Production method for a fiber composite component

Abstract

A method for producing a fiber composite component is disclosed. A sensor device having a flexible circuit carrier and/or a sensor module is integrated in the fiber composite component. The method comprises: loading a tool configured to produce the fiber composite component with textile layers and the sensor device; closing the loaded tool and compressing the textile layers and the sensor device; introducing a liquid matrix into the closed tool and impregnating the textile layers to produce the fiber composite component; detecting an acceleration in relation to the closing of the tool and/or the introducing of the liquid matrix, using at least one of the sensor device and the sensor module of the sensor device; and determining a process state and/or a process parameter based on a spectral analysis of the detected acceleration in a frequency domain.

Claims

1. A method for producing a fiber composite component, a sensor device having at least one of a flexible circuit carrier and a sensor module being integrated in the fiber composite component, the method comprising: loading a tool configured to produce the fiber composite component with textile layers and the sensor device; closing the loaded tool and compressing the textile layers and the sensor device; introducing a liquid matrix into the closed tool and impregnating the textile layers to produce the fiber composite component; detecting an acceleration in relation to at least one of the closing of the tool and the introducing of the liquid matrix, using at least one of the sensor device and the sensor module of the sensor device; and determining at least one of a process state and a process parameter based on a spectral analysis of the detected acceleration in a frequency domain.

2. The method according to claim 1 further comprising: opening the tool after introducing the liquid matrix, wherein detecting the acceleration and determining the at least one of the process state and the process parameter is also effected in relation to at least one of the impregnating of the textile layers and the opening of the tool.

3. The method according to claim 1, the determining of the at least one of the process state and the process parameter further comprising: zero padding in a time domain.

4. The method according to claim 1, where the sensor module is a micromechanical acceleration sensor module.

5. The method according to claim 1, the closing the loaded tool further comprising: closing the loaded tool in an airtight manner.

6. The method according to claim 1, where the liquid matrix is a resin.

7. The method according to claim 6, where the resin is a pure resin.

8. The method according to claim 1, the detecting the acceleration further comprising: detecting the acceleration in real time.

9. The method according to claim 1, the determining the at least one of the process state and the process parameter further comprising: determining the at least one of the process state and the process parameter based on a spectral analysis of the detected acceleration in a discrete frequency domain.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further features and advantages of the aspects of the present disclosure are explained below on the basis of embodiments with reference to the figures.

(2) In the figures:

(3) FIGS. 1a, 1b show schematic illustrations of a process step during the production of a fiber composite component according to the present disclosure (view into the interior of the tool/section through the tool);

(4) FIG. 2 shows a flow diagram of a production method according to the present disclosure;

(5) FIG. 3 shows a flow diagram of a test method according to the present disclosure.

DETAILED DESCRIPTION

(6) FIG. 1a shows a schematic illustration of a process step during the production of a fiber composite component 2 according to the present disclosure. The illustration shows a process step during production in a Liquid Composite Molding (LCM) method of a fiber composite component 2 comprising a sensor device 1 with a flexible circuit carrier 3 and/or a sensor module 4, said sensor device being arranged in the fiber composite component 2. The process step illustrates the melt flow (matrix flow or resin flow) at an early point in time after resin injection 10.

(7) The upper part of the illustrated view is a plan view of the tool 30 (view into the interior of the tool/section through the tool). The lower part is a side view of the tool 30 on the sectional axis A-A.

(8) A signal profile 6 of the sensor device 1 or of the acceleration detected by the sensor module 4 in the time domain is plotted schematically alongside the views of the tool 30.

(9) The acceleration 6 detected in the time domain is converted into the frequency domain 7 in the context of process monitoring or process optimization for spectral analysis. This is illustrated in FIG. 1a on the basis of the illustration of the envelopes 7 of the frequency components of the detected signal profile 6.

(10) The signal profiles in the time domain 6 and in the frequency domain 7 illustrated by means of the solid line represent the signal profile that was detected shortly before the arrival of the melt 10 at the sensor device 1 or the sensor module 4.

