CN104512039A - 用于制造纤维-塑料复合结构产品的成型设备 - Google Patents
用于制造纤维-塑料复合结构产品的成型设备 Download PDFInfo
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- CN104512039A CN104512039A CN201410642417.8A CN201410642417A CN104512039A CN 104512039 A CN104512039 A CN 104512039A CN 201410642417 A CN201410642417 A CN 201410642417A CN 104512039 A CN104512039 A CN 104512039A
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- 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
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
- B29C70/386—Automated tape laying [ATL]
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- 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
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/20—Making multilayered or multicoloured articles
- B29C43/203—Making multilayered articles
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- 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
- B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
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- 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
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
- B29C2045/14237—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure the inserts being deformed or preformed outside the mould or mould cavity
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/003—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor characterised by the choice of material
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- 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
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
- B29C45/14221—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure by tools, e.g. cutting means
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- 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
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
- B29C45/14786—Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
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- 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
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
- B29C45/14811—Multilayered articles
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- 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
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
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- 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
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
- B29C65/7841—Holding or clamping means for handling purposes
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- 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
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
- B29C65/7841—Holding or clamping means for handling purposes
- B29C65/7847—Holding or clamping means for handling purposes using vacuum to hold at least one of the parts to be joined
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- 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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/03—After-treatments in the joint area
- B29C66/034—Thermal after-treatments
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- 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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
- B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
- B29C66/112—Single lapped joints
- B29C66/1122—Single lap to lap joints, i.e. overlap joints
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- 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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
- B29C66/43—Joining a relatively small portion of the surface of said articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
- B29C66/472—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially flat
- B29C66/4722—Fixing strips to surfaces other than edge faces
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- 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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
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- 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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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- B29C66/721—Fibre-reinforced materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
