EADS Innovation Works devotes oneself to A350-1000 airframe to braid the appraisal of casing, develop use at shaping beforehand the fiber of complex and local consolidate fills piece.
The archetypal sheet axis of EADS IW braids prefabricated component product line to use accurate infinite technology, use at carbon fiber to make prefabricated component of A350 annular casing, subsequently infuse colophony. The target is to realize taller automation, lower cost and laden weight to optimize, function and beforehand dip frame comparatives.
Fiber fills piece shape beforehand (FPP) fill short staple automatically piece place in any positions and direction, build with compose have beforehand the comfortable form dry fiber of the three-dimensional geometry appearance that dip makings cannot achieve shapes beforehand (ask additionally refer to below one piece of picture) . In growing the FPP of joist to be being developed, the target is with beforehand dip expects photograph comparing saves the cost of 45% .
The conception of this artist revealed FPP system shop to set the homocentric circle pattern that by FPP“ patch ” constitutes one.
Graph 1:EThe odd axis of ADS IW braids equipment to be used in the first method only reinforce a line. Opposite annulus detour way uses auxiliary yarn.
Graph 2:EThe odd axis of ADS IW braided craft to reduce fiber ripple to spend significantly, raised carbon the compressive strength of composite material, enhanced the integral physical characteristic of CFRP casing. The fiber ripple that this piece of picture showed the sample layer pressing plate that is a feature with traditional basketwork is medium is spent. Below one piece of picture showed a similar sample book that is a feature with BRaF basketwork. Origin: EADS IW
Graph 2b: The fiber ripple that this sample showed the solid in BRaF process to have is spent reduce.
Graph 3a: Here, of arbor of square of BRaF device edge left and on the right side of between braid laid 0°UD works fiber area. Cut two half when level of quadrate prefabricated component, this adhesive plaster and two flange of the Caesarean birth of generation are right neat, be similar to UD Liang Gai.
Graph 3B: Here, 90°UD layer edge is circumferential twine. This function will be the crucial factor that BRaF creates the capacity that optimizes casing highly for A350-1000.
Graph 4: The experience lesson that acquires from this prototype will be used at designing final manufacturing facilities. The batch production that braids frame prefabricated component will award a supplier, be like the partner SGL Kuêmpers of EADS IW. (the specification of concerned number project, refer to next graphs please. ) origin: EADS IW
According to the report, FPP sticks an appearance to be able to be in ±0.1 millimeter (±0.04 inch) the accurately fixed position inside tolerancepublic errand limits. Origin: EADS IW
Empty guest A350-1000 is headquarters the plane OEM that is located in at present of French graph Lu is newest also be the biggest A350XWB jet-propelled plane. Its airframe diameter and familial medium other jet aircraft is identical, but will compare be about to the A350-900 of put into production is 7 meters long / 23 feet. More powerful but heavier engine will make 1000 model add boat course of development exceeds 900 model 600 kilometers / 373 miles, effective load increases 40 metric ton (88185 pounds) . However, the empty weight of this plane will increase 2.4 metric ton (5291 pounds) , the cost of the plane will compare 900 many 9 million dollar.
Airbus company is reducing weight and cost hard. Among them a project aims automation production, optimize 1000 model carbon fiber enhances polymer (CFRP) the weight of airframe casing and function. Airframe casing is to surround the cricoid costal region of airframe internal diameter, with fore-and-aft joist the framework that makes an aircraft together.
The long airframe of A350-1000 (opposite A350-900) increase need 11 casing, 5 are in wing is hind, 6 advanced ministries. The circle with same production already simple cheap, but do not use every casing to be designed according to its in the position in the structure normally ask in order to satisfy specific machinery. because such, a lot of casing by excessive design, because this added needless weight. To prevent this kind of situation, airbus company chooses a ground load of susceptive of every airframe general is custom-built the every machine figure of airframe (see on the right side of the “A350 XWB that editorial choice ” issues “ updates ……” ) , include its casing. The challenge is the method of the CFRP compound casing with the alone and custom-built production in finding a kind to produce an environment in batch, have cost effectiveness.
