert de pièces entre les différents postes de transformation, ce qui permet d’acheminer facilement ces pièces d’un poste à un autre. Par ailleurs, la tour de stockage comprend selon l’invention au moins une balancelle permettant d’accueillir les pièces. Par ailleurs, la balancelle selon l’invention se déplace dans la structure de support de la tour afin de recevoir les pièces par l’un ou l’autre niveau. Ainsi, dans le premier poste de transformation au premier niveau, la tour est chargée puis déplacée jusqu’au second poste de transformation placé au second niveau. La balancelle est alors déplacée en hauteur selon par exemple un mouvement ée rotation-translation afin de l’aligner avec le second niveau où les pièces sont déchargées afin d’être transférées dans le second poste de transformation. Inversement, les pièces en sortie du second poste de transformation peuvent être récupérées au niveau du second niveau pour être chargées sur la balancelle de la tour de stockage puis transportées par cette tour mobile jusqu’au premier poste de fabrication où elles sont déchargées au niveau du premier niveau, en vue de l’usinage des pièces. Ainsi, la tour de stockage permet de répartir le flux de pièces entre les différents postes ce qui limite les ruptures de charge et améliore la vitesse de fabrication. According to the invention, the installation for the manufacture of brake discs therefore comprises a tower for storing and transferring parts between the various transformation stations, which makes it possible to easily transport these parts from one station to another. Furthermore, the storage tower comprises according to the invention at least one swing for receiving the parts. Furthermore, the balancelle according to the invention moves in the support structure of the tower in order to receive the parts by one or the other level. Thus, in the first transformer station on the first level, the tower is loaded and then moved to the second transformer station placed on the second level. The swing is then moved in height according to, for example, a rotation-translation movement in order to align it with the second level where the parts are unloaded in order to be transferred to the second transformation station. Conversely, the parts leaving the second transformation station can be recovered at the level of the second level to be loaded onto the swing of the storage tower then transported by this mobile tower to the first manufacturing station where they are unloaded at the level of the first level, with a view to machining the parts. Thus, the storage tower makes it possible to distribute the flow of parts between the various stations, which limits load breaks and improves manufacturing speed.
Selon un mode avantageux de l’invention, la tour comprend une pluralité de balancelles. Le nombre de balancelles dans une tour peut être choisi de façon à permettre de stocker simultanément un chargement complet et un déchargement complet d’une enceinte thermique. Ainsi, un chargement de pièces à partir du premier poste est chargé sur la tour, qui est acheminée en vis-à-vis du second poste. Les pièces traitées dans le second poste sont d’abord déchargées sur les balancelles disponibles de la tour, puis les pièces non traitées amenées par la tour sont immédiatement chargés dans le second poste. Ceci réduit au minimum le temps d’attente du second poste entre deux cycles de traitement. L’installation selon l’invention peut comprendre une ou plusieurs des caractéristiques suivantes, prises isolément les unes des autres ou en combinaison les unes avec les autres : According to an advantageous mode of the invention, the tower comprises a plurality of swings. The number of swings in a tower can be chosen so as to allow simultaneous storage of a full load and a full unloading of a thermal chamber. Thus, a load of parts from the first station is loaded onto the tower, which is routed opposite the second station. The parts treated in the second station are first unloaded onto the available swings of the tower, then the untreated parts brought by the tower are immediately loaded into the second station. This minimizes the waiting time for the second workstation between two processing cycles. The installation according to the invention may comprise one or more of the following characteristics, taken separately from each other or in combination with each other:
- la tour de stockage et de transfert comprend une interface agencée sur la structure de support et apte à coopérer avec un véhicule autonome guidé pour déplacer la tour ; - the storage and transfer tower comprises an interface arranged on the support structure and capable of cooperating with a guided autonomous vehicle to move the tower;
- un dispositif de commande électrique apte à commander le déplacement de la tour de stockage et le déplacement de la balancelle ; - an electric control device capable of controlling the movement of the storage tower and the movement of the swing;
- la tour de stockage et de transfert comprend des roues sur lesquelles est montée la structure de support ; - the storage and transfer tower comprises wheels on which the support structure is mounted;
- la tour de stockage et de transfert comprend un premier passage des pièces donnant accès au premier niveau et un deuxième passage des pièces donnant accès au second niveau ; - the storage and transfer tower comprises a first parts passage giving access to the first level and a second parts passage giving access to the second level;
- la distance séparant le premier passage et le deuxième passage est comprise entre 2 m et 20, de préférence comprise entre 5 m et 10 m ; - The distance between the first passage and the second passage is between 2 m and 20, preferably between 5 m and 10 m;
- la tour de stockage et de transfert comprend une pluralité de rangées de balancelles superposées et réparties sur deux colonnes, chacune des balancelles étant aptes à se placer dans la structure de support ; - the storage and transfer tower comprises a plurality of rows of swings superimposed and distributed over two columns, each of the swings being able to be placed in the support structure;
- la structure de support présente une largeur comprise entre 2 m et 20m, de préférence comprise entre 5 m et 10 m et une profondeur inférieure à la largeur de la structure de support, par exemple comprise entre comprise entre 2 m et 8 m. - the support structure has a width comprised between 2 m and 20 m, preferably comprised between 5 m and 10 m and a depth less than the width of the support structure, for example comprised between comprised between 2 m and 8 m.