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- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- 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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
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- B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
- B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- 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
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- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
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Abstract
本发明涉及一种用于制造复合结构产品、尤其是纤维-塑料复合结构产品的成型设备,其具有存放有优选纤维加强的基本载体的第一贮存架;输送装置,用于从第一贮存架中取出基本载体;存放架,在该存放架上可放置由所述输送装置取出的基本载体;存放有加强元件的第二贮存架,至少一个加强元件能够由输送装置放到处于所述存放架上的基本载体上;接合装置,用于将所述加强元件与所述基本载体连接成复合结构产品;加热装置,所述复合结构产品能够由所述输送装置输送到所述加热装置中,并且在该加热装置中能够将所述复合结构产品加热到共同构成所述复合结构产品的一种塑料的熔化温度以上;成型机,在成型机中能够挤压并且固化加热后的复合结构产品。
Description
技术领域
本发明涉及一种用于制造复合结构产品、尤其纤维-塑料复合结构产品的成型设备。此外,本发明涉及一种用于制造这种复合结构产品的方法。
背景技术
纤维加强塑料在技术上作为结构材料意义越来越大。十年来短纤维加强塑料已经用于如此有针对性地适配塑料的特性,使得所述特性能够满足其使用目的。因为近年来对刚性和降低重量的要求连续提高而不同的基质***只能小幅度提高其强度,所以加强纤维的机械特性或者加强纤维的长度对这些机械特性具有重大意义。这个要求的提高导致从长纤维加强向连续纤维加强发展。对于这种纤维-塑料复合结构产品,不仅采用热固性塑料,而且采用热塑性基质***。具有热固性塑料基质材料的连续纤维加强塑料大约从60年代开始已经用于飞机构件,而热塑连续纤维加强构件只是近年来才取得日益重大的意义。
一般这样的纤维复合结构产品具有的优点是:视使用目的而定能够按尺寸裁剪特性。这种按尺寸裁剪从选择基质和改善基层涂层附着性的不同基质增附剂时开始并且在加强纤维及其涂层时结束。
推动连续纤维加强塑料发展的另一个因素是轻质结构。由于塑料和纤维的密度低,所以有可能研发出一种具有低密度的高强度和刚性的纤维复合材料。另外,各纤维材料具有突出的机械特性,这些机械特性部分甚至超过钢。因而,可以用纤维与基质的材料结合制备非常轻的复合材料。因而,这样的纤维复合材料近来非常经常地在运输业中采用,以便一方面降低运营成本并且另一方面减少CO2排放。作为实例列举民用航空波音787。在那里50重量%采用复合结构产品,由此使飞机重量降低约20%。另外,这种复合结构产品也用于制造车辆,以便在这里也降低车辆重量并且由此也降低CO2排放。车辆结构的实例是BMW的项目i。上述两个实例采用热固性塑料基质。对于热塑性基质***,加工工艺还处于研发阶段。
GMT方法(GMT=Glasmattenverstaerkte Thermoplaste,玻璃毡加强热塑性塑料)描述一种在第一步骤中生产半成品的方法。这种半成品由玻璃纤维毡和熔融聚合物构成。在GMT半成品生产中给玻璃纤维毡施加熔融聚合物并且接着在双带压机上加热、固化、挤压这两个组成部分并且最后再冷却。接着,对于该加工工艺,这种半成品必须被再次加热到熔化温度上并且接着可以在冷压机中被挤压。因为在这种方法中不发生聚合,所以与反应方法相比实现较短的周期时间。该方法最大的缺点在于所采用的蓬乱纤维,其中,不存在纤维优选取向并且纤维的机械特性不能得到最优地充分利用,由此不可能为了产生的产品对原材料进行按尺寸裁剪。
GMT方法的进一步发展是有机片材。制造有机片材时不使用蓬乱毡,在这里采用定向为加强的连续纤维。有机片材逐层地构造,其中,在两个塑料膜之间装入加强材料。接着,在双带压机中将这种包括加强材料和塑料膜的夹层结构熔化、在压力下固化并且接着又冷却。接着,还将有机片材以期望长度剪下。在理论上由此可以有针对性地改变加强纤维和纤维角度,以便由此制造按尺寸裁剪的半成品。但因为这种按尺寸裁剪分别取决于构件,所以在层角度在0°和90°之间的情况下,纤维边角料(Faserverschnitt)提高,这样的半成品的制造成本并且因此也提高价格。该方法的另一缺点是,局部的厚度跳动只有通过横向于生产方向的分级辊压才可实现。更多的加工工艺与GMT方法一样。半成品又被加热到熔化温度以上并且接着可以被成型或者功能化。