(11) FIG. 1b shows a schematic illustration of a process step during the production of a fiber composite component 2 according to the present disclosure. The process step illustrates the point in time directly upon the arrival of the melt flow (matrix flow or resin flow) 10 at the sensor module 4.

(12) The upper part of the illustrated view is a plan view of the tool 30. The lower part is a side view of the tool 30 on the sectional axis A-A.

(13) A signal profile 6 of the sensor device 1 or of the acceleration detected by the sensor module 4 in the time domain is plotted schematically alongside the views of the tool 30. The acceleration detected in the time domain is converted into the frequency domain in the context of process monitoring or process optimization for spectral analysis. This is illustrated in FIG. 1b on the basis of the illustration of the envelopes 7 of the frequency components of the detected signal profile 6.

(14) The signal profiles in the time domain 6 and in the frequency domain 7 illustrated by means of the dashed line represent the signal profile that was detected directly upon the arrival of the melt 10 at the sensor device 1 or the sensor module 4.

(15) It is readily evident from the illustrations that the representation in the frequency domain permits significantly more and significantly clearer evaluations of the sensor signal profile by comparison with the signal profile in the time domain.

(16) The method has the advantage that as a result of the analysis of the detected acceleration or of the sensor signal 7 in the frequency domain, i.e. following the spectral analysis, features of the sensor signal become better visible, or actually visible in the first place, in comparison with the signal in the time domain 6.

(17) In this regard, process states and/or process parameters can be derived more easily. The evaluation of the derived process parameters can be used for the optimization thereof (process optimization).

(18) FIG. 2 shows a flow diagram of a production method 200 according to the present disclosure.

(19) The production method 200 is suitable for producing a fiber composite component 2 in which a sensor device 1 with a flexible circuit carrier 3 and/or a sensor module 4 is arranged or integrated.

(20) The method 200 comprises the following steps 201 to 205 illustrated in FIG. 2.

(21) In step 201, a tool 30 for producing the fiber composite component 2 is loaded with textile fibers or a textile semifinished product (textile layers) and the sensor device 1.

(22) In step 202, the loaded tool 30 is closed and the textile layers and the sensor device 1 are compressed.

(23) The tool 30 can be closed in an airtight manner.

(24) In step 203, a liquid matrix 10 is introduced into the closed tool 30 for producing the fiber composite component 2.

(25) The matrix 10 can be a resin. The resin can be a pure resin.

(26) Step 204 involves detecting an acceleration 6 in relation to introducing in 203 and/or closing the tool 302 by means of the sensor device 1 or the sensor module 4 of the sensor device 1.

(27) The detecting 204 can be effected in real time.

(28) In step 205, the process parameters of the production method 300 are derived, evaluated depending on the detected acceleration 6. In this case, the deriving and evaluating are effected on the basis of a spectral analysis of the detected acceleration 6 in the frequency domain 7.

(29) The steps of loading 201, closing 202 and introducing 203 have a mandatory order corresponding to the order presented. The steps of detecting 204 and deriving, evaluating and optimizing 205 can be effected in parallel with the other steps 201 to 203 of the method 200. These steps 204, 205 can be effected multiply or regularly or permanently or continuously during the production method 200.

(30) FIG. 3 shows a flow diagram of a test method according to the present disclosure.

(31) The test method 300 can be effected during the curing in the tool 30 in the context of the production of a fiber composite component 2 according to the present disclosure. The fiber composite component 2 has a sensor device 1 with one or a plurality of flexible circuit carriers 3 and/or one or a plurality of sensor modules 4. The fiber composite component 2 may have been produced or be produced according to the production method 200 according to the present disclosure.

(32) In step 301, an acceleration 6 is detected by means of the sensor device 1 or the sensor module 4 of the sensor device 1.

(33) The step of detecting 301 can be effected in reaction to a predetermined impulse being applied to the fiber composite component 2 to be tested and/or to a tool 30 for producing a fiber composite component 2 having the fiber composite component 2 to be tested.

(34) In step 302, a degree of curing of the fiber composite component 2 to be tested is determined depending on the detected acceleration 6. In this case, the determination of the degree of curing is effected on the basis of a spectral analysis of the detected acceleration 6 in the frequency domain 7.