DE102011050102B4 - Device and method for producing a fiber composite component for a motor vehicle - Google Patents

Abstract

Device (4) for transporting and inserting flat fiber composite mats (1) into a mold (2) for the production of motor vehicle components, wherein the device (4) has telescopic grippers (3) for receiving the fiber composite mat (1), characterized in that at least an Informleiste (5) on the device (4) is arranged, wherein the grippers (3) take the fiber composite mat (1) next to the molding strip (5) and the by the gripper (3) in the form (2) filed fiber composite mat (1 ) is einreifbar by the molding strip (5) in the mold (2).

Description

The present invention relates to a device for transporting and inserting flat fiber composite material mats into a device according to the features in the preamble of patent claim 1.

The present invention further relates to a method for producing a fiber composite component according to the features in the preamble of claim 8.

It is nowadays both due to legal requirements, as well as manufacturer requirements of the automotive industry, the desire to minimize the fuel consumption of vehicles and, consequently, to reduce CO ₂ emissions.

For this purpose, there are various approaches, which are seen for example in regenerative or alternative drives, energy recovery or downsizing of internal combustion engines.

Another important starting point for reducing fuel consumption and CO ₂ emissions is a consistent lightweight construction policy, which purports to reduce the total weight of a motor vehicle. As a result, significantly less mass is accelerated and transported, which in this sense has no utility value for the mere transport of persons or goods.

For the implementation of lightweight concepts, there are again different approaches, especially in the bodywork of motor vehicles. For example, high-strength or ultra-high-strength steels are used, which significantly reduce the overall weight of a motor vehicle body.

Another approach is the use of lightweight materials, in particular first the use of light metals for the production of individual components or even the entire vehicle body.

Another approach to the use of lightweight materials is the production of automotive components from fiber composites. In this case, fiber mats, for example made of glass fiber, carbon fiber or even aramid fiber or other fiber types are prepared by means of resins such that emerge particularly rigid, break-resistant and manufactured with a very low specific weight components. However, the processes for the production of fiber composite parts are inferior due to the at least two-component and possibly the multi-layer, strong fluctuations and difficult to commercialize such that they are feasible in the automotive industry with very short cycle times with high accuracy while maintaining the predetermined manufacturing tolerances.

For example, is from the DE 101 52 232 A1 a method and a production line for the automated handling of resin mats known. Here, blanks of resin mats are picked up by suction grips, placed on various intermediate stages and placed in a heated mold. In the mold itself, while applying pressure, forming and simultaneous pre-hardening of the resin mats take place. The resin mats are then removed from the forming tool and transferred to a cooling tool and then in turn fed into collection container further processing steps. However, such a production line and implementation of a method is very expensive, since an entire production line is exclusively associated with the handling and production of a single component. If other components are to be produced on such a production line, the different handling devices and the forming tool and cooling devices must be replaced accordingly.

From the DE 600 13 348 T2 and from the DE 101 52 232 A1 Receiving devices are known which have telescopic gripper with which it is possible to receive a fiber composite mat and deposit by means of the telescopic gripper on a mold. In addition, pressing means are known with which it is possible to press the deposited fiber composite mat to the mold by translational method. In this case, however, air pockets between stored and pressed-fiber composite mat and shape may arise or a fold occurring during placement may not or only inadequately compensated by the pressing means under certain circumstances.

The object of the present invention is therefore to simplify the industrial production of motor vehicle components made of fiber composite material and to further increase the production accuracy.

The aforementioned object is achieved with a device for transporting and loading of surface fiber composite mats in a mold having the features in claim 1.

The procedural part of the object is provided with a method for producing a Motor vehicle fiber composite component according to the features in claim 8 solved.

Advantageous embodiments of the present invention are part of the dependent claims.

The device for transporting and inserting flat fiber composite mats into a mold for the production of motor vehicle components, wherein the device telescopic gripper for receiving the fiber composite mat, according to the invention is characterized in that at least one molding strip is disposed on the device, wherein the grippers the fiber composite mat next to Grab the molding strip and the fiber composite material mat deposited by the grippers in the mold can additionally be grasped into the mold by the molding strip.