CH 704 406 A1示出一种用于制造预成型产品的方法。根据该方法的一种实施变型方案设置有三个阶段,也就是半成品卷的剪切、纤维加强的坯体的存放以及最后对预成型件的铺设和焊接。在该文中只论及生产过程的部分区域并且没有论及对最终制成的复合结构产品的制造。
DE 10 2010 050 740 A1示出一种用于制造飞机结构构件的方法和设备。在该文中没有描述货仓并且也只是详细描述了生产过程的一部分区域。
EP 1 844 914 A1同样如此,其示出用于基于LEDs的“预成型”三维制造的方法。
在文献WO 2009/042225和WO 2013/016487中给出用于半成品生产的另一解决方案。作为原料使用纤维加强的半成品。这个半成品作为纤维加强的带片存在并在下文中称作“带”。在加工工艺中该带从卷中展开、切成一定长度并限定地放置在模具表面上。在将带放在模具表面上时固定该带子并且接着将其焊接。在此,可以实现各种不同的纤维角度,因为该模具表面能够绕Z轴线旋转。由此,通过这个生产过程能够制造按尺寸裁剪的半成品,其中,不仅厚度跳动而且各种不同的纤维角度是可能的。然而,这种生产过程是如此费时间的,使得该半成品必须离线制造并且不能直接耦合到进一步的加工上。由此,这种方法只对具有最高程度复杂的纤维和层结构的小批量生产才有用。
对于大批量生产,所有这些工艺都不适用,这是因为一方面半成品生产确定周期时间并且另一方面工业上优选的是联机解决方案。如果采用较宽的带,以便减少各个带条的数量并由此也缩短半成品的制造时间,那么边角料区域也自动变得较大并由此使得半成品成本上升和经济性降低。因此,构成较宽的带对于生产过程只有在一定条件下才比较经济。
发明内容
因此,本发明的目的在于,实现一种相对于现有技术改进的成型设备和一种改进的制造方法。特别是复合结构产品的制造应该尽可能快速、简单、成本低廉并能大批量生产。
这通过具有权利要求1的特征的成型设备实现。因此,该成型设备包括:其中存放有优选纤维加强的基本载体的第一贮存架;输送装置,用于从第一贮存架中取出基本载体;其上可放置由输送装置取出的基本载体的存放架;其中存放有加强元件的第二贮存架,其中,至少一个加强元件能由输送装置放到处于存放架上的基本载体上;接合装置,用于将加强元件与基本载体连接成复合结构产品;加热装置,复合结构产品能由输送装置输送到该加热装置中,并且在该加热装置中能够将复合结构产品加热到共同构成该复合结构产品的塑料的熔化温度以上;和成型机,在该成型机中能够挤压并固化加热后的复合结构产品。由此,可以降低半成品的成本,其方式是,在一个生产过程和一个设备中使用标准半成品作为原材料,其能够精明地组合在发生最终加工的那个生产线中。由此可以通过局部的按尺寸裁剪来产品特定地适配机械特性。因此,该生产过程也适用于大批量生产,这是因为如上所述的那样,通过有针对性地采用局部加强来降低半成品的成本,因为该半成品不再在整个面上而只在需要的部位上得到加强。
为了能够尽可能准确地放置基本载体和加强元件(带),优选设置有定位装置用于将基本载体定位在存放架上和/或将加强元件定位在基本载体上。在此,根据第一实施变型方案可以规定:定位装置具有推移装置和构造在存放架上的至少一个止挡,其中,由推移装置能够使基本载体和/或加强元件运动直到止挡到理论位置中。输送装置也可以承担推移装置的任务。与此相反,根据备选的第二实施变型方案规定:该定位装置具有至少一个位置传感器和控制程序,经由该控制程序能够对由所述至少一个位置传感器检测的基本载体和/或加强元件相对存放架的实际位置进行分析处理并且将其与控制程序中储存的或算出的理论位置进行比较,其中,能由控制程序向输送装置传输控制脉冲,并且由输送装置能使基本载体和/或加强元件运动到理论位置中。例如压力传感器、终点开关、激光器、重量传感器和/或指向存放架的照相机可以作为位置传感器起作用。特别优选地对放下过程进行照相机控制,其中,对该照相机的照片进行图形分析处理并将至少一个值传递向整个成型设备的控制程序、优选闭环或开环控制单元。接着,根据这个分析处理可以对放下加强元件进行修正。另外,还可以通过这些照片确定质量特征。在此,照相机可以安置在输送装置上。但是,该照相机优选静止地设置在存放架的区域中。理论位置由此原则上能够通过计算求得和检验,或者机械地实现。当然,混合变型方案也是可能的。
存放架本身可以处于成型设备的任意位置上。重要的是,该存放架能够由输送装置良好地达到。为此该存放架例如可以集成在第一贮存架中。但该存放架也可以是加热装置的一部分。但优选规定:存放架构造在分开的存放台上。
所述存放架设置在什么地方是无所谓的,但优选可以规定:存放架具有用于可靠定位地保持基本载体的真空板。此外,可以设置具有至少一个旋转轴线的旋转台,在该旋转台上可固定存放架,或该旋转台构成存放架。