Airbus company and company of spaceflight of Wu of air defence of boat of parent company Europe (EADS, holand Amsterdam) had been use beforehand the A350-900 casing that dip expects developed this one technology. But to A350-1000, still have improvement opportunity. EADS innovation factory (EADS IW, ottobrun, germany) Matthew Beaumont of director of operation of composite material technology expresses: We know “ in certain domain we can reduce weight further. ”“ because this, we did not await the 5 next platform after arriving 10 years, saw A350-1000 is in however two to 3 years immanent weight is managing the opportunity that with workmanship dovish sex respect gains fast victory. He revealed ” the image that A350-900 regards generation composite material as airframe, a350-1000 regards 1.5 generation as the image of airframe.
Braid CFRP frame
To cast off beforehand the limitation that dip expects, EADS IW group of Beaumont and airbus company and SGL Kumpers GmbH&Co.KG (German Lai mattress) cooperated 10 years, developed a kind of accurate infinite technology, use the machine of high automation circle that suits with photograph of plane airframe diameter, use at carbon fiber to make odd axis braid shape beforehand. Pass computer pilot machining and EADS patent craft to be opposite next shape beforehand have colophony infuse, solidify and precision work.
Beaumont claims: “ the flow that this is automation of a kind of low risk, height. ” but to empty guest, this is a brand-new flow. “ this is a tremendous change, from what place machine laid automatically beforehand dip material semifinished product is braided to infuse resinous dry fiber beforehand dip makings. ” also is a new measure for this pair of EADS IW, develop to true component from research. Beaumont admits, this is a still half-baked job. “ accords with the requirement of empty guest to prove craft and product, we still have a lot of jobs to want to do. ”
One braids casing (BRaF) archetypal product line begins to use from 2008, install the empty guest in German Si Dade at first center of composite material technology (CTC) . After this, it is arrived to be located in larger CFK Nord research center of Sidade likewise by move.
Odd axis is braided reduce ripple to spend
BRaF automation braids product line is the workstation that is based on SGL Kümpers to have at first. Although it can be carried,reduce manufacturing cost, but the inherent fiber ripple in be being braided as a result of the tradition is spent, the product that it produces shows poorer physical characteristic. In addition, this group observes, the course is woven in the tradition in, fiber often is brought to bear on to the shearing force on fiber damages or be weakened, or the attrition as a result of crossing. EADS IW knows, use the machine that contains two to braid annulus to be able to reduce this kind of attrition, but fiber ripple spends a problem to still exist. Because of this, EADS IW company begins to study its obtain patent odd axis to braid craft.
According to American patent 2007/0193439A1, this are new craft solved fiber through two development corrugate problem. Above all, all bobbin that EADS IW is not a tradition contain enhance fibrous to install, use on the first method only however contain the bobbin that enhances a line, and the bobbin that on opposite circular way use belt assists a line (“ is called to prop up line ” in patent) (see a picture 1, on the right side of) . The 2nd, auxiliary yarn / in the line that prop up at least a few (if not be complete sentence) it is thermoplastic fiber, its are heated in order to fuse, be cooled next with again solidify, produce good slip character thereby, reduce across to braid the attrition between the line thereby, and fiber injury. Thermoplastic silk thread still will enhance fiber to place in braid core (arbor) after going up, maintain in proper place. This patent explains: “ flexibility is thermoplastic plastic wire is placed cheek by jowl enhancing a line between, make enhance a line almost parallel place, both between without any spaces, because this does not have any wave ” almost (see a picture 2, on the right side of) . Accordingly, the compressive strength of carbon fiber rises significantly, the integral machinery belongings of finished product profile or frame also rises significantly.
