MACHINE SYSTEM FOR PRODUCING A HYBRID COMPONENT
20180304560 · 2018-10-25
Assignee
Inventors
Cpc classification
B29C66/12421
PERFORMING OPERATIONS; TRANSPORTING
B29C66/12
PERFORMING OPERATIONS; TRANSPORTING
B29C70/747
PERFORMING OPERATIONS; TRANSPORTING
G05B2219/49023
PHYSICS
B29C70/86
PERFORMING OPERATIONS; TRANSPORTING
B29C70/521
PERFORMING OPERATIONS; TRANSPORTING
B29C66/12425
PERFORMING OPERATIONS; TRANSPORTING
B29C66/1242
PERFORMING OPERATIONS; TRANSPORTING
B29C64/124
PERFORMING OPERATIONS; TRANSPORTING
G05B19/41865
PHYSICS
B29C64/106
PERFORMING OPERATIONS; TRANSPORTING
B29C64/118
PERFORMING OPERATIONS; TRANSPORTING
B29C64/112
PERFORMING OPERATIONS; TRANSPORTING
B29C70/78
PERFORMING OPERATIONS; TRANSPORTING
B29C31/008
PERFORMING OPERATIONS; TRANSPORTING
B29C66/12423
PERFORMING OPERATIONS; TRANSPORTING
B29C70/523
PERFORMING OPERATIONS; TRANSPORTING
B29C70/682
PERFORMING OPERATIONS; TRANSPORTING
B29C66/30325
PERFORMING OPERATIONS; TRANSPORTING
B29C65/565
PERFORMING OPERATIONS; TRANSPORTING
B29C64/153
PERFORMING OPERATIONS; TRANSPORTING
B29C64/165
PERFORMING OPERATIONS; TRANSPORTING
International classification
B29C70/52
PERFORMING OPERATIONS; TRANSPORTING
B29C70/86
PERFORMING OPERATIONS; TRANSPORTING
B29C70/74
PERFORMING OPERATIONS; TRANSPORTING
B29C70/78
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The invention relates to a method for producing a support structure in the form of a hybrid component with a base structure and with at least one reinforcement structure, having the following steps: producing the at least one reinforcement structure for each base structure, wherein the at least one reinforcement structure, in particular all of the reinforcement structures, is/are made of a composite material comprising fibers and a matrix using a pultrusion and/or extrusion process, and connecting the at least one reinforcement structure to the base structure such that the at least one reinforcement structure is connected to the base structure in a connection position, and the base structure together with the at least one reinforcement structure forms the support structure.
Claims
1-15. (canceled)
16. A method for producing a support structure as a hybrid component with a base structure and with at least one reinforcing structure having the following steps: producing the at least one reinforcing structure for each base structure in a way that the at least one reinforcing structure, in particular all of the reinforcing structures, is or are made of a composite material comprising fibers and a matrix by means of pultrusion and/or extrusion and a pultrusion unit and/or an extrusion unit as a PE-machine for producing the reinforcing structure is moved in space such that the at least one reinforcing structure, in particular all of the reinforcing structures, is or are pultruded and/or extruded onto the base structure at the respective required connection position after the pultrusion and/or extrusion, providing the base structure by means of a G-machine, connecting the at least one reinforcing structure to the base structure such that the at least one reinforcing structure is connected to the base structure in a connection position and the base structure together with the at least one reinforcing structure forms the support structure, wherein the method is implemented with a machine system and in the machine system the number of the at least one G-machine and the number of the at least one PE-machine are different and the base structure, provided by means of the at least one G-machine, is moved by means of a conveying system to the at least one PE-machine.
17. The method according to claim 16 wherein, the base structure is produced by means of the at least one G-machine.
18. The method according to claim 16 wherein, a plurality of base structures are provided by means of the at least one G-machine and are moved with the conveying system to the at least one PE-machine and by means of the at least one PE-machine the reinforcing structures are produced onto the base structures.
19. The method according to claim 16 wherein, for the production of the reinforcing structure the pultrusion is carried out as a first step and as a second step, the extrusion is carried out, so that the in the first step partially produced pultruded at least one reinforcing structure, in particular all of the reinforcing structures, is or are post-processed with extrusion.
20. The method according to claim 16 wherein, the base structure, in particular base structures, provided by means of the at least one G-machine, is or are moved to the at least one PE-machine by means of a conveyor belt and/or a robot.
21. The method according to claim 16 wherein, after the production of the least one reinforcing structure onto the base structure the base structure with the least one reinforcing structure is moved back by means of the conveying system from the at least one PE-machine to the at least one G-machine and onto the already produced reinforcing structure a further base structure as an additional base structure is produced by means of the at least one G-machine.