原则上,加强元件与基本载体的连接或者焊接能够例如通过粘接或类似方式进行。但是,该接合装置优选具有超声波发生器,以便由此来加热这两个需连接的部件的彼此贴靠的面并且使之软化,从而使它们在冷却之后材料锁合地彼此连接。为了尽可能有效地设计整个流程,在此可以规定:接合装置安装在输送装置上。
加强元件优选构造为加强带。这个带优选基于聚酰胺6以单向玻璃纤维加强成分来制造。基本载体优选是纤维加强的热塑性半成品。作为备选方案,基本载体也可以由金属或其他载体材料取代。由此,原则上使复合结构产品一方面由基本载体构成并且另一方面由加强元件构成。在此,所述复合结构产品成分中的至少一个成分应该具有塑料组分,由此,所述复合结构产品通过利用接合装置加热或利用加热装置加热而可以较容易地变形。优选这两个复合结构产品成分至少具有塑料组分。这两个复合结构产品部件优选具有纤维加强成分。
为此也可以提出:原则上所述加热装置可以构成接合装置。由此,不必把这两个装置构成为成型设备的分开的工位,相反地可以通过加热装置一方面将加强元件与基本载体接合并且另一方面还可以同时或依次进行对整个复合结构产品的加热。反之,还绝对可以只利用接合装置来实现热处理,使得也同时加热整个复合结构产品,从而在这样一种情况下接合装置同时构成加热装置。但接合装置和加热装置优选构成成型设备的功能分开的工位,其中,它们绝对可以在位置上彼此接近或者可以集成在一个共同的工位上。
输送装置本身可以任意构造,例如构造成输送带的形式。但优选规定了,输送装置是操作机器人。为了能够操作基本载体和加强元件,在此输送装置或者操作机器人优选具有抓取元件(例如粘附抓持器或握钳)。当然,成型设备还可以包括多个并联的或串联的操作机器人。
另外,所述成型设备还可以包括剪切装置,其中,加强元件在放在基本载体上之前可以由该剪切装置进行裁剪。由此基本载体本身也可以得到裁剪。
原则上,彼此独立的不同的***用于控制成型设备的各个工位。但为了保障使整个成型设备中的条理分明的且自动的进行,可以设置用于闭环或开环控制成型设备的闭环或开环控制单元,其中,至少输送装置、接合装置、加热装置和成型机共同由这样的闭环或开环控制单元来闭环或开环控制。在该成型设备中的所有工位优选与这个唯一的闭环或开环控制单元连接。定位装置的控制程序优选也是该闭环或开环控制单元的一部分。特别优选地,在成型机上本来存在的操作单元优选起中央闭环或开环控制单元的作用。
所述成型机可以构造成压机或注模机的形式。然而,成型机优选是注射成型机。
根据本发明的目的也通过具有权利要求16的特征的方法得以实现。由此设置有以下步骤:通过输送装置从存放有优选纤维加强的基本载体的第一贮存架中取出基本载体;将由输送装置取出的基本载体放在存放架上;通过输送装置从存放有加强元件的第二贮存架中取出加强元件;将该加强元件放在处于存放架上的基本载体上;通过接合装置将加强元件与基本载体连接成复合结构产品;将该复合结构产品输送到加热装置中;在加热装置中将复合结构产品加热到共同构成该复合结构产品的塑料的熔化温度以上;并且在成型机中挤压和固化加热后的复合结构产品。原则上,各个方法步骤还可以视可能性而定按另一顺序进行。该方法优选准确地以权利要求16中给出的步骤顺序进行,其中,绝对还可以将一些步骤在时间上部分地或完全地交叉进行。作为结束步骤还可以在该成型机中进行对复合结构产品的功能化。此外,基本载体和/或加强元件优选通过定位装置放在存放架上的理论位置中或移动到理论位置中。
附图说明
以下参照附图中示出的实施例借助附图说明来对本发明的其它细节和优点作详细说明。附图中:
图1示意性示出带有各个工位的整个成型设备;
图2示出各个工位的另一个示意图;
图3至7示意性示出各个方法步骤;
图8示意性示出固定在旋转台上的基本载体;
图9示意性示出输送装置连同接合装置的细节图;
图10和11示出用于加强元件的分离装置的两种变型方案。
具体实施方式
图1示意性示出带有不同工位的成型设备1。作为用于制造复合结构产品2、优选纤维-塑料复合结构产品的出发点,在第一贮存架3上存放大量基本载体4。在第二贮存架7上存放加强元件8(加强带)。另外,设置有存放架6,该存放架构造在分开的存放台19上,其中,基本载体4和/或加强元件8预先可能还在剪切装置26中得到裁减。在存放台处静止地设置有照相机18,其构成定位装置12的一部分。另外,输送装置5构造成操作机器人23的形式。在该操作机器人23的抓取元件24上保持有复合结构产品,该复合结构产品包括基本载体4和加强元件8,所述基本载体与加强元件由接合装置9连接。作为下一步,示出加热装置10,接着之后是成型机11,在具体情况下是注射成型机。该机器一方面包括用于注入塑料熔液的注入机构29并且另一方面包括带有成型夹紧板和横梁的闭模单元30。此外,在该成型机11上安置有操作单元,该操作单元构成用于整个成型设备1的闭环或开环控制单元25。该闭环或开环控制单元25具有屏幕27和带有按键的操作区28。此外,用于定位装置12的控制程序16是该闭环或开环控制单元25的一部分。该闭环或开环控制单元经由信号线39而与成型设备的各个工位连接。