To prove BRaF, this group uses HTS40 F13 12K 800tex (Toho Tenax Europe GmbH, wuppertal Germany) as enhance fiber, use EMS-GRILTECH (Domat/EMS, switzerland) those who make but fiber of frit polyamide K85 Grilon serves as auxiliary yarn. The area weight of all layers all is 260 grams / square metre (7.7 ounce / code 2) . Demonstrate implement pile order includes 12, these layers around move the aluminous core axis of a quadrate cross section piles up. These layers with + 30° or - the angle of 30° brings to bear on, pass next twine 90° layer or interweave one-way (UD) dry fiber belt brings to bear on as 0° flange layer identical buildup fiber. Beaumont explains: The limits of true fiber angle of “ average braiding machine comes for ±10° ±75° . ”“ because this, it is crucial that BRaF includes 0° and 90° function. One-way dry fiber takes ”0° along quadrate arbor left and on the right side of laid is between braid. Shape beforehand when square be cut by the level two half, this adhesive plaster and two flange with C sectional form are right neat, be similar to along adhesive plaster of UD of laid of alar bridge cap. 90°UD layer edge is circumferential twine (see a picture 3, on the right side of) . Beaumont points out, adding 0° and 90° layer effectively is a development that SGL Kümpers raises.
Graph 4 (on the right side of) indicated the position that demonstrates equipment. Carriage system by described as can with adaptive the position and span clamp. Braiding machine and winding machine can transverse shift, winding machine still has horn to spend corrective function. This kind of equipment is decorated can realize alterable casing radius and abdomen board height. It still can make complex draw a frame round, the ply that includes braid and 0°UD layer falls off, compositive and local reinforcement (produce like FPP those, describe later) .
Braid and twine after finishing, annulus of quadrate and sectional prefab fiber is cut two half, profile of two C form gets off from arbor. The photograph of plane airframe diameter of C form and regulation matchs, can pass use mould and can expand silicone plug-in unit will among them convert of flange of form of a C comes with forming Z body farther figuration. SGL Kümpers report says, BRaF“ can realize the biggest design flexibility and unapproachable but repeatability, the big batch demand that creates in order to satisfy prospective plane. ”
According to Introduction Beaumont, the prototype that braids casing product line can make the draw a frame round with an all ready function now, comparative with the draw a frame round that producing in batch at present. “ learns the experience lesson that arrive from this archetypal machine, he says ” , “ will be used at designing final manufacturing facilities. ”
Fiber-optic stick piece shape beforehand
EADS IW and its partner Oxeon (Swedish Borås) with Manz AG (German Tübingen) developed another kind of technology, be aimed at CFRP casing not only, still be aimed at long joist (carling) the local consolidate with face plate of airframe of large composite material (if window cut is mixed,the door is surrounded) . This one process is called fiber-optic stick piece shape beforehand (FPP- Fiber Patch Preforming) .
FPP is considered as a kind of method that produces composite material construction automatically, because develop attacks,be optimized and other and advanced CAD technology, composite material structure can produce very complex geometry figure finally. The structure of metal of design excel tradition of these composite material, have complex three-dimensional fiber way, use existing technology (be like beforehand dip adhesive plaster) not easy production.
