Tool system and method for producing a fiber composite semi-finished product and method for producing a fiber composite component

Abstract

Tool system (1) for producing a fiber composite semi-finished product (H), comprising: - a holding arrangement (10) with at least two holding devices (11) for holding a core (K) to be wound with a band- or thread-like fibre material (F), - a winding device (20) with at least one rotor (21, 22) rotatable about a rotational axis (23), which is designed as a divisible circular ring or in the shape of a circular segment and which at least partially defines a winding space (24) for receiving the core (K), at least one material carrier (25, 26) arranged stationary relative to the rotor (21, 22) for providing the fiber material (F), and a guide bracket (27, 28) assigned to the respective material carrier (25, 26) and projecting from the rotor (21, 22) toward the rotational axis (23) for guiding the fiber material (F), wherein the winding device (20) is movable translationally along a movement path (T) such that a movement of the winding device (20) along the movement path (T) has at least one directional component that coincides with the rotational axis (23), wherein an outer contour (20a) of the winding device (20) defines an enveloping surface (29h) during the movement along the movement path (T), which defines a working space (29) of the winding device (20), wherein the holding devices (11) are each coupled to the winding device (20) in such a way that they can be moved out of the working space (29) of the winding device (20) during the translatory movement of the winding device (20), wherein the tool system (1) has a winding device positioning device (40) for moving the winding device (20) along the movement path (T), wherein the winding device positioning device (40) is designed as a guide arrangement (41) with at least one first guide rail (42) running in a first spatial direction (X), a second guide rail (43) guided on the first guide rail (42) and running in a second spatial direction (Y), and a third guide rail (44) guided on the second guide rail (43) and running in a third spatial direction (Z), and with a holder (45) which is guided on the third guide rail (44) and is connected to the winding device (20).

Description

[0001] The present invention relates to a tool system and a method for producing a fiber composite semi-finished product as well as methods for producing a fiber composite component.

[0002] Fiber composite components, which are formed from a matrix material with reinforcing fibers embedded in it, are frequently used as structural components in fuselage structures, e.g., of aircraft. Typically, a fiber composite semi-finished product for the production of such a fiber composite component is formed by wrapping the reinforcing fibers around a core that has the external shape of the fiber composite component to be produced. To produce the fiber composite component, this fiber composite semi-finished product is then infiltrated with the matrix material.

[0003] WO 2011 / 096805 A1 discloses a tool system and a method for producing a fiber composite semi-finished product, in which a circular ring-shaped core is rotated about its central axis by means of drive rollers, while two stationary winding rings rotate around the core and wrap it with fiber material.

[0004] From DE 10 2012 109 222 A1 a device for connecting two components in a joining area is known, wherein the device has a circular segment-shaped winding ring that can be moved by means of a robot for wrapping the components in the joining area with fabric tape.

[0005] WO 2006 / 076384 A2 describes a device for wrapping a core with a strip or thread material. This device comprises a stationary, openable impeller in which a carrier is rotatably mounted. Reels of the strip or thread material are mounted on the carrier. To wrap the core, it is moved translationally through the rotating carrier, and the strip or thread material is thus drawn off the reels.

[0006] Furthermore, EP 2 037 028 A1 describes a device and a method for braiding fibers into a multi-layer braided structure.

[0007] It is an object of the present invention to provide a tool system and a method with which fiber composite semi-finished products with a core wrapped in a fiber material can be produced in an efficient and reliable manner, as well as a method for producing a fiber composite component from such fiber composite semi-finished products.

[0008] This object is achieved by a tool system having the features of claim 1, by a method having the features of claim 6 and by a method having the features of claim 11.

[0009] Advantageous embodiments and further developments are the subject of subclaims 2 to 5 and 7 to 10, respectively.

[0010] According to a first aspect of the invention, a tool system for producing a fiber composite semi-finished product is provided, wherein the tool system has a holding arrangement with at least two holding devices for holding a core to be wound with a ribbon-like or thread-like fiber material and a winding device with at least one rotor rotatable about a rotational axis, which rotor at least partially defines a winding space for receiving the core, at least one material carrier arranged stationary relative to the rotor for providing the fiber material and a guide bracket or storage head assigned to the respective material carrier and projecting from the rotor towards the rotational axis for guiding the fiber material.

[0011] The winding device is movable translationally along a movement path such that a movement of the winding device along the movement path has at least one directional component that coincides with the axis of rotation.

[0012] An outer contour of the winding device defines an enveloping surface during the movement along the movement path, which defines a working space of the winding device or at least partially delimits this, wherein the holding devices are each coupled to the winding device in such a way that they can be moved out of the working space of the winding device during the translational movement of the winding device.

[0013] In particular, the holding devices are each functionally coupled to the winding device in such a way that they can be moved out of the working space of the winding device during the translational movement of the winding device.

[0014] Due to the fact that the holding devices are each coupled to the winding device in such a way that they can be moved out of the working space of the winding device during the translational movement of the winding device, cores designed as closed frames in particular can be wound with a continuous band-shaped fiber material, since the winding device can be moved continuously, e.g. without reversing a feed direction, along the entire circumference of the core.

[0015] The material carriers can, for example, be designed as rolls or spools on which the ribbon- or thread-like fiber material can be stored in wound form and removed by pulling it off.

[0