In the context of the invention, an injection molding strip is to be understood as an injection molding tool which stretches or presses through a departing scraping movement, the fiber composite mat inserted into the mold. The manufactured motor vehicle component made of fiber composite material thereby has a particularly precisely fitting contour, as is made possible by the Einformleiste an exact molding into the mold. In addition, excess resin is stripped off by the molding strip and the grazing motion of the molding strip, so that on the one hand, the component has no contamination by dripping of the resin or the like, on the other hand contamination of the tools itself is avoided by the abgestriffene resin.

The fiber composite mats may also be a mat stack within the scope of the invention.

In the context of the invention thus takes place a recording and transport of the preferred pre-impregnated fiber composite mat with the device and a subsequent deposition in a mold. A form here is, for example, a molding tool or else directly a component which is to be coated or reinforced with a fiber composite material mat, for example. So that the fiber composite mat placed in the mold rests against this with high precision, in particular while maintaining required manufacturing tolerances, according to the invention at least one molding strip is formed on the device. With the molding strip, it is additionally possible to additionally strip or strip the fiber composite mat placed in the mold. Optionally, a heating device may also be assigned to the device so that the fiber composite mat is optimally thermally heat-treatable during transport or during the depositing process.

In order to further increase the accuracy of fit, the molding strip can be adapted within the scope of the invention to the inner topology of the mold. By way of this it is again possible to use the device universally by changing the molding strip and the mold in interaction with the relatively movable grippers. In addition, the moldings can be easily replaced if worn or dirty.

In order to ensure an additional better adaptation of the molding strips to the inner contour of the mold and thus an increase in the production accuracy of the fiber composite component to be produced, the molding strips are preferably formed at least in sections, in particular completely flexible. The moldings are in particular made of plastic, so that on the one hand by the choice of the plastic material gives the flexibility, on the other by the plastic material itself or a corresponding coating of the plastic material, sticking of the matrix resin is avoided on the molding.

The molding strip is furthermore coupled to the device at least via a setting actuator. This makes it possible to carry out a relative movement of the molding strip at any time during the transport or the depositing or shaping of the fiber composite mat in the mold. In the context of the invention, the molding strip can preferably be coupled to the device such that a free kinematic movement is performed independently of the device by the molding strips. The device according to the invention is characterized in particular because a massaging or a Einstreifen is particularly advantageous feasible.

In a further particularly preferred embodiment variant, a heating element is arranged on the device for at least partial heat treatment of the fiber composite material mat. By means of the heating element, it is possible within the scope of the invention to heat the fiber composite mat already during transport and / or during depositing. During the heating process, the resin initially liquefies, so that a homogeneous distribution of the resin in the fiber composite mat is given. Thereafter, for example, a thermally activated adhesive is transferred to a curing process. By integrating the heater directly to the device, it is possible, on the one hand to save production time, on the other hand, no separate heating tool is necessary, which is known as known from the prior art Heating tool contaminated by dripping or sticking resin, so here high cleaning times are necessary. The arrangement of the heating element directly to the device, it is also possible to heat the fiber composite mat particularly efficient, fast and full-surface. This in turn affects the quality, in particular the mechanical properties of the fiber composite component produced.

Preferably, the heating element is designed as a heat radiator, in particular as a halogen radiator. The halogen radiator preferably has a strong emission in the infrared range. This makes it possible, in just a few seconds, preferably less than 10, in particular less than 8 and more preferably less than 5 seconds, the component to a temperature range between 40 and 110, in particular between 50 and 100 and particularly preferably between 50 and 90 degrees Celsius to warm up. In particular, the heating takes place over the entire surface, penetrating the entire fiber composite mat.

In the context of the invention, furthermore, the grippers are preferably pneumatically actuatable and designed as suction grippers or vacuum grippers. However, it is also conceivable that the grippers are designed as a needle gripper and / or as a freezer gripper. In the context of the invention, it is particularly conceivable that the grippers are designed as a combination of the aforementioned gripper types. For example, it is thus possible to use a combined vacuum gripper, ie suction gripper combined with a needle gripper.