In FPP craft, short (20 millimeter multiply 60 millimeter or 0.79 inches multiply 2.36 inches) exhibit silk bundle one-way fiber piece by cut, place along any direction by special robot next, build the dry fiber prefabricated component that has accurate and custom-built fiber structure with compose. It maintained complex form and the consistency that geometrical appearance needs, receive without drape or bridge. The robot is in manufacturing cost was not reduced below sacrificial precision or the situation that produce waste material. Earning shapes beforehand use at standard colophony inject and perfusion craft easily, include colophony to transfer moulding (RTM) assist technology with the patent vacuum of EADS (VAP) , they are OK also with other type shape beforehand a combination use. (VAP won patent 2002, it is craft of perfusion of colophony of bag of a kind of double vacuum, among them inside bag it is film of a kind of poriferous gas, can extract volatile, use as at the same time colophony protective screen. )
FPP dry fiber shapes beforehand can use as beforehand of structure of dip material semifinished product local increase, use during autoclave solidify come from beforehand the colophony of semifinished product of dip stuff stuff or additional colophony film come macerate is very thin shape beforehand (layer of a few 100g/m² ) . Beaumont still cited the catenary of craft of completely three-dimensional number of FPP will help raise made dovish sex: “ begins from the CAD model of the spare parts, be analysed through stress and stick a fixed position, to to shaping beforehand a shop put a robot to undertake process designing, undertake the robot is placed next, the information of the spare parts won't be deleted from inside digital CAD world forever. ”
FPP detail
The partner of EADS IW is offerred one-way increase and robot equipment. EADS IW interior developed FPP robot, and already accredit Manz Automation Tübingen is duplicate this robot. Oxeon offers TeXero UD Spread Tow Tapes (all Oxeon product sells with the trade name of TeXtreme now) , one of side have hot activation adhesive, can secure after place. Beaumont explanation says, FPP not silk of spread out of bureau be confined to bundle material. We also can use “ the fabrics that does not have drape, he says ” . “ however, our target is to have a kind to shape beforehand craft, this craft can be made piece as far as possible agile geometrical appearance. Accordingly, we use 12K silk bundle, every are stuck piece use a few fiber, weight is 1g about, exhibit its as far as possible below the case that does not lose stability smooth, it is 20 millimeter about [0.79 inches of] . ”
According to the report, the area weight that because its are bigger,Beefier does not have curly fabric restricted possible geometrical appearance and appearance with ply. Thinner reinforce often provides drapability and flexibility more; They also conduce to guide a patch to arrive another patch —— in other words, the direction of every patch and position. Beaumont says: “ this is us the cornerstone of prefab club. ”“ the craft that this is spare parts of a low volume, tall complexity. What we say is a gram / of the hour lay aside rate, is not kilogram / hour. ”
Although to large part rate is too slow, but the custom-built fiber design that this craft can realize the place of small-sized spare parts that has intricate geometry figure to need. Because “ is stuck piece too small, we lowered deposit rate, but we obtained flexibility and cut out unwanted material, this is our prime target. ” Bo Meng says especially, the component that fiber weight is less than 500 grams is the target with charming FPP.
Original, make this plant complex shape beforehand the method is to be based on advanced fiber spray technology, the purpose is online adjust fiber length and angle of control fiber lay up. However, the experiment makes clear, this kind of craft did not reach the material mass of needs Gao Shuiping. Accordingly, used current technology. As a result of need short staple is stuck piece, because this was developed,one kind can designate the equipment of special and mechanical cut of cut length. Laser is regarded as the substitute of mechanical cut by exploration, but they do not have improvement on craft or speed. About dimension, beaumont comments on: “ so far, we had used what 20 millimeter multiply 60 millimeter to stick piece, but we not this dimension mixes be confined to appearance. For example, we can use a triangle to stick piece. ”
The robot folds layer machine collect fiber-optic stick piece, the definition that controls a file according to the number is placed. The head that fold a layer is made by stretch material, can have optimal contact with complex curved surface, even pressure brings to bear on when sticking a deposit.
The quality during cut and shop are put assures (QA) from the problem that is EADS IW attention at the beginning. Beaumont expresses, measure of “ quality control is to be in what its build in whole development process, is not the consideration of after the event between archetypal design and production. ” the first pace ensures fiber won't break up, and be after cut stick an appearance correct. In next QA measure, the robot folds a machine to be stuck from fiber of the collect on conveyer belt piece, move its a workstation, over laser equipment basically can film stick piece photograph. Real time evaluates a robot stick on moulage piece the position and direction, have data of the basket on its and CAD comparative. If need to undertake corrective, communicate its the robot, the robot sticks any change of a position on compensation moulage subsequently, make modulate coming back requires degree, be in with be being placed in moulage shape beforehand when going up corrective moulage position. Accordingly, every fill piece the inherent part that geometrical appearance and position regard a process as undertakes checking.
FPP is used turn to a system basically. Basically, the robot uses a site 1 (stick piece start) with the dot 2 (stick piece terminal) X, Y and Z coordinate will locate stick piece, because this needs 6 numbers and a start only,reference can locate accurately. Change system and QA examination photograph to union, can realize ±0.1mm (±0.04 inch) stick a fixed position public errand.
