Production device, in particular SMC production device, for a production of thermoset semifinished products

Abstract

A production device for a production of thermoset semifinished products comprises at least one material application unit (12) for applying a material (14) to a carrier element (16), wherein the production device further comprises at least one recording unit (18), which has at least one sensor element (20), for recording a thickness (22) of the material (14) applied to the carrier element (16).

Claims

1. A production device for a production of thermoset semifinished products, comprising at least one material application unit (12) for applying a material (14) to a carrier element (16), and at least one recording unit (18), which has at least one sensor element (20) for recording a thickness (22) of the material (14) applied to the carrier element (16).

2. The production device as claimed in claim 1, wherein the sensor element (20) is formed as a confocal-chromatic sensor.

3. The production device as claimed in claim 1, wherein the recording unit (18) has at least one holding-down element (24), which is configured to subject the carrier element (16) at least section-wise to a force in the direction of a bearing surface (26) of the material application unit (12), on which the carrier element (16) at least partially rests.

4. The production device as claimed in claim 1, wherein the recording unit (18) has at least one holding-down element (24), the sensor element (20) and the holding-down element (24) being arranged overlapping.

5. The production device as claimed in claim 1, wherein the recording unit (18) has at least one holding-down element (24), which is formed as a negative-pressure holding element.

6. The production device as claimed in claim 1, wherein the recording unit (18) has at least one holding-down element (24), which has a maximum holding-surface extent (28) which is less than a maximum transverse extent (30) of a bearing surface (26) of the material application unit (12).

7. The production device as claimed in claim 1, wherein the recording unit (18) has at least one holding-down element (24), which is arranged on a bearing surface (26) of the material application unit (12) within a recording region of the sensor element (20).

8. The production device as claimed in claim 1, further comprising at least one actuator unit (32), which is configured to set at least one position of a closing and/or stripping element (34) of the material application unit (12) in relation to a bearing surface (26) of the material application unit (12) and/or in relation to the carrier element (16) in dependence on a thickness (22) of the applied material (14) recorded by means of the sensor element (20).

9. A method for a production of thermoset semifinished products, wherein in at least one method step (38), a thickness (22) of a material (14) applied to a carrier element (16) is recorded by means of a sensor element (20) of a recording unit (18).

10. The method as claimed in claim 9, wherein in at least one method step (38), the carrier element (16) is at least section-wise subjected to a force in the direction of a bearing surface (26) of a material application unit (12) on which the carrier element (16) at least partially rests, by means of a holding-down element (24) of a recording unit (18).

11. The production device as claimed in claim 1, wherein the production device is embodied as an SMC production device.

12. The production device as claimed in claim 1, wherein the at least one material application unit (12) is embodied as a doctor blade unit.

13. The production device as claimed in claim 1, wherein the at least one sensor element (20) is an optical sensor element.

14. The production device as claimed in claim 1, wherein the recording unit (18) has at least one holding-down element (24), the sensor element (20) and the holding-down element (24) being arranged overlapping along a direction running at least substantially perpendicularly to a bearing surface (26) of the material application unit (12).

15. The production device as claimed in claim 5, wherein the at least one holding-down element (24) is embodied as a vacuum gripper.

16. The method as claimed in claim 9, wherein the method for producing thermoset semifinished products is performed by using the production device as claimed in claim 1.

17. The method as claimed in claim 9, wherein the material (14) is a resin matrix.

Description

DRAWINGS

[0020] Further advantages will become evident from the following description of the drawings. The drawings illustrate an exemplary embodiment of the invention. The drawings, the description and the claims contain numerous features in combination. A person skilled in the art will also expediently consider the features individually and combine them to form appropriate further combinations.

[0021] In the figures:

[0022] FIG. 1 shows a production device according to the invention as part of a production installation, in particular an SMC production installation, in a schematic representation,

[0023] FIG. 2 shows a basic representation of a way of functioning of a material application unit and a recording unit of the production device according to the invention in a schematic representation,

[0024] FIG. 3 shows a sectional view of the material application unit and the recording unit of the production device according to the invention in a schematic representation,

[0025] FIG. 4 shows a view of a detail of the recording unit of the production device according to the invention in a schematic representation and

[0026] FIG. 5 shows a sequence of a method according to the invention, at least for a production of thermoset semifinished products, in a schematic representation.