图2示意性示出俯视图,基本载体4和加强元件8处于共同的贮存架3和7中。输送装置5经由抓取元件24刚好取出一个基本载体。在该图下方可清楚地看出定位装置12,该定位装置具有两个曝光源32并且作为位置传感器15具有照相机18。通过照相机18来检验基本载体4的或者加强元件8的实际位置PIsT并且将其与控制程序16中储存和算出的理论位置PSOLL相比较。当存在偏差时,由控制程序16向输送装置5传输相应的控制信号17,其立即进行位置修正。作为备选方案,定位装置12也可以纯机械地构造。为此,在图2中用虚线画出推移装置13和设置在存放架6上的止挡14。另外,在该图2中可看到构成模具的模具半体31,这些模具半体在成型机11的闭模单元30的区域中夹紧。此外,从上侧示出用于热塑性构件的加热装置10。
图3至7直观地示出方法流程。在图3中,输送装置5正从第一贮存架3中取出纤维加强的基本载体4,该基本载体被受到限定地放在存放台19的存放架6上。此后,根据图4输送装置5从第二贮存架7中取出加强元件8并将其放到基本载体4上。接着,根据图5通过接合装置9借助超声波发生器22的超声波使基本载体4与加强元件8至少一次材料锁合地相互连接。内联按尺寸裁剪(Massschneiderung)的过程可以任意重复多次,直到基本载体4具有所期望的加强。于是,新的材料复合结构产品(纤维-塑料复合结构产品2)又由输送装置5接收并且根据图6输送向加热装置10。在该加热装置中将复合结构产品2加热到使复合结构产品2的塑料部分至少部分熔化的温度,由此使复合结构产品2能够更容易地变形。对于基于PA6的复合结构产品2的示例性温度范围为210℃至280℃。于是,加热后的复合结构产品2又由输送装置5接收并且被输送到成型机11的打开的模具中用于成型或者功能化(见图7)。最后,闭合该模具并且挤压以及固化、必要时功能化复合结构产品2。功能化例如可以意味着喷射筋条结构、注射包封复合结构产品2或注射包封***件。最后可能还能进行质量控制,例如利用照相机(闪光灯温度记录器)来进行。
如果应在两侧加强基本载体4,则需要旋转台21,该旋转台能够使构件围绕至少一根轴线A旋转(见图8。为了能够接收基本载体4,旋转台21具有框架33和保持器件34。因为基本载体4(半成品)通常不是非常抗弯的部件,所以为了将带(加强元件8)接合到基本载体4上,在背侧能够移出以与基本载体4接触的压模,以便局部承受接合压力。
图9示出设置在输送装置5上的接合装置9,该接合装置作为超声波焊接机构造有超声波发生器22。可看到的是:输送装置5具有两个抓取元件24(例如粘附抓持器、真空吸盘、夹紧元件或类似物),通过所述抓取元件来保持加强元件8。
因为加强元件8(带)可能带有静电并且因此可以彼此吸附,所以根据图10的分离装置35应该保证将各带条分离。为了能够有针对性地将带8分离,贮存架7设置在输送带36上方。该输送带36具有略带粘性的表面或者与真空板相似地构造并且由此确保输送带36与带8之间良好的接触。为了接着从贮存架7只取出一个带8,贮存架7具有仅略高于带厚的开口。为了将各个带8向下挤压,可以设置有未示出的压膜,用于对各个带8施加力F。于是,由输送装置5可以取出所分离的带8。因为存在带8可能带有静电并且由此两个带8会彼此吸附的可能性,所以贮存架7可以配备金属刷来导出电荷。由此能够使带8不再彼此静电吸附。另外也可设想的是:直接在输送装置5的抓持器上导出电荷。
图11示出另一种使带8分离的可能性。这个功能与印刷机中的纸张引入器类似。带8或者涂有橡胶的辊子37相对彼此挤压,接着辊子37开始旋转并且由此将带8输送到接收台上。带8的最终位置可以经由辊子37旋转的圈数或者经由终点开关38限定。为了在这里将带8分离,如此设计在涂有橡胶的辊子37与贮存架7之间的间隙,使得只能取出一个单个带8。在这里还可以经由压膜40施加力F用于将带子8举起。在该图11中接收台构造为真空板38。以相同的方式,存放架6也可以构造成这种真空板38的形式。
如果存在照相机18或整个的照相机***,那么照相机18也可以瞄准贮存架3和7。接着,又借助图像加工装置对数据进行分析处理。于是可以根据这些数据相应地向输送装置发指令。如果照相机18设置在抓取元件24的区域中,那么可以附加地监视并且必要时修正构件接收或者构件存放。
由此,通过本发明实现的是:纤维加强的半成品(基本载体4)有针对性地利用第二纤维加强的半成品(加强元件8)进行“内联地”加强。在这里的“内联inline”意味着半成品组合在最终加工过程中进行。该组合后接着将彼此连接的半成品加热到熔化温度以上并且最后该半成品在成型机11的模具内固化和成型和/或功能化。
Claims (18)
1.用于制造复合结构产品(2)、尤其是纤维-塑料复合结构产品的成型设备(1),该成型设备具有:
●第一贮存架(3),在所述第一贮存架中存放有优选纤维加强的基本载体(4);
●输送装置(5),用于从所述第一贮存架(3)中取出基本载体(4);
●存放架(6),在该存放架上可放置由所述输送装置(5)取出的基本载体(4);
●第二贮存架(7),在所述第二贮存架中存放有加强元件(8),至少一个加强元件(8)能够由所述输送装置(5)放到处于所述存放架(6)上的基本载体(4)上;