22. The method according to claim 16 wherein, the number of base structures provided per time unit by means of only one G-machine is less than the number of reinforcing structures for each base structure produced per time unit by means of only one PE-machine and in the machine system the number of the at least one G-machine is higher than the number of the at least one PE-machine, in particular the machine system comprises only one PE-machine, or the number of base structures provided per time unit by means of only one G-machine is higher than number of reinforcing structures for each base structure produced per time unit by means of only one PE-machine and in the machine system the number of the at least one PE-machine is higher than the number of the at least one G-machine, in particular the machine system comprises only one G-machine.
23. The method according to claim 16 wherein, different base structures are produced by means of the G-machine.
24. The method according to claim 16 wherein, different reinforcing structures are produced by means of the PE-machine.
25. The method according to claim 16 wherein, the method is implemented by means of a machine system according to claim 15.
26. The method according to claim 16 wherein, the pultruded and/or extruded at least one reinforcing structure, in particular all of the reinforcing structures, after the pultrusion and/or extrusion and after laying onto the base structure is or are not moved relative to the base structure.
27. The method according to claim 16 wherein, the matrix of the pultruded and/or extruded reinforcing structure, in particular all of the reinforcing structures, hardens at the respective required connection position at and/or on the base structure.
28. The method according to claim 16 wherein, the at least one reinforcing structure, preferably all of the reinforcing structures, is or are produced, in particular continuously, in a way that the pultrusion unit and/or extrusion unit, in particular continuously, is moved in space in a movement path at the respective required connection position in a distance to the base structure.
29. Method according to claim 16 wherein, the at least one reinforcing structure as a rod is at least 50%, 70%, 80% or 90% in its length at the outer side connected to the base structure.
30. A machine system for producing a support structure as a hybrid component with a base structure and with at least one reinforcing structure, comprising at least one G-machine in order to provide a base structure, at least one PE-machine with a pultrusion unit and/or an extrusion unit for the production of the at least one reinforcing structure, wherein the number of the at least one G-machine is different from the number of the at least one PE-machine and the machine system comprises a conveying system for moving the base structure from the G-machine to the PE-machine.
31. The machine system according to claim 30 wherein, the G-machine is a 3D printer and/or an injection molding machine and/or a storage for the base structure.
32. The machine system according to claim 30 wherein, the conveying system is a conveyor belt and/or a robot.
33. The machine system according to claim 30 wherein, the machine system comprises a robot for moving the PE-machine in a movement path in space and the PE-machine is fixed at the robot, so that the at least one reinforcing structure is producible onto the base structure at the respective required connection position.
34. The machine system according to claim 15 wherein, the method according to claim 30 is workable by means of the machine system.
35. The machine system according to claim 15 wherein, the machine system is designed in a way that the number of base structures provided per time unit by means of only one G-machine is less than number of reinforcing structures for each base structure produced per time unit by means of only one PE-machine and in the machine system the number of the at least one G-machine is higher than the number of the at least one PE-machine, in particular the machine system comprises only one PE-machine, or the machine system is designed in a way that the number of base structures provided per time unit by means of only one G-machine is higher than number of reinforcing structures for each base structure produced per time unit by means of only one PE-machine and in the machine system the number of the at least one PE-machine is higher than the number of the at least one G-machine, in particular the machine system comprises only one G-machine.
Description
[0044] Embodiments of the invention are described in more detail below with reference to the accompanying drawings.
[0045] It shows:
[0046]
[0047]
[0048]
[0049]
[0050]
[0051]
[0052]
[0053]
[0054]
[0055]
[0056]
[0057]
[0058]
[0059]
[0060]
[0061]
[0062]
[0063]
[0064]
[0065]
[0066]
[0067] The pultrusion unit 6 and the extrusion unit 7 are connected to one another by means of a connecting part 20, for example a housing which is only partially shown in
[0068] During the production of the reinforcing structure 1 from the composite material 29 with the fibers and the matrix, the composite material 29 is first conveyed through the pultrusion unit 6 and subsequently through the extrusion unit 7 by means of the conveying device 12, as shown in
[0069] The reinforcing structures 1 produced by the method are straight or curved rods 2. The rods 2 are produced by the process unit 5 at the respective required connection positions on a base structure 4, so that the process unit 5 is moved on a movement path 26 as a straight line 27 or a curved line 27 by means of motion arms 28 of a robot 48 greatly simplified in
[0070] In a further exemplary embodiment of the process unit 5 (not shown), the fibers, for example glass fibers, aramid fibers or carbon fibers, are rolled on coils 22, and the matrix as the thermoplastic material is separated in a container with a container heating in a heated state and is conveyed to the pultrusion unit 6 by means of a matrix conveying device (not shown). The pultrusion unit 6 and the extrusion unit 7 can also be designed as a single component 29 in a way that for example after the pultrusion the extrusion is immediate operated, that is to say the final shaping of an outer side 33 of the rod 2 is operated without an arrangement of the conveyor 12 between the extrusion unit 7 and the pultrusion unit 6.
