Preforming Cell based on single fibre manipulation

在斯图加特大学的飞机设计研究所（IFB），高性能纤维增强复合材料（FRC）领域的轻量化结构和创新制造技术被研究、开发并转化为面向应用的原型。为此，虚拟设计和计算方法并行创建，资源高效和可持续的材料和产品制造过程在认证测试技术的帮助下开发和验证。在FRC轻量化结构模拟与制造技术研究领域，IFB正在申请一种基于单纤维操纵的一体化预成型单元，以期为未来航空领域FRC结构的研究开辟新的途径。基于单纤维操作的综合预成型单元旨在将不同的加工技术（所谓的单纤维加工模块）结合到一个快速可配置、相互连接、网络化、自我监控和传感器支持的生产环境中，用于实验室级别的FRC组件。在加工过程中，一种或多种定向增强纤维的目标和传感器监控操作和指导是单纤维操作的特征，目的是生成符合负载路径和接近净形状零件的特定可调纤维结构。增强纤维应该能够以粗纱、纱线、铺布和粘结带（包括薄层）和拖带的形式进行加工，以便探索未来用于高性能应用的半成品纤维产品。为了生产平面、平面和近净形状的预制体，将使用添加的单纤维铺设工艺，除了弯曲的、沿轮廓的纤维路径外，还可以生产直的、单向的路径。在另一个加工模块中，三维中空纤维结构将在编织过程中使用新的线轴载体技术来创建。在径向编织过程中，可自由配置的单个纤维操作将通过首次使用电子线轴装置来实现，该装置将在研究所自己的初步工作的基础上为该单元开发。因此，除了当前工艺窗口的重大转变之外，纱线力可以在工艺中进行可变调整，这将导致全新的负载适当的纤维结构。由于编织过程中纱线力的变化，以及目标材料进料和缩回的可能性，因此也可以加工以前不可能编织的部件几何形状。作为软件定义制造方法的基础，工厂模块将通过物联网平台进行数字连接。连续的工艺数据采集、存储和并行评估为未来数字化支持的产品和工艺开发提供了以前不可用的研究基础。

At the Institute for Aircraft Design (IFB) at the University of Stuttgart, lightweight structures and innovative manufacturing techniques in the field of high-performance fibre-reinforced composites (FRC) are researched, developed and transferred into application-oriented prototypes. For this purpose, virtual design and calculation methods are created in parallel, resource-efficient and sustainable material and product manufacturing processes are developed and validated with the help of certified testing techniques. For the research area of lightweight construction simulation and manufacturing technology of FRC, the IFB is applying for an integrative preforming cell based on single fibre manipulation in order to open up new research approaches for FRC structures in aviation in future. The integrative preforming cell based on single fibre manipulation aims to combine different processing techniques, so-called processing modules of single fibres into a rapidly configurable, interlinked, networked, self-monitoring and sensor-supported production environment for components made of FRC at laboratory level. The targeted and sensor-monitored manipulation and guidance of one or more directed reinforcement fibres during processing characterises the single-fibre manipulation in order to generate specifically adjustable fibre architectures of the load-path-compliant and near-net-shape parts. The reinforcement fibres should be able to be processed in the form of rovings, yarns, spread and bindered tapes (incl. thin-ply) and tow-pregs in order to explore future semi-finished fibre products for high-performance applications. For the production of flat, planar and near-net-shape preforms, additive single-fibre laying processes will be used, which, in addition to curved, contour-following fibre paths, can also produce straight, unidirectional paths. In another processing module, three-dimensional hollow fibre architectures are to be created using a new bobbin carrier technology in the braiding process. The freely configurable individual fibre manipulation in the radial braiding process is to be achieved through the first-time use of electronic bobbin units, which are to be developed for this cell on the basis of the institute's own preliminary work. The yarn force that can thus be variably adjusted in the process will lead to completely new load-appropriate fibre architectures in addition to a significant shift in the current process windows. Due to the variable yarn force during braiding as well as the possibility of a targeted material feed and retraction, it is thus also possible to process component geometries that were previously impossible to braid. As the basis for a software-defined manufacturing approach, the plant modules are to be digitally linked via an IoT platform. Continuous process data acquisition, storage and parallel evaluation provide a previously unavailable basis for research into future digitally supported product and process developments.