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

纤维体积含量在50%以上的纤维增强塑料(FRP)结构件的大批量生产的一个决定性问题是，到目前为止所应用的工艺只有部分自动化，工艺稳健性低，没有得到控制，为了对零件进行质量控制合格，必须进行耗时的后处理。因此，在860课题组的研究中，已经开发了三个用于玻璃钢结构件的系列化生产的工艺链。除了对流程有广泛的了解外，还可以在所有流程链中发展关于流程监测和自动化流程指导的全面知识。根据这些结果，确定了开发一种方法的研究要求，该方法通过将不同的单独解决方案结合成整体方法来实现受控和质量保证的过程。作为一种创新和科学的方法，将追求这样的假设，即通过将不同的传感器集成到一个注射单元中，可以实现对所有质量决定过程参数的控制和对冲。除了热电偶，还将把介电和压力传感器集成到注射单元中。因此，可以在线测量树脂体系的转化率、制件的孔隙率和预制件的渗透率。通过选择压力传感器的布置，可以建立在线流变仪。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，因此有必要进行广泛的科学调查。因此，为了保证质量和过程控制的校准，必须通过适当的参考测量，将测量的参数传递到零件特性上。以玻璃钢垂直尾翼配件为例，对该方法进行了研究。对于这些部件的合格，根据航天工业的高检测标准，目前需要进行广泛的部件测试。垂直后飞机配件特别适合于计划中的研究项目，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结合到注射单元的整体方法中。最后，需要对该方法和所属的注射单元进行广泛的验证和验证。因此，用不同的无损和无损检测方法来确定特定的零件值，并将其与注塑单元质量保证系统的数据进行对比。此外，将制造的部件与使用最先进的注射系统制造的部件进行比较。

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.