[0071] In another exemplary embodiment, which is not shown, a thermosetting plastic or plastic as reactive hotmelt respectively hotmelt adhesive respectively melt polymer is used instead of thermoplastic as the matrix. The thermosetting plastic is separately stored in a container and fed by means of a matrix conveying device to the extrusion unit 7 and/or the pultrusion unit 6. The thermosetting plastic is hardened by means of an irradiation or an addition of chemical additives. The hardening of the plastic as reactive hotmelt respectively hotmelt adhesive respectively melt polymer is especially implemented by heating as the change parameter during the processing of the matrix in the pultrusion unit 6 and/or the extrusion unit 7. Deviating from this the hardening of the plastic as reactive hotmelt can be achieved with moisture and/or UV light and/or oxygen withdrawal. If the hardening is processed with UV light, after the laying of the at least one reinforcing structure 1 on the base structure 4 an irradiation of the least one reinforcing structure 1 with UV light with an UV light source is implemented (not shown).
[0072] At the process unit 5 are attached pre-processing devices 34, 36, 38 as a tool 34 as a milling tool 35, a heating device 36 for the base structure 4, for example a laser 37 or an infrared radiator 38, and an adding device 39 for adhesive 31 (shown only in
[0073] Subsequently, the surface of the base structure 4 is heated in the region of the cutout 32 with the heating device 36 for the base structure 4, so that the matrix of the composite material 29 can be cohesively connected to the material of the base structure 4 and after cooling and hardening of the composite material 29 and the base structure 4 a solid cohesive connection between the base structure 4 and the reinforcing structure 1 consists.
[0074] Adhesive 31 is then applied to the surface of the base structure 4 in the region of the cutout 32 by means of the adding device 39, in order to connect the reinforcing structure 1 to the base structure 4 in a material-locking manner after placing the reinforcing structure 1 on the base structure 4 and hardening the adhesive 31. In general, depending on the material of the base structure 4, only the heating device 36 for the base structure 4 or only the adding device 39 is operated. In the case of a base structure 4 made of metal, for example steel or aluminum, only the adding device 39 and not the heating device 36 for the base structure 4 are operated. In the case of a base structure 4 made of thermoplastic material, not the adding device 39 and only the heating device 36 for the base structure 4 is operated.
[0075]
[0076]
[0077]
[0078]
[0079]
[0080]
[0081]
[0082] In
[0083] In
[0084] Overall, significant advantages are resulted from the method according to the invention for reinforcing the base structure 4. The reinforcing structures 1 are made of the composite material 29 with fibers and a matrix. During production, the process unit 5 is moved as a straight or curved movement path 26 along a longitudinal axis of the reinforcing structure 1, in particular rod 2, so that the rods 2 made of the composite material 29 are already produced on the surface of the base structure 4 at the respective required connection position and thereby the costs of producing the support structure 3 are substantially reduced. When using the hybrid yarn 21, the proportion of the matrix and the fibers in the rods 2 is constant. By using a different number of hybrid yarns 21 respectively fibers for producing a respective rod 2, it is also possible to produce rods 2 with a different diameter. Furthermore, the rods 2 can also be produced in a different cross-sectional shape. For this purpose, the end of the extrusion channel 15 has an exchangeable shaping part, not shown in
[0085] In the machine system 40 the number of G-machines 41 is optimally balanced to the number of PE-machines 42, this means that because of the existing sum of number of cycles of G-machines 41 and PE-machines 42 the G-machines 41 as well as the PE-machines 42 are during the production of the hybrid components 3 always in the main occupied. As a consequence there are in an advantageous way for the production of the hybrid components 3 for each hybrid component 3 low machine costs. In a greater amount unnecessary rests periods of the G-machine 41 or the PE-machine 42 can be avoided in an advantageous way. The hybrid components 3 can be used for different applications, for example in mechanical engineering as support structures 3 or also in applications for everyday live, for example platters for eating or as shoe soles. The term support structure 3 is to be interpreted broad as a hybrid component 3 and the special load carrying effect of the support structure 3 respectively the hybrid component 3 is not always necessary.