L’invention concerne également un procédé de fabrication de disques de frein pour un aéronef comprenant les étapes suivantes : The invention also relates to a method for manufacturing brake discs for an aircraft comprising the following steps:
- (a) fournir des pièces en matériau composite comprenant une matrice et un renfort fibreux, au sein d’un premier poste de transformation présentant une première entrée agencée sur un premier niveau, - (a) supply parts made of composite material comprising a matrix and a fibrous reinforcement, within a first transformation station having a first entrance arranged on a first level,
- (b) charger les pièces à partir du premier niveau dans une tour de stockage et de transfert comprenant une structure de support et au moins une balancelle mobile dans la structure de support, - (b) loading the parts from the first level into a storage and transfer tower comprising a support structure and at least one movable swing in the support structure,
- (c) déplacer la tour de stockage et de transfert vers un second poste de transformation présentant une seconde entrée agencée sur un second niveau de l’installation surélevé par rapport au premier niveau, - (c) move the storage and transfer tower to a second transformer station having a second entrance arranged on a second level of the installation raised above the first level,
- (d) déplacer la balancelle de sorte à atteindre le second niveau, - (e) transférer les pièces dans le second poste de transformation à partir du second niveau, - (d) move the swing so as to reach the second level, - (e) transfer the parts to the second transformation station from the second level,
- (f) transformer les pièces pour fournir les disques de frein. - (f) convert parts to supply brake discs.
Avantageusement, selon le procédé, la balancelle est mobile en rotation dans la structure de support. Advantageously, according to the method, the swing is rotatable in the support structure.
Brève description des figures Brief description of figures
D’autres caractéristiques et avantages ressortiront de la description qui suit, d’un mode de réalisation non limitatif de l’invention, en référence aux dessins annexés sur lesquels : Other characteristics and advantages will emerge from the following description of a non-limiting embodiment of the invention, with reference to the appended drawings in which:
[Fig.1 ] la figure 1 est une vue schématique d’une installation pour la fabrication de disques de frein pour un aéronef; [Fig.1] Figure 1 is a schematic view of an installation for manufacturing brake discs for an aircraft;
[Fig.2] la figure 2 est une vue schématique en perspective d’un élément de l’installation, [Fig.2] Figure 2 is a schematic perspective view of an element of the installation,
[Fig.3] la figure 3 est une vue en coupe longitudinale d’un autre élément de l’installation, [Fig.3] Figure 3 is a longitudinal sectional view of another element of the installation,
[Fig.4] la figure 4 est une vue en perspective d’un exemple d’une tour de stockage selon l’invention, [Fig.4] Figure 4 is a perspective view of an example of a storage tower according to the invention,
[Fig.5] la figure 5 est une vue schématique d’un procédé selon l’invention. [Fig.5] Figure 5 is a schematic view of a method according to the invention.
Description détaillée de l’invention Detailed description of the invention
Les disques de frein sont destinés à être montés dans des roues freinées qui équipent un train d’atterrissage d’aéronef. Les disques de frein sont formés d’un renfort fibreux et d’une matrice. Le renfort fibreux est notamment densifié par la matrice. La matrice est par exemple une matrice en carbone et le renfort fibreux comprend par exemple des fibres de carbone. Le matériau composite est communément appelé dans le domaine de l’invention composite carbone-carbone (C-C). The brake discs are intended to be mounted in the braked wheels which equip an aircraft landing gear. Brake discs are made of a fibrous reinforcement and a matrix. The fibrous reinforcement is in particular densified by the matrix. The matrix is for example a carbon matrix and the fibrous reinforcement comprises for example carbon fibers. The composite material is commonly referred to in the field of the invention as carbon-carbon (C-C) composite.
Une installation 1 de fabrication des disques de frein selon l’invention est représentée à titre d’exemple sur la figure 1. L’installation 1 comprend un premier poste 3 de transformation de pièces 2 présentant une première entrée 30 agencée sur un premier niveau Z0 de l’installation 1. Les pièces 2 sont des disques de frein semi-finis et représentent ainsi selon la présente invention, les disques de frein partiellement élaborés. Le premier poste 3 de transformation comprend par exemple une cellule textile 31 , réalisant des opérations textiles pour former des pièces 2 sous forme de préformes fibreuses, éventuellement une cellule d’écroutage 32 destinée à former des pièces 2 sous forme d’ébauches et éventuellement une cellule d’usinage 33 destinée à former les disques de frein dans leur forme finale. An installation 1 for manufacturing brake discs according to the invention is shown by way of example in FIG. 1. Installation 1 comprises a first station 3 for converting parts 2 having a first inlet 30 arranged on a first level Z0 of the installation 1. The parts 2 are semi-finished brake discs and thus represent, according to the present invention, the partially developed brake discs. The first processing station 3 comprises, for example, a textile cell 31, carrying out textile operations to form parts 2 in the form of fiber preforms, possibly a peeling cell 32 intended to form parts 2 in the form of blanks and possibly a machining cell 33 intended to form the brake discs in their final shape.