• – Bereitstellen einer Faserverbundwerkstoffmatte,
• – Aufnehmen der Faserverbundwerkstoffmatte,
• – zumindest partielles Wärmebehandeln der Faserverbundwerkstoffmatte mit an der Vorrichtung angeordneten Heizelementen,
• – Einlegen der erwärmten Faserverbundwerkstoffmatte in die Form, wobei die Faserverbundwerkstoffmatte während und/oder nach dem Einlegen in der Form durch die Einformleiste in der Form abgestriffen wird.

The above-mentioned object is further used by a method for producing a motor vehicle fiber composite material part, wherein a fiber composite material mat is carried out by a device having an embodiment already described above and is characterized by the following method steps:

• Providing a fiber composite mat,
• Picking up the fiber composite mat,
• At least partially heat-treating the fiber-composite mat with heating elements arranged on the device,
• - Inserting the heated fiber composite mat in the mold, wherein the fiber composite mat is stripped during and / or after insertion in the mold through the molding strip in the mold.

The inventive method is characterized in particular by the fact that the recorded fiber composite mat is already heated during transport. There are no additional facilities in the field of a production line necessary to further heat the fiber composite mat here or to heat.

The fiber composite mat is stripped during and / or after insertion into the mold through the moldings in the mold or pressed against this. This can be done actively or passively within the scope of the invention. In the case of a passive further gripping into the mold, the molding is under a biasing force, which can be applied for example by a spring or caused by the flexibility of the molding itself and is performed by the lowering movement for inserting the fiber composite mat in the mold itself. In this case, therefore, stripping or stripping of the fiber composite material mat takes place through the molding strip.

In the case of an active movement of the molding itself is a Stellaktuator, which is for example electromechanically, pneumatically, hydraulically or otherwise actively controlled, an additional relative movement of the molding to the lowering or insertion movement or after the lowering or insertion movement of Device performed. It is particularly advantageous in this case that excess resin, which emerges from the inserted fiber composite material mat, is additionally stripped off by the molding strip. Due to the molding movement in combination with a flexibly configured molding strip and / or a molding strip, which is adapted to the inner surface topology of the mold, a particularly accurate fit conditioning of the fiber composite mat on the mold surface itself.

For this purpose, the fiber composite mat is smoothed in the form of the molding strip and / or streamlined and / or fixed. A production which is carried out by the method according to the invention is characterized by a high product quality and good reproducibility. The fiber composite components produced therewith are inferior to production fluctuations only to a small extent, which is why a method used according to the invention is suitable for mass production.

In the context of the invention, the recorded fiber composite mat can be heated to 30 to 110 degrees Celsius, preferably 40 to 100 degrees Celsius and in particular 50 to 90 degrees Celsius. In particular, due to the heating elements used, particularly preferably from radiant heaters, a good temperature input into the recorded fiber composite mat is possible.

In a particularly preferred embodiment of the method according to the invention, a fiber composite mat is inserted directly into a motor vehicle component itself. As a result, in particular, a reinforcement of a motor vehicle component is realized by a fiber composite material. For example, in the context of the invention, a fiber composite mat directly into a B-pillar or other motor vehicle component can be inserted and adapted by the Einformleisten invention fit accurately to the inner contour and created. As a result, any air pockets, which are caused by the deposition process itself, eliminated by the Einformleisten itself, so that it comes to a substantially full-surface concerns between fiber composite mat and motor vehicle component. In this way, a particularly high frictional and / or cohesive connection between the fiber composite material mat and the motor vehicle component is produced.

In a further preferred embodiment variant, the fiber composite mat accommodated by the draping tool is placed on a hotplate in order to heat it up. The heating can be done in addition to the heating with arranged on the draping tool heating elements. Subsequently, the fiber composite mat is fed by the draping tool to the further processing method.

Further advantages, features, characteristics and aspects of the present invention are part of the following description. Preferred embodiments are shown in the schematic figures, which serve the simple understanding of the invention. Show it:

1a C shows the implementation of a method according to the invention and a device with molding strips.

In the figures, the same reference numerals are used for the same or similar components, even if a repeated description is omitted for reasons of simplicity.

