Development of process- and system-engineering fundamentals for a quality controlled and fully automated manufacturing of RTM-Aerospace-parts by a novel and adaptable injection-unit

开发工艺和系统工程基础，通过新颖且适应性强的注射装置实现 RTM 航空航天零件的质量控制和全自动制造

• 批准号: 252772351
• 负责人: Professor Dr.-Ing. Christian Hopmann
• 金额: --
• 依托单位: Institut für Kunststoffverarbeitung (IKV) in Industrie und Handwerk an der RWTH Aachen
• 依托单位国家: 德国
• 项目类别: Research Grants (Transfer Project)
• 财政年份: 2014
• 资助国家: 德国
• 起止时间: 2013-12-31 至 2016-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/252772351?language=en
• 关键词: Development; process; system; engineering; fundamentals

A decisive problem for the high volume production of structural parts out of fibre reinforced plastics (FRP) with fibre volume contents of 50 % and more is, that the processes applied up to now are only partly automated, have a low process robustness, are not controlled and for a quality controlled qualification of the parts, time consuming post processes are necessary. Therefore, three process chains for the serial production of FRP structural parts have been developed during the investigations of the Research Group 860. In addition to an extensive understanding of the processes a comprehensive knowledge about process monitoring and the guidance of automated processes could be developed in all process chains. Based on these results the research requirements to develop a method, which enables a controlled and quality secured process, by combining different individual solutions into a holistic approach were defined. As an innovative and scientifically approach the hypothesis will be pursued, that the control and the hedging of all quality decisive process parameter could be achieved, by integrating different sensors into an injection unit. Beside thermocouples, dielectrical and pressure sensors will be integrated into the injection unit. Thus the online measuring of the conversion of the resin system, the porosity of the manufactured part and the permeability of the preform is possible. By a selected arrangement of the pressure sensors the build-up of an online rheometer is enabled. Due to integrating the sensors into the injection unit and the thereby possible build-up of an online quality assurance and process control, extensive scientific investigations are necessary. Thereby, the measured parameters have to be transferred on the part characteristics for the quality assurance and the calibration of the process control, by suitable reference measurements. The development of this method takes place on the example of FRP vertical tailplane fittings. For the qualification of these parts, according to the high testing standard of the aerospace industry, currently extensive component testing is necessary. The vertical tailplane fittings are particularly suitable for the planed research project, because the currently used manufacturing process of this part implies all steps and sub-processes which are combined into the holistic method of the injection unit.Finally an extensive verification and validation of the methodology and the belonging injection unit is necessary. Therefore, specific part values are determined with different destructive and non-destructive testing methods, which are brought into contrast with the data of the quality assurance system of the injection unit. Furthermore, the manufactured parts are compared with parts, which are manufactured with a state of the art injection system.

由纤维体积含量为50%或更高的纤维增强塑料（FRP）大批量生产结构部件的决定性问题是，迄今为止所应用的工艺仅部分自动化，具有低的工艺鲁棒性，不受控制，并且对于部件的质量控制鉴定，耗时的后处理是必要的。因此，在860研究小组的调查过程中，开发了三条用于FRP结构件系列生产的工艺链。除了对工艺的广泛理解之外，还可以在所有工艺链中开发关于工艺监测和自动化工艺指导的全面知识。基于这些结果的研究要求，开发一种方法，使一个控制和质量保证的过程，通过将不同的个人解决方案结合成一个整体的方法进行了定义。作为一种创新和科学的方法，将追求的假设，控制和对冲的所有质量决定性的过程参数可以实现，通过集成不同的传感器到一个注射单元。除了热电偶，介电和压力传感器将被集成到注射单元。因此，可以在线测量树脂体系的转化率、制造部件的孔隙率和预成型件的渗透率。通过压力传感器的选定布置，能够建立在线流变仪。由于将传感器集成到注射单元中，从而可能建立在线质量保证和过程控制，因此需要进行广泛的科学研究。因此，必须通过适当的参考测量将测量参数转移到零件特征上，以保证质量并校准过程控制。这种方法的发展发生在玻璃钢垂直尾翼配件的例子。对于这些部件的合格性，根据航空航天工业的高测试标准，目前需要进行广泛的部件测试。垂直尾翼接头特别适合于计划的研究项目，因为该部件目前使用的制造工艺包含了所有步骤和子工艺，这些步骤和子工艺被组合成注射单元的整体方法。最后，需要对方法和所属注射单元进行广泛的验证和确认。因此，特定的零件值是通过不同的破坏性和非破坏性测试方法确定的，并与注射装置质量保证系统的数据进行对比。此外，将制造的零件与使用最先进的注射系统制造的零件进行比较。