L’installation 1 comprend en outre un second poste 4 de transformation des pièces 2. Le second poste 4 présente une seconde entrée 40 agencée sur un second niveau Z1 de l’installation 1. Le second poste 4 comprend généralement une ou plusieurs enceintes 41 capables d’au moins une opération de carbonisation, et/ou d’au moins une opération de densification, et/ou au moins une opération de traitement thermique. Préférentiellement, en vis-à-vis de chaque enceinte 41 au niveau Z1 se trouve une entrée 40. Comme montré sur la figure 1 , le second niveau Z1 est surélevé par rapport au premier niveau Z0. La distance D, mesurée selon l’axe Z, séparant le premier et le second niveau Z0, Z1 est de l’ordre de quelques mètres, par exemple comprise entre 2 m et 20 m. The installation 1 further comprises a second station 4 for transforming the parts 2. The second station 4 has a second entrance 40 arranged on a second level Z1 of the installation 1. The second station 4 generally comprises one or more enclosures 41 capable of at least one carbonization operation, and/or at least one densification operation, and/or at least one heat treatment operation. Preferably, opposite each enclosure 41 at level Z1 is an entrance 40. As shown in FIG. 1, the second level Z1 is raised with respect to the first level Z0. The distance D, measured along the Z axis, separating the first and the second level Z0, Z1 is of the order of a few meters, for example between 2 m and 20 m.
L’installation 1 comprend en outre une tour 5 de stockage et de transfert des pièces 2 apte à se déplacer entre le premier poste 3 et le second poste 4 de transformation. Selon les configurations, l’installation 1 peut comprendre une pluralité de tours 5 de stockage et de transfert. Avantageusement, la tour 5 de stockage et de transfert présente une hauteur mesurée selon l’axe Z, égale à la distance D. The installation 1 further comprises a tower 5 for storing and transferring the parts 2 capable of moving between the first station 3 and the second station 4 for processing. Depending on the configurations, the installation 1 can comprise a plurality of storage and transfer towers 5. Advantageously, the storage and transfer tower 5 has a height measured along the Z axis, equal to the distance D.
Les pièces 2 sont fabriquées de manière unitaire au sein de la cellule textile 31 sous la forme de préformes annulaires. The parts 2 are manufactured individually within the textile cell 31 in the form of annular preforms.
La fabrication des préformes annulaires au sein de la cellule textile 31 comprend des opérations textiles destinées à produire une préforme annulaire en fibres de carbone, en utilisant comme matière première des câbles formés d’une pluralité de filaments notamment d’un grand nombre de filaments. La préforme annulaire épaisse est formée d’un empilement de nappes textiles liées entre elles par exemple par aiguilletage, nappe après nappe. La nature chimique de ces nappes peut être organique par exemple si les nappes sont formées de câbles de fibres en polyacrylonitrile ou en carbone dans le cas de câbles de fibres de carbone. Ensuite, les pièces 2, sont regroupées par lot 20 représenté à titre d’exemple sur la figure 2. Une pluralité de lots 20 sont généralement formés. The manufacture of the annular preforms within the textile cell 31 comprises textile operations intended to produce an annular carbon fiber preform, using as raw material cables formed from a plurality of filaments, in particular a large number of filaments. The thick annular preform is formed from a stack of textile layers bonded together, for example by needling, layer after layer. The chemical nature of these plies can be organic, for example if the plies are formed from tows of polyacrylonitrile fibers or from carbon in the case of tows of carbon fibers. Then, the parts 2 are grouped by lot 20 shown by way of example in Figure 2. A plurality of lots 20 are generally formed.
Le lot 20 de pièces 2 comprend ainsi une pluralité de piles 21 de pièces 2 regroupées sur un plateau 22. Avantageusement, le plateau 22 est circulaire et présente un diamètre compris par exemple entre 1 m et 5 m, par exemple 3 m. Le plateau 22 comprend une pluralité d’orifices permettant le passage des gaz et une uniformisation de la température dans les pièces 2 au sein de l’enceinte 41. The batch 20 of coins 2 thus comprises a plurality of stacks 21 of coins 2 grouped together on a plate 22. Advantageously, the plate 22 is circular and has a diameter comprised for example between 1 m and 5 m, for example 3 m. The plate 22 comprises a plurality of orifices allowing the passage of gases and a standardization of the temperature in the parts 2 within the enclosure 41.
De manière préférée, les pièces 2 comprennent un organe d’identification permettant de positionner les pièces 2 dans l’installation 1. L’organe d’identification est par exemple une puce RFID, un gravage ou un usinage des pièces 2. L’organe d’identification est intégré directement sur les pièces 2 ou sur le plateau 22. Preferably, the parts 2 comprise an identification member making it possible to position the parts 2 in the installation 1. The identification member is for example an RFID chip, an engraving or a machining of the parts 2. The member identification is integrated directly on the parts 2 or on the tray 22.
Les lots 20 sont ensuite stockés dans la tour 5 représentée à titre d’exemple sur la figure 4. Batches 20 are then stored in tower 5 shown by way of example in Figure 4.
La tour 5 comprend une structure de support 51 et au moins une balancelle 52. Tower 5 includes a support structure 51 and at least one swing 52.
La structure de support 51 est préférentiellement réalisée en acier. La structure de support 51 est préférentiellement une structure mécanosoudée. La structure de support 51 présente par exemple une base rectangulaire et s’étend verticalement selon l’axe Z. La structure de support 51 présente par exemple une largeur L, mesurée selon l’axe Y et perpendiculairement à l’axe Z, comprise entre 2 m et 20 m, de préférence comprise entre 5 m et 10 m, par exemple 8 m. La profondeur P de la structure de support 51 , mesurée selon l’axe X, est par exemple inférieure à sa largeur L. La profondeur P est par exemple comprise entre 2 m et 8 m, par exemple 4m. Ces dimensions préférées permettent de réduire l’encombrement de la tour 5 au sol. The support structure 51 is preferably made of steel. The support structure 51 is preferably a mechanically welded structure. The support structure 51 has for example a rectangular base and extends vertically along the Z axis. The support structure 51 has for example a width L, measured along the Y axis and perpendicular to the Z axis, comprised between 2 m and 20 m, preferably between 5 m and 10 m, for example 8 m. The depth P of the support structure 51, measured along the X axis, is for example less than its width L. The depth P is for example between 2 m and 8 m, for example 4 m. These preferred dimensions make it possible to reduce the footprint of tower 5 on the ground.