1 shows the process sequence according to the invention for inserting a fiber composite mat 1 in a mold 2 wherein the fiber composite mat 1 over grapple 3 is recorded and according to 1a over the form 2 is positioned. Indicated is a device 4 at the gripper 3 and also in 1a laterally illustrated Einformleisten 5 are arranged.

The grippers 3 be according to 1b positioned so that the fiber composite mat 1 a substantially U-shaped cross-sectional configuration 6 taking it to the inner topology 7 the form 2 is adjusted. In the next in 1c The method step shown is the fiber composite mat 1 on the mold surface 8th the form 2 filed and the outer gripper 3a and 3d dissolve. The molding moldings 5 Press the fiber composite mat 1 from a backside 9 out to the mold surface 8th the form 2 at. The device according to the invention optionally includes a heating element 10 with which it is possible to use the fiber composite mat 1 to heat during transport and / or insertion process.

LIST OF REFERENCE NUMBERS

1

Fiber composite mat

2

shape

3

grab

3a

outer gripper

3b

inner gripper

3c

inner gripper

3d

outer gripper

4

contraption

5

Einformleiste

6

U-shaped configuration

7

inside topology

8th

form surface

9

back

10

heating element

Claims (13)

Contraption ( 4 ) for transporting and inserting flat fiber composite mats ( 1 ) into a form ( 2 ) for the manufacture of motor vehicle components, the device ( 4 ) telescopic grippers ( 3 ) for receiving the fiber composite mat ( 1 ), characterized in that at least one molding strip ( 5 ) on the device ( 4 ), wherein the grippers ( 3 ) the fiber composite mat ( 1 ) next to the molding strip ( 5 ) and by the grippers ( 3 ) in the shape ( 2 ) laid fiber composite mat ( 1 ) through the molding strip ( 5 ) in the form ( 2 ) is palpable. Device according to claim 1, characterized in that the molding strip ( 5 ) to the inner topology ( 7 ) the form ( 2 ) is adjusted. Device according to one of claims 1 or 2, characterized in that the molding strip ( 5 ) via at least one actuating actuator with the device ( 4 ) is coupled. Device according to one of claims 1 to 3, characterized in that the molding strip ( 5 ) is designed to be flexible so that it presses against the molding surface ( 8th ) the form ( 2 ) adapts. Device according to one of claims 1 to 4, characterized in that at least one heating element ( 10 ) for at least partial Heat treatment of the fiber composite mat ( 1 ) on the device ( 4 ) is arranged. Device according to claim 5, characterized in that the heating element ( 10 ) is a heat radiator, preferably a halogen radiator. Device according to one of claims 1 to 6, characterized in that the grippers ( 3 ) are pneumatically actuated, preferably the grippers ( 3 ) formed as a suction gripper, and / or that the gripper ( 3 ) are designed as needle grippers and / or that the grippers ( 3 ) are designed as a freeze gripper. A method for producing a motor vehicle fiber composite component, wherein a fiber composite mat of a device ( 4 ) according to at least one of claims 1 to 7, in a form ( 2 ), characterized by the following process steps: - providing a fiber composite mat ( 1 ), - picking up the fiber composite mat ( 1 ), - at least partially heat treating the fiber composite mat ( 1 ) with at the device ( 4 ) arranged heating elements ( 10 ), - inserting the heated fiber composite mat ( 1 ) in the form ( 2 ), wherein the fiber composite mat ( 1 ) during and / or after insertion in the mold ( 2 ) through the molding strip ( 5 ) in the shape ( 2 ) is stripped off. A method according to claim 8, characterized in that the fiber composite mat ( 1 ) is heated to 30 to 110 ° C, preferably 40 to 100 ° C, in particular 50 to 90 ° C. Method according to one of claims 8 or 9, characterized in that the fiber composite mat ( 1 ) in the shape ( 2 ) through the molding strip ( 5 ) is smoothed and / or streamlined and / or fixed. Method according to one of claims 8 to 10, characterized in that excess resin through the molding strip ( 5 ) is stripped off. Method according to one of claims 8 to 11, characterized in that the fiber composite mat ( 1 ) is inserted directly into a motor vehicle component. Method according to one of claims 8 to 12, characterized in that the recorded fiber composite mat ( 4 ) is deposited in an intermediate step on a hot plate.

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