Description of the exemplary embodiment

[0027] FIG. 1 shows a production installation 42, in particular an SMC production installation, for a production of thermoset semifinished products. The production installation 42 preferably comprises a mixing unit 44 for producing a material 14, in particular a resin matrix, to be applied to a carrier element 16. The mixing unit 44 is preferably configured, in a way already known to a person skilled in the art, for mixing individual components of the material 14 to be applied, such as for example a crosslinkable resin and/or additives, such as for example additives for reducing shrinkage, release agents, catalysts or the like. It is however also conceivable that, as an alternative or in addition to the mixing unit 44, the production installation 42 has a material feeding unit (not represented any more specifically here), which is configured to feed an already ready-mixed material 14 to be applied, for example from an external material tank (not represented any more specifically here) at least to a production device 10, comprising a material application unit 12, of the production installation 42. The mixing unit 44 or the material feeding unit is preferably connected by way of feed lines of the production installation 42 at least to the material application unit 12, in particular in order to feed the material 14 to be applied to the material application unit 12. The material application unit 12 is configured for applying the material 14, in particular the resin matrix, to the carrier element 16, in particular a carrier film. The material application unit 12 is formed in particular as a doctor blade unit.

[0028] The production installation 42 preferably comprises at least one fiber-cutting unit 46 and/or a fiber-feeding unit 48, which are/is configured to feed or apply, in particular in a way already known to a person skilled in the art, fibers, in particular cut fibers, to the carrier element 16, to which the material 14, in particular the resin matrix, has already been applied. The production installation 42 preferably has a further production device 52, which at least comprises a further material application unit 50 and is preferably connected to the mixing unit 44 or to the material feeding unit by way of feed lines of the production installation 42, in particular in order likewise to feed material 14 to the further material application unit 50. The further material application unit 50 is preferably configured to feed material 14 to the carrier element 16, in particular once the fibers have been fed, or to feed material 14 to a further carrier element 54 which can be brought together in an overlapping manner, in particular in a way already known to a person skilled in the art, with the carrier element 16 to which material 14 and fibers have already been applied. The production device 10 and the further production device 52 preferably have an analogous configuration.

[0029] The production installation 42 preferably comprises a drying unit 56 for drying the applied material 14, in particular in a way already known to a person skilled in the art. The drying unit 56 is in particular operatively connected, in a manner already known to a person skilled in the art, by means of a conveying and/or transporting unit 58 of the production installation 42, in particular in order to realize feeding of the carrier element 16 and/or of the further carrier element 54. In particular, the conveying and/or transporting unit 58 of the production installation 42 is configured to feed the thermoset semifinished products, obtained as a result of drying, to further processing of a further-processing production device 60, such as for example a press etc., or to a storage device (not represented any more specifically here) for storage.

[0030] FIG. 2 shows a basic diagram of the production device 10. The following description of the production device 10 preferably also applies to the further production device 52. The production device 10 comprises at least the material application unit 12, in particular the doctor blade unit, for applying the material 14, in particular the resin matrix, to the carrier element 16. The carrier element 16 is formed in particular as a carrier film. It is however also conceivable that the carrier element 16 is formed as a conveyor belt, in particular of the conveying and/or transporting unit 58, and the material application unit 12 applies the material 14 directly to the conveyor belt. The production device 10 comprises at least one recording unit 18, which has at least one sensor element 20, in particular an optical sensor element, for recording a thickness 22, in particular maximum thickness, of the material 14 applied to the carrier element 16. The recording unit 18 is preferably configured to contactlessly record a thickness 22, in particular maximum thickness, of the material 14 applied to the carrier element 16. The recording unit 18 is preferably configured to optically record a thickness 22, in particular maximum thickness, of the material 14 applied to the carrier element 16. The sensor element 20 is preferably formed as an optical sensor element, such as for example as a light sensor, in particular a laser sensor or a confocal-chromatic sensor or the like. The sensor element 20 is preferably formed as a confocal-chromatic sensor.

[0031] The sensor element 20 is preferably arranged in a vicinity of an application opening 62 (cf. FIG. 3) of the material application unit 12. A size, in particular a height, of the application opening 62 can preferably be set by means of a closing and/or stripping element 34 (cf. FIG. 3), in particular a doctor blade element, of the material application unit 12, in particular as a result of a movement of the closing and/or stripping element 34 in relation to a material receiving element 64 (cf. FIG. 3), in particular a doctor box, of the material application unit 12. A thickness 22, in particular maximum thickness, of the material 14 applied to the carrier element 16 can preferably be predetermined by a size, in particular a height, of the application opening 62. By means of the recording unit 18, a thickness 22, in particular maximum thickness, of the material 14 applied to the carrier element 16, which can be applied to the carrier element 16 through the application opening 62, can be checked. If there is a deviation from the desired thickness 22, in particular maximum thickness, of the material 14 applied to the carrier element 16, a readjustment, in particular an automatic and/or manual readjustment, of the thickness 22, in particular maximum thickness, of the material 14 applied to the carrier element 16 can advantageously take place as a result of changing a position of the closing and/or stripping element 34, in particular the doctor blade element, of the material application unit 12 in relation to the material receiving element 64, in particular the doctor box. The production device 10 or the production installation 42 comprises at least one computing unit 66. The computing unit 66 is preferably configured at least to evaluate signal data of the sensor element 20.