Par ailleurs, la structure de support 51 comprend un premier passage 50a et un second passage 50b des pièces 2 et en particulier, des lots 20. Le premier passage 50a donne accès au premier niveau Z0 de l’installation 1 et le second passage 50b donne accès au second niveau Z1 de l’installation 1. Avantageusement, la distance H séparant le premier passage 50a et le second passage 50b est égale à la distance D. Elle est comprise par exemple entre 2 m et 20 m, de préférence entre 5 m et 10 m. La distance H est par exemple de 7 m. Ainsi, selon l’invention, la tour 5 est capable de recevoir et de transférer les pièces 2, sous forme de lots 20, aussi bien du premier niveau Z0 que du second niveau Z1 . Furthermore, the support structure 51 comprises a first passage 50a and a second passage 50b of the parts 2 and in particular, the batches 20. The first passage 50a gives access to the first level Z0 of the installation 1 and the second passage 50b gives access to the second level Z1 of the installation 1. Advantageously, the distance H separating the first passage 50a and the second passage 50b is equal to the distance D. It is for example between 2 m and 20 m, preferably between 5 m and 10m. The distance H is for example 7 m. Thus, according to the invention, tower 5 is capable of receiving and transferring 2 coins, in the form of 20 batches, both from the first level Z0 and from the second level Z1.
Par ailleurs, la structure de support 51 définit un espace interne 53 dans lequel est agencée la balancelle 52. Furthermore, the support structure 51 defines an internal space 53 in which the swing 52 is arranged.
Avantageusement, la tour 5 comprend une pluralité de balancelles 52. Préférentiellement, la tour 5 comprend des balancelles 52 en quantité double du nombre de plateaux 22 chargés dans I’ enceinte 41 . Comme représenté par exemple sur la figure 4, des rangées de balancelles 52 sont superposées et réparties principalement sur deux colonnes et agencées dans l’espace interne 53. Préférentiellement, la première et dernière rangée respectivement située au niveau du premier et second passage 50a, 50b ne comprend qu’une balancelle 52 centrée dans l’espace interne 53. Cette configuration permet de faciliter l’entrée et/ou la sortie des pièces 2. Advantageously, the tower 5 comprises a plurality of swings 52. Preferably, the tower 5 comprises swings 52 in a quantity twice the number of trays 22 loaded in the enclosure 41 . As shown for example in Figure 4, rows of swings 52 are superimposed and distributed mainly on two columns and arranged in the internal space 53. Preferably, the first and last row respectively located at the level of the first and second passage 50a, 50b only comprises a swing 52 centered in the internal space 53. This configuration allows facilitate the entry and/or exit of parts 2.
Par ailleurs, les balancelles 52 sont formées d’un cadre en acier comprenant deux parois latérales 54 montées sur deux glissières 55 transversales par rapport aux parois latérales 54 et solidaires de la structure de support 51. Les balancelles 52 comprennent en outre un fond 56 d’appui des plateaux 22. Furthermore, the swings 52 are formed of a steel frame comprising two side walls 54 mounted on two slides 55 transverse to the side walls 54 and secured to the support structure 51. The swings 52 further comprise a bottom 56 d tray support 22.
Les balancelles 52 selon l’invention sont aptes à se déplacer dans la structure de support 51 . Le déplacement des balancelles 52 au sein de la structure de support 51 permet de réduire l’encombrement de la tour 5. Par exemple, les balancelles 52 sont montées mobiles en rotation et éventuellement en translation dans la structure de support 51 . Le système permettant d’entrainer en rotation les balancelles 52 comprend par exemple un dispositif de commande électrique et un moyen d’entrainement de l’ensemble des balancelles 52 tel qu’une courroie ou une chaine. Ceci permet ainsi aux balancelles de se déplacer dans la structure de support pour répartir le flux de pièces 2. En effet, lorsque la tour 5 est présente au niveau du premier poste 3 de transformation, un premier lot 20 est chargé sur une première balancelle 52 via le premier passage 50a situé au premier niveau Z0. Ensuite, les balancelles sont déplacées par un mouvement de rotation indiqué à titre d’exemple par la flèche sur la figure 4. Une autre balancelle 52 se déplace ainsi en rotation pour se placer au niveau du premier passage 50a remplaçant la balancelle 52 chargée par une balancelle 52 non chargée. Un lot 20 supplémentaire peut ainsi être agencé dans la tour 5 et ainsi de suite jusqu’à charger dans la tour 5 le nombre de balancelles 52 correspondant au chargement complet de l’enceinte 41 de densification. The swings 52 according to the invention are able to move in the support structure 51 . The displacement of the swings 52 within the support structure 51 makes it possible to reduce the size of the tower 5. For example, the swings 52 are mounted mobile in rotation and possibly in translation in the support structure 51 . The system making it possible to drive the swings 52 in rotation comprises, for example, an electric control device and a means for driving all of the swings 52, such as a belt or a chain. This thus allows the swings to move in the support structure to distribute the flow of parts 2. Indeed, when the tower 5 is present at the level of the first station 3 of transformation, a first batch 20 is loaded on a first swing 52 via the first passage 50a located at the first level Z0. Then, the swings are moved by a rotational movement indicated by way of example by the arrow in FIG. 4. Another swing 52 thus moves in rotation to be placed at the level of the first passage 50a replacing the swing 52 loaded with a Swing 52 not loaded. An additional batch 20 can thus be arranged in tower 5 and so on until the number of swings 52 corresponding to the complete loading of the densification enclosure 41 is loaded into tower 5.