Fill when discovery piece jackknife mode affects composite material to shape beforehand significantly when intensity, the scale form that developed a kind to have circular around edge fills piece, fill in order to allow piece inside couplet nest. Fill piece still conduce to high strenth and stiffness maintain in the part that has complex curvature and geometrical figure.
Study the group discovers, earning composite material can resist between the layer statified expand with crackle. Enhance composite material photograph to compare with successive fiber, FPP layer pressing plate is shown on intensity drop lesserly (14% ) , but have identical stiffness actually. Another experiments make clear, be no longer in force basically is created. Beaumont explains: Because these “ sticking piece in have short and discontinuous thread, you may be being stuck piece between occurrence breakdown, but sample did not show this. The result of the result that breakdown test shows and pressing plate of successive fiber layer is same. ”“ pounds a test to still make clear, compare with photograph of pressing plate of successive fiber layer, it can be absorbed relative to higher blow energy, have lesser damaged area and taller remains to reduce intensity.
BRaF and FPP move ahead
In its inchoate phase, BRaF was obtained award of JEC automation innovation and Niederachsen innovated 2010 award, this award issue on congress of year CFK Valley Stade, the development of degree of particularly tall innovation is had in order to commend in respect of structure of light qualitative CFRP. Notable is, commissioner of JEC innovation award is forecasted, this craft will make composite material can compete with the metal, use at structural airframe component. But this job still the formal proceed with BRaF II, the target is to optimize whole process, those who include auxiliary yarn is online and fixed (fuse and cool) , automatic cut and what lade and uninstall a station is careful change. Still will study new arbor material, and online QA measure, if the fiber inside twister and braiding machine is monitored, and the optical angle of braid detects. The development target of prospective BRaF material is to reduce exterior weight, raise bearing stress and enhance the brim to fight concussion to protect.
Did not come two years, empty guest will develop fund for the technology, undertake qualificatory appraisal and attestation to casing spare parts and craft thereby. This will casing attestation remit to 2013, but the beginning that it should get used to A350-1000 component very easily to produce, the ongoing travel that in the plane the plan uses at was being thrown 2017 is assembled and check. The batch production that braids casing prefabricated component will award a supplier, be like the partner SGL Kümpers of EADS IW.
Meanwhile, FPP obtained EADS IW to be approbated in another JEC in automation category, it is this to regard as innovated 2011 the person be seleted of award. The process of the first application of FPP, developing in the IMac Pro project that by European Union committee the 7th frame plans to aid financially. EADS IW heads this project, the target is with aluminous profile photograph comparing saves the weight of 20% at least, with beforehand profile photograph compares dip to reduce the weight of 5% at least, cost drops 45% .
Exploring a variety of craft to consolidate at present grow joist prefabricated component with solidify, include to have the RTM that can get used to component, sedimentation in order to compensate prefabricated component (ply decreases) , successive colophony inject and high speed microwave heat. The plan undertakes 3 times demonstrating: (1) there are 4 on dip makings skin beforehand beforehand of solidify long joist strengthen board; (2) have 4 long joist to shape beforehand and at the same time of the fabric surface layer of solidify strengthen board; And (3) goods motherboard is unit, unit of this goods motherboard is comprised by bent casing profile, straight beam and Z form pillar.
Beaumont also saw the potential of FPP and BRaF photograph be identical. Beaumont says: “FPP suits production very much local increase, for example, in the floor Liang Lian is received (airframe) the place of annular casing, need more fine peace keeping only specific custom-built fold a layer. ” he still thinks it can improve consolidate composition, be like the door all round. Beaumont expresses: We see “ really end ministry is used what making A350-1000 to enhance material when braiding CFRP casing, but the FPP that we do not know to this one process is to resemble be being developed up to now it seems that is more primitive still. ”
FPP is used at the local consolidate of airframe face plate, answer to use the patulous capacity of craft morely.
Note: Textual " Airbus A350 Update : BRaF&FPP " 2012.1.2 " empty guest A350 updates: BRaF and FPP "
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