[0032] The production device 10 comprises at least one actuator unit 32 (cf. FIG. 3), which is configured to set at least one position of the closing and/or stripping element 34 of the material application unit 12 in relation to a bearing surface 26 (cf. FIGS. 3 and 4) of the material application unit 12 and/or in relation to the carrier element 16 in dependence on a thickness 22 of the applied material 14 recorded by means of the sensor element 20. The actuator unit 32 may be configured to move the closing and/or stripping element 34 translationally or rotationally. The actuator unit 32 is preferably configured to move the closing and/or stripping element 34 translationally along a movement axis 68 (cf. FIG. 3) of the closing and/or stripping element 34 that runs at least substantially perpendicularly to the bearing surface 26. The closing and/or stripping element 34 is preferably movably mounted translationally in relation to a counter element, in particular a counter doctor blade (not represented any more specifically here) of the material application unit 12. The counter element, in particular the counter doctor blade, is arranged at the application opening 62, in particular on the material receiving element 64, such that it lies opposite the closing and/or stripping element 34, in particular considered along a direction running at least substantially parallel to the movement axis 68. The computing unit 66 is preferably configured to activate the actuator unit 32 in dependence on processing of sensor signals of the sensor element 20.

[0033] The recording unit 18 has at least one holding-down element 24 (cf. FIGS. 2 to 4), which is configured to subject the carrier element 16 at least section-wise to a force in the direction of the bearing surface 26 of the material application unit 12 on which the carrier element 16 at least partially rests. The holding-down element 24 is preferably arranged on the bearing surface 26 on a side of the carrier element 16 that is facing away from the sensor element 20.

[0034] The carrier element 16 can preferably be moved over the holding-down element 24 during operation of the production device 10, in particular along a direction running at least substantially parallel to the bearing surface 26, while the holding-down element 24 is subjecting the carrier element 16 to a force in the direction of the bearing surface 26. The holding-down element 24, in particular a holding-down surface 70 of the holding-down element 24, preferably has a maximum longitudinal extent which is a multiple less than a maximum longitudinal extent of the bearing surface 26. In a state of the holding-down element 24 in which it is arranged on the bearing surface 26, the maximum longitudinal extent of the holding-down element 24, in particular the holding-down surface 70 of the holding-down element 24, preferably runs at least substantially parallel to a transporting direction 72 (cf. FIGS. 2 and 3) of the production device 10, in particular in the region of the material application unit 12 along which the carrier element 16 is moved during operation of the production device 10.

[0035] The recording unit 18 has at least one holding-down element 24, the sensor element 20 and the holding-down element 24 being arranged overlapping (cf. FIGS. 2 to 4), in particular considered along a direction running at least substantially perpendicularly to the bearing surface 26 of the material application unit 12. The holding-down element 24 and the sensor element 20 are preferably arranged at a distance in relation to one another along the direction running at least substantially perpendicularly to the bearing surface 26 of the material application unit 12.

[0036] The recording unit 18 has at least the holding-down element 24, which is formed as a negative-pressure holding element, in particular as a vacuum gripper or as a flow gripper. The holding-down element 24 may be formed as a flat suction gripper, as a bellows suction gripper or as some other vacuum gripper that appears appropriate to a person skilled in the art. The recording unit 18 preferably comprises a connection interface 74 for a connection of the holding-down element 24 to an external negative-pressure device (not represented any more specifically) or the recording unit 18 itself comprises a negative-pressure generator 76 (cf. FIG. 3), which is connected to the holding-down element 24 by means of a negative-pressure line 78 of the recording unit 18, in particular by way of the connection interface 74. It is also conceivable that the holding-down element 24 generates the negative pressure itself, such as for example by the holding-down element 24, which is supplied with compressed air, controlling or regulating, such as for example by means of a valve arranged on the holding-down element 24, an intensity of the compressed air, in particular of the compressed air flowing out of the holding-down element 24, in particular in order to vary a magnitude of a holding-down force. The recording unit 18 has at least the holding-down element 24, which is arranged on the bearing surface 26 of the material application unit 12 within a recording region of the sensor element 20. The recording unit 18 has at least the holding-down element 24, which has a maximum holding-surface extent 28 (cf. FIG. 4) which is less than a maximum transverse extent 30 of the bearing surface 26 of the material application unit 12. The holding-down surface 70 of the holding-down element 24 is preferably arranged on the bearing surface 26 of the material application unit 12 within the recording region of the sensor element 20. A main emitting direction 80 (cf. FIG. 2) of the sensor element 20 preferably intersects the holding-down surface 70 of the holding-down element 24. The main emitting direction 80 of the sensor element 20 preferably runs transversely, in particular at least substantially perpendicularly, to the bearing surface 26 of the material application unit 12 (cf. FIGS. 2 to 4).