La tour 5 comprend avantageusement une interface (non représentée) agencée sur la structure de support et apte à coopérer avec un véhicule autonome guidé (AGV, pour Automatic Guided Vehicle en langue anglaise). Ainsi, la tour 5 peut être déplacée par le véhicule entre chaque poste de transformation 3, 4. The tower 5 advantageously comprises an interface (not shown) arranged on the support structure and capable of cooperating with an autonomous guided vehicle (AGV, for Automatic Guided Vehicle in English). Thus, the tower 5 can be moved by the vehicle between each transformer station 3, 4.
La tour 5 comprend par ailleurs des roues (non représentées), de préférence articulées. La structure de support 51 est montée sur les roues, de préférence quatre roues montées sur la base rectangulaire de la structure de support 51. Les roues facilitent le déplacement de la tour 5 entre le premier poste 3 et le second poste 4 de transformation. La tour 5 peut selon l’invention, se déplacer en translation dans l’installation 1 au niveau Z0 dans le plan défini par les axes X et Y. Les roues articulées facilitent un tel déplacement. The tower 5 also comprises wheels (not shown), preferably articulated. The support structure 51 is mounted on wheels, preferably four wheels mounted on the rectangular base of the support structure 51. The wheels facilitate the movement of the tower 5 between the first station 3 and the second station 4 of transformation. The tower 5 can, according to the invention, move in translation in the installation 1 at level Z0 in the plane defined by the axes X and Y. The articulated wheels facilitate such movement.
De manière préférée, l’installation 1 comprend le dispositif de commande électrique (non représenté) permettant de commander le déplacement des balancelles 52 et avantageusement de la tour 5. Preferably, the installation 1 comprises the electrical control device (not shown) making it possible to control the movement of the swings 52 and advantageously of the tower 5.
Ainsi, la tour 5 est déplacée du premier poste 3 au second poste 4 de transformation sur une distance par exemple de 200 m, de manière à se positionner par exemple en vis-à-vis de l’enceinte 41 de densification à décharger puis recharger. Thus, the tower 5 is moved from the first station 3 to the second station 4 of transformation over a distance for example of 200 m, so as to position itself for example opposite the enclosure 41 of densification to be unloaded then reloaded .
Les pièces 2 traitées thermiquement sont déchargées de l’enceinte 41 de densification et transférées à travers le second passage 50b vers la tour 5 au niveau Z1 . De la même manière que précédemment, la première balancelle 52 vide située au niveau du second passage 50b est chargée avec un lot 20 traité thermiquement, puis le système de balancelles 52 est actionné en rotation dans la structure de support 51 pour positionner la balancelle 52 vide suivante au niveau du second passage 50b. Un lot 20 supplémentaire est ainsi chargé dans la tour 5, puis un autre, jusqu’à ce que l’enceinte 41 de densification soit complètement déchargée. The heat-treated parts 2 are unloaded from the densification chamber 41 and transferred through the second passage 50b to tower 5 at level Z1. In the same way as before, the first empty swing 52 located at the level of the second passage 50b is loaded with a heat-treated batch 20, then the system of swings 52 is rotated in the support structure 51 to position the empty swing 52 following at the level of the second passage 50b. An additional batch 20 is thus loaded into tower 5, then another, until the densification enclosure 41 is completely unloaded.
Les lots 20 chargés de pièces 2 non traitées thermiquement sont alors déchargés de leur balancelle 52 vers l’enceinte 41 de densification au niveau du passage 50b, jusqu’à ce que l’enceinte 41 soit complètement chargée. The batches 20 loaded with non-heat-treated parts 2 are then unloaded from their swing 52 towards the densification enclosure 41 at the level of the passage 50b, until the enclosure 41 is completely loaded.
Pour faciliter le transfert des pièces 2 au stade semi-fini dans ou en dehors de la tour 5 par le premier passage 50a, l’installation 1 comprend par exemple un convoyeur et un système de positionnement au niveau du premier passage 50a. De la même manière, pour faciliter le transfert des pièces 2 en dehors ou dans la tour 5 par le second passage 50b, la tour 5 comprend par exemple un pont roulant reliant le second passage 50b et la seconde entrée 40. Un bras articulé ou un crochet permet d’appréhender et de positionner les pièces 2 dans ou en dehors de la tour 5. To facilitate the transfer of the parts 2 at the semi-finished stage into or outside the tower 5 via the first passage 50a, the installation 1 comprises for example a conveyor and a positioning system at the level of the first passage 50a. In the same way, to facilitate the transfer of the parts 2 outside or in the tower 5 by the second passage 50b, the tower 5 comprises for example a traveling crane connecting the second passage 50b and the second entrance 40. An articulated arm or a hook makes it possible to apprehend and position the parts 2 in or outside the tower 5.