●接合装置(9),用于将所述加强元件(8)与所述基本载体(4)连接成复合结构产品(2);
●加热装置(10),所述复合结构产品(2)能够由所述输送装置(5)输送到所述加热装置中,并且在该加热装置中能够将所述复合结构产品(2)加热到共同构成所述复合结构产品(2)的塑料的熔化温度以上;
●成型机(11),在所述成型机中能够挤压并且固化加热后的复合结构产品(2)。
2.根据权利要求1所述的成型设备,其具有定位装置(12),用于将所述基本载体(4)定位在存放架(6)上和/或将所述加强元件(8)定位在所述基本载体(4)上。
3.根据权利要求2所述的成型设备,其中,所述定位装置(12)具有推移装置(13)和构造在存放架(6)上的至少一个止挡(14),其中,由所述推移装置(12)能够使所述基本载体(4)和/或所述加强元件(8)运动直到止挡到理论位置(PSOLL)中。
4.根据权利要求2所述的成型设备,其中,所述定位装置(12)具有至少一个位置传感器(15)和控制程序(16),经由该控制程序能对由所述至少一个位置传感器(15)检测的基本载体(4)和/或加强元件(8)相对存放架(6)或者相对基本载体(4)的实际位置(PIST)进行分析处理并且能将其与在所述控制程序(16)中储存的或算出的理论位置(PSOLL)进行比较,其中,由所述控制程序(16)能够向输送装置(5)传输控制脉冲(17)并且由所述输送装置(5)能够使基本载体(4)和/或加强元件(8)运动到理论位置(PSOLL)中。
5.根据权利要求4所述的成型设备,其中,压力传感器、终点开关(38),激光器、重量传感器和/或指向所述存放架(6)的照相机(18)起位置传感器(15)的作用。
6.根据权利要求5所述的成型设备,其中,所述照相机(18)静止地安装在存放架(6)上或优选可运动地固定在输送装置(5)上。
7.根据权利要求1至6中任一项所述的成型设备,其中,所述存放架(6)
●集成在所述第一贮存架(3)上,或者
●构造为分开的存放台(19),或者
●集成到所述加热装置(10)中。
8.根据权利要求1至7中任一项所述的成型设备,其中,所述存放架(6)具有真空板(20),用于定位可靠地保持所述基本载体(4)。
9.根据权利要求1至8中任一项所述的成型设备,该成型设备设有围绕至少一根轴线(A)可运动的旋转台(21),所述存放架(6)能够固定在所述旋转台上,或者所述存放架(6)构造在所述旋转台上。
10.根据权利要求1至9中任一项所述的成型设备,其中,所述接合装置(9)具有超声波发生器(22)。
11.根据权利要求1至10中任一项所述的成型设备,其中,所述接合装置(9)安装在所述输送装置(5)上。
12.根据权利要求1至11中任一项所述的成型设备,其中,所述输送装置(5)是操作机器人(23),该操作机器人优选具有抓取元件(24)。
13.根据权利要求1至12中任一项所述的成型设备,该成型设备设有用于闭环或开环控制所述成型设备(1)的闭环或开环控制单元(25),其中,至少所述输送装置(5)、所述接合装置(9)、所述加热装置(10)和所述成型机(11)能够共同由所述闭环或开环控制单元(25)来闭环或开环控制。
14.根据权利要求4和权利要求13所述的成型设备,其中,所述定位装置(12)的控制程序(16)是所述闭环或开环控制单元(25)的一部分。
15.根据权利要求1至14中任一项的成型设备,该成型设备设有剪切装置(26),其中,所述加强元件(8)在放在所述基本载体(4)上之前能够由所述剪切装置(26)裁剪。
16.用于尤其在根据权利要求1至15中任一项所述的成型设备(1)中制造复合结构产品(2)的方法,具有以下步骤:
●通过输送装置(5)从存放有优选纤维加强的基本载体(4)的第一贮存架(3)中取出基本载体(4);
●将由所述输送装置(5)取出的基本载体(4)放在存放架(6)上;
●通过所述输送装置(5)从存放有加强元件(8)的第二贮存架(7)中取出加强元件(8);
●将所述加强元件(8)放在处于所述存放架(6)上的基本载体(4)上;
●通过接合装置(9)将所述加强元件(8)与所述基本载体(4)连接成复合结构产品(2)、优选纤维-塑料复合结构产品;
●将所述复合结构产品(2)输送到加热装置(10)中;
●在所述加热装置(10)中将所述复合结构产品(2)加热到共同构成所述复合结构产品(2)的塑料的熔化温度以上;和
●在成型机(11)中挤压和固化加热后的复合结构产品(2)。
17.根据权利要求16所述的方法,其中,在所述成型机(11)中将所述复合结构产品(2)功能化。
18.根据权利要求16或17所述的方法,其中,所述基本载体(4)和/或所述加强元件(8)通过定位装置(12)而放在存放架(6)上的理论位置(PSOLL)中。
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CN111315057A (zh) * | 2018-12-11 | 2020-06-19 | 恩格尔奥地利有限公司 | 成型机 |
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