[0037] FIG. 5 shows a schematic sequence of a method 36 for a production of thermoset semifinished products, in particular by using the production device 10. Preferably, the material 14 to be applied is produced in at least one method step 82, in particular as a result of mixing of individual components of the material 14, such as for example a crosslinkable resin, additives, such as for example additives for reducing shrinkage, release agents, catalysts or the like. After production, in particular after mixing, the material 14 to be applied is preferably fed to the production device 10, in particular the material application unit 12, in at least one method step 84. In particular after mixing, the material 14 to be applied is preferably applied to the carrier element 16 by means of the material application unit 12 in at least one method step 86.

[0038] In at least one method step 38, the thickness 22, in particular maximum thickness, of the material 14, in particular the resin matrix, applied to the carrier element 16 is recorded by means of the sensor element 20, in particular the optical sensor element, of the recording unit 18. The thickness 22, in particular maximum thickness, of the material 14, in particular the resin matrix, applied to the carrier element 16 is preferably monitored in the method step 38, in particular as a result of an evaluation of the signal data of the sensor element 20 by the computing unit 66. In the method step 38, the carrier element 16 is at least section-wise subjected to a force in the direction of the bearing surface 26 of the material application unit 12 on which the carrier element 16 at least partially rests, by means of the holding-down element 24 of the recording unit 18.

[0039] In at least one method step 40, preferably fibers, in particular cut fibers, are applied to the carrier element 16, on which the material 14, in particular the resin matrix, has already been applied. In particular, in at least one method step 88, the material 14, in particular the resin matrix, is once again applied to the carrier element 16 on which the material, in particular the resin matrix, and the fibers have already been applied. Preferably, in at least one method step 90, feeding of the carrier element 16 and of the material 14 applied to it to the drying unit 56 of the production installation 42 takes place. Alternatively, it is also conceivable that the production installation is formed without the drying unit 56, feeding of the carrier element 16 and the material 14 applied to it to a storage unit (not represented any more specifically here) taking place in at least one method step, in order to carry out a maturing process. For example, for the maturing process, the carrier element 16 and the material 14 applied to it are brought into a temperature-controlled space of the storage unit, the carrier element 16 and the material 14 applied to it remaining there for a predetermined time, in particular a few days, to mature. During the maturing, preferably the viscosity of the resin matrix increases, so that during the following further processing the carrier element 16 can be pulled off from the material 14 and the material 14 can therefore also be handled without the carrier element 16. As already stated above, the maturing process can be realized within a short time period by means of the drying unit 56 of the production installation 42, in order to make advantageous direct further processing possible, in particular in a configuration of the method as a direct SMC production process. Drying, in particular by means of the drying unit 56 of the production installation 42, is preferably followed by further processing or storage of the carrier element 16 and the material 14 applied to it—in particular the thermoset semifinished product.

DESIGNATIONS

[0040] 10 Production device

[0041] 12 Material application unit

[0042] 14 Material

[0043] 16 Carrier element

[0044] 18 Recording unit

[0045] 20 Sensor element

[0046] 22 Thickness

[0047] 24 Holding-down element

[0048] 26 Bearing surface

[0049] 28 Holding-surface extent

[0050] 30 Transverse extent

[0051] 32 Actuator unit

[0052] 34 Closing and/or stripping element

[0053] 36 Method

[0054] 38 Method step

[0055] 40 Method step

[0056] 42 Production installation

[0057] 44 Mixing unit

[0058] 46 Fiber-cutting unit

[0059] 48 Fiber-feeding unit

[0060] 50 Material application unit

[0061] 52 Production device

[0062] 54 Carrier element

[0063] 56 Drying unit

[0064] 58 Conveying and/or transporting unit

[0065] 60 Production device

[0066] 62 Application opening

[0067] 64 Material receiving element

[0068] 66 Computing unit

[0069] 68 Movement axis

[0070] 70 Holding-down surface

[0071] 72 Transporting direction

[0072] 74 Connection interface

[0073] 76 Negative-pressure generator

[0074] 78 Negative-pressure line

[0075] 80 Main emitting direction

[0076] 82 Method step

[0077] 84 Method step

[0078] 86 Method step

[0079] 88 Method step

[0080] 90 Method step