L’enceinte 41 de densification est par exemple représentée sur la figure 3. L’enceinte 41 est de préférence cylindrique. Elle comprend une paroi 42, par exemple en acier, qui s’étend verticalement et délimite un espace intérieur 44 dans lequel les lots 20 de pièces 2 sont agencés. L’enceinte 41 comprend en outre une série de vannes 43 permettant d’introduire les gaz de densification. Les plateaux 22 présentant des orifices, les gaz peuvent atteindre de manière efficace les pièces 2. Les pièces 2 sont par ailleurs soumises à un traitement thermique dans l’enceinte 41 à une température comprise entre 800°C et 2500°C suivant le type de traitement thermique recherché. De préférence, la seconde entrée 40 du second poste 4 de transformation est ménagée au niveau Z1 en vis-à-vis de l’enceinte 41. Ainsi, lorsque le second poste 4 comprend une pluralité d’enceintes 41 , chaque enceinte 41 comprend une seconde entrée 40. The densification enclosure 41 is for example represented in FIG. 3. The enclosure 41 is preferably cylindrical. It comprises a wall 42, for example made of steel, which extends vertically and delimits an interior space 44 in which the batches 20 of parts 2 are arranged. The enclosure 41 further comprises a series of valves 43 allowing the densification gases to be introduced. The plates 22 having orifices, the gases can effectively reach the parts 2. The parts 2 are also subjected to a heat treatment in the enclosure 41 at a temperature between 800°C and 2500°C depending on the type of heat treatment desired. Preferably, the second input 40 of the second processing station 4 is provided at level Z1 opposite the enclosure 41. Thus, when the second station 4 comprises a plurality of enclosures 41, each enclosure 41 comprises a second entry 40.
La tour 5 chargée avec les pièces 2 densifiées et traitées thermiquement est de nouveau déplacée pour revenir au premier poste 3 de transformation. Les pièces 2 traitées thermiquement, sont alors déposées au sein de la cellule d’écroutage 32.The tower 5 loaded with the densified and heat-treated parts 2 is moved again to return to the first transformation station 3. The heat-treated parts 2 are then deposited within the peeling cell 32.
Dans la cellule d’écroutage 32, les pièces 2 sont soumises de manière unitaire à un usinage permettant d’ouvrir les porosités du matériau composite des pièces 2 afin de combler les porosités au cœur même du matériau. Puis les pièces 2 sont de nouveau regroupées par lots 20 pour être soumis à un traitement thermique au sein de l’enceinte 41 de densification. La tour 5 est utilisé comme précédemment pour assurer le transfert des pièces 2 dans l’enceinte 41 . Par la suite, les pièces 2 sont transférées via la tour 5 dans la cellule d’usinage 33 pour former les disques de frein. In the peeling cell 32, the parts 2 are individually subjected to machining making it possible to open the porosities of the composite material of the parts 2 in order to fill the porosities at the very heart of the material. Then the parts 2 are again grouped into batches 20 to be subjected to heat treatment within the densification chamber 41. Tower 5 is used as before to ensure the transfer of parts 2 into enclosure 41 . Subsequently, the 2 parts are transferred via the 5 lathe into the 33 machining cell to form the brake discs.
Un procédé de fabrication de disques de frein pour un aéronef va maintenant être décrit. A method of manufacturing brake discs for an aircraft will now be described.
Dans une première étape (a) du procédé, on fournit les pièces 2 de disques de frein en matériau composite tel que décrit précédemment au sein du premier poste 3 de transformation tel que décrit précédemment. Plus particulièrement, dans l’étape (a) les pièces 2 sont fournies dans la cellule textile 31 . Les pièces 2 fournies dans l’étape (a) sont appelées dans le domaine technique de l’invention préformes annulaires. In a first step (a) of the method, the parts 2 of brake discs made of composite material as described above are provided within the first processing station 3 as described above. More particularly, in step (a) the parts 2 are provided in the textile cell 31 . The parts 2 provided in step (a) are called in the technical field of the invention annular preforms.
Le procédé comprend ensuite de manière préférée une étape (a1 ) de formation de lots 20 de pièces 2, chaque lot 20 comprenant une pluralité de piles 21 de pièces 2, les piles 21 étant agencées sur un plateau 22 tel que décrit précédemment. The method then preferably comprises a step (a1) of forming batches 20 of coins 2, each batch 20 comprising a plurality of stacks 21 of coins 2, the stacks 21 being arranged on a tray 22 as described above.
Les pièces 2, préférentiellement sous forme de lots 20, sont chargées lors d’une étape (b) dans la tour 5 à partir du premier niveau Z0 via le premier passage 50a de la tour 5. 2 pieces, preferably in the form of 20 batches, are loaded in a step (b) in tower 5 from the first level Z0 via the first passage 50a of tower 5.
La tour 5 est alors déplacée lors d’une étape (c) vers le second poste 4 de transformation. Le second poste 4 comprend notamment une ou des enceintes 41 de de densification ou traitement thermique, la seconde entrée 40 étant agencée en vis- à-vis de la paroi supérieure de l’enceinte 41 . La balancelle 52 est alors déplacée dans une étape (d) pour atteindre le second niveau Z1 de l’installation 1. La balancelle 52 est de préférence déplacée en rotation et éventuellement en translation dans la structure de support 51 . The tower 5 is then moved during a step (c) to the second station 4 of transformation. The second station 4 comprises in particular one or more enclosures 41 for densification or heat treatment, the second inlet 40 being arranged opposite the upper wall of the enclosure 41 . The swing 52 is then moved in a step (d) to reach the second level Z1 of the installation 1. The swing 52 is preferably moved in rotation and possibly in translation in the support structure 51 .
Les pièces 2 sont alors transférées dans une étape (e) dans le second poste 4 de transformation à partir du second niveau Z1 , à travers par exemple le second passage 50b de la tour 5. The parts 2 are then transferred in a step (e) to the second processing station 4 from the second level Z1, for example through the second passage 50b of the tower 5.
Les pièces 2 sont alors transformées dans une étape (f) pour fournir des disques de frein. The parts 2 are then transformed in a step (f) to provide brake discs.
L’étape (f) comprend de manière optionnelle une étape (f1 ) de traitement thermique dans l’enceinte 41 , puis une étape (f2) de chargement des pièces 2 dans la tour 5 à partir du second niveau Z1 , suivi d’une étape (f3) de déplacement de la tour 5 vers le premier poste 3 de transformation, par exemple vers la cellule d’écroutage 32. Ensuite, une étape (f4) de déplacement de la balancelle 52 pour atteindre le premier niveau Z0 est réalisée. Les pièces 2 sont alors transférées dans une étape (f5) dans le premier poste 3 pour subir une opération d’écroutage. Optionnellement après l’étape (f5), les étapes (b), (c), (d), (e) et (f) sont répétées jusqu’à obtenir les disques de frein dans leur forme finale. Step (f) optionally comprises a step (f1) of heat treatment in the enclosure 41, then a step (f2) of loading the parts 2 into the tower 5 from the second level Z1, followed by a step (f3) of moving the tower 5 towards the first transformation station 3, for example towards the peeling cell 32. Then, a step (f4) of moving the swing 52 to reach the first level Z0 is carried out. The parts 2 are then transferred in a step (f5) to the first station 3 to undergo a peeling operation. Optionally after step (f5), steps (b), (c), (d), (e) and (f) are repeated until the brake discs are obtained in their final shape.
Ainsi, selon l’invention, la fabrication des disques de frein est réalisée en continu sans rupture de charge entre le premier poste 3 et le second poste de fabrication 4. La tour 5 selon l’invention permet de répartir le flux de pièces 2 en assurant leur stockage et transfert entre le premier niveau Z0 et le second niveau Z1 . Thus, according to the invention, the manufacture of the brake discs is carried out continuously without break in load between the first station 3 and the second manufacturing station 4. The tower 5 according to the invention makes it possible to distribute the flow of parts 2 in ensuring their storage and transfer between the first level Z0 and the second level Z1.

Claims

REVENDICATIONS
1. Installation (1 ) pour la fabrication de disques de frein pour un aéronef, formés d’un matériau composite comprenant une matrice et un renfort fibreux, l’installation (1 ) comprenant : 1. Installation (1) for the manufacture of brake discs for an aircraft, formed from a composite material comprising a matrix and a fibrous reinforcement, the installation (1) comprising:
- un premier poste (3) de transformation de pièces (2) présentant une première entrée (30) agencée sur un premier niveau (Z0) de l’installation (1 ); - a first station (3) for converting parts (2) having a first entrance (30) arranged on a first level (Z0) of the installation (1);
- un second poste (4) de transformation des pièces (2) présentant une seconde entrée (40) agencée sur un second niveau (Z1 ) de l’installation (1 ), le second niveau (Z1 ) étant surélevé par rapport au premier niveau (Z0); et - a second station (4) for transforming the parts (2) having a second entrance (40) arranged on a second level (Z1) of the installation (1), the second level (Z1) being raised with respect to the first level (Z0); and
- une tour (5) de stockage et de transfert des pièces (2) apte à se déplacer entre le premier poste (3) et le second poste (4), la tour (5) comprenant : - a tower (5) for storing and transferring parts (2) able to move between the first station (3) and the second station (4), the tower (5) comprising:
- une structure de support (51 ) et - a support structure (51) and
- au moins une balancelle (52) apte à se déplacer dans la structure de support (51 ) pour recevoir les pièces (2) du premier poste (3) à partir du premier niveau (Z0) et les transférer au second poste (4) par le second niveau (Z1 ). - at least one swing (52) able to move in the support structure (51) to receive the parts (2) from the first station (3) from the first level (Z0) and transfer them to the second station (4) by the second level (Z1 ).
2. Installation (1 ) selon la revendication 1 , caractérisée en ce que la tour (5) de stockage et de transfert comprend une interface agencée sur la structure de support (51 ) et apte à coopérer avec un véhicule autonome guidé pour déplacer la tour (5). 2. Installation (1) according to claim 1, characterized in that the storage and transfer tower (5) comprises an interface arranged on the support structure (51) and capable of cooperating with an autonomous vehicle guided to move the tower (5).
3. Installation (1 ) selon la revendication 1 ou 2, caractérisée en ce qu’elle comprend un dispositif de commande électrique apte à commander le déplacement de la tour (5) et le déplacement de la balancelle (52). 3. Installation (1) according to claim 1 or 2, characterized in that it comprises an electric control device capable of controlling the movement of the tower (5) and the movement of the swing (52).
4. Installation (1 ) selon l’une quelconque des revendications précédentes, caractérisée en ce que la tour (5) comprend des roues sur lesquelles est montée la structure de support (51 ). 4. Installation (1) according to any one of the preceding claims, characterized in that the tower (5) comprises wheels on which is mounted the support structure (51).
5. Installation (1 ) selon l’une quelconque des revendications précédentes, caractérisée en ce que la tour (5) comprend un premier passage (50a) des pièces (2) donnant accès au premier niveau (Z0) et un deuxième passage (50b) des pièces (2) donnant accès au second niveau (Z1 ). 5. Installation (1) according to any one of the preceding claims, characterized in that the tower (5) comprises a first passage (50a) of rooms (2) giving access to the first level (Z0) and a second passage (50b) of the rooms (2) giving access to the second level (Z1).
6. Installation (1 ) selon la revendication 5, caractérisée en ce qu’unedistance (H) séparant le premier passage (50a) et le deuxième passage (50b) est comprise entre 2 m et 20 m, de préférence comprise entre 5 m et 10 m. 6. Installation (1) according to claim 5, characterized in that a distance (H) separating the first passage (50a) and the second passage (50b) is between 2 m and 20 m, preferably between 5 m and 10m.
7. Installation (1 ) selon l’une quelconque des revendications précédentes, caractérisée en ce que la tour (5) comprend une pluralité de rangées de balancelles (52) superposées et réparties sur deux colonnes, chacune des balancelles (52) étant aptes à se déplacer dans la structure de support (51 ). 7. Installation (1) according to any one of the preceding claims, characterized in that the tower (5) comprises a plurality of rows of swings (52) superimposed and distributed over two columns, each of the swings (52) being able to move in the support structure (51).
8. Installation (1 ) selon l’une quelconque des revendications précédentes, caractérisée en ce que la structure de support (51 ) présente une largeur (L) comprise entre 2 m et 20m, de préférence comprise entre 5 m et 10 m et une profondeur (P) inférieure à la largeur (L) de la structure de support (51 ), par exemple comprise entre comprise entre 2 m et 8 m. 8. Installation (1) according to any one of the preceding claims, characterized in that the support structure (51) has a width (L) of between 2 m and 20 m, preferably between 5 m and 10 m and a depth (P) less than the width (L) of the support structure (51), for example between between 2 m and 8 m.
9. Procédé de fabrication de disques de frein pour un aéronef, le procédé comprenant les étapes suivantes : 9. Method for manufacturing brake discs for an aircraft, the method comprising the following steps:
- (a) fournir des pièces (2) en matériau composite comprenant une matrice et un renfort fibreux, au sein d’un premier poste (3) de transformation présentant une première entrée (30) agencée sur un premier niveau (Z0), - (a) supplying parts (2) made of composite material comprising a matrix and a fibrous reinforcement, within a first processing station (3) having a first entrance (30) arranged on a first level (Z0),
- (b) charger les pièces (2) à partir du premier niveau (Z0) dans une tour (5) de stockage et de transfert comprenant une structure de support (51 ) et au moins une balancelle (52) mobile dans la structure de support (51 ), - (b) loading the parts (2) from the first level (Z0) into a storage and transfer tower (5) comprising a support structure (51) and at least one swing (52) movable in the support (51 ),
- (c) déplacer la tour de stockage (5) et de transfert vers un second poste (4) de transformation présentant une seconde entrée (40) agencée sur un second niveau (Z1 ) de l’installation (1 ) surélevé par rapport au premier niveau (Z0),- (c) moving the storage tower (5) and transfer to a second processing station (4) having a second entrance (40) arranged on a second level (Z1) of the installation (1) raised with respect to the first level (Z0),
- (d) déplacer la balancelle (52) de sorte à atteindre le second niveau (Z1 ),- (d) move the swing (52) so as to reach the second level (Z1),
- (e) transférer les pièces (2) dans le second poste (4) de transformation à partir du second niveau (Z1 ), - (e) transferring the parts (2) to the second processing station (4) from the second level (Z1),
- (f) transformer les pièces (2) pour fournir les disques de frein. 15 - (f) transform the parts (2) to supply the brake discs. 15
10. Procédé de fabrication selon la revendication précédente, caractérisé en ce que la balancelle (52) est mobile en rotation dans la structure de support (51 ). 10. Manufacturing process according to the preceding claim, characterized in that the rocker (52) is rotatable in the support structure (51).
PCT/FR2021/051472 2020-08-24 2021-08-18 Installation and method for manufacturing brake discs WO2022043632A1 (en)

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FR2008629 2020-08-24
FR2008629A FR3113490B1 (en) 2020-08-24 2020-08-24 INSTALLATION AND METHOD FOR MANUFACTURING BRAKE DISCS

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Citations (2)

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US3178041A (en) 1961-10-23 1965-04-13 Libbey Owens Ford Glass Co Sheet handling apparatus
EP3680201A1 (en) * 2019-01-09 2020-07-15 Movetro S.r.l. Device and method for moving plate-like elements

Patent Citations (2)

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Publication number Priority date Publication date Assignee Title
US3178041A (en) 1961-10-23 1965-04-13 Libbey Owens Ford Glass Co Sheet handling apparatus
EP3680201A1 (en) * 2019-01-09 2020-07-15 Movetro S.r.l. Device and method for moving plate-like elements

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Title
RANCSO BENCE: "Manufacture and examination of carbon ceramic brakes", 8 October 2016 (2016-10-08), XP055800580, Retrieved from the Internet <URL:https://www.researchgate.net/publication/308937291_Manufacture_and_examination_of_carbon_ceramic_brakes> [retrieved on 20210430], DOI: 10.13140/rg.2.2.25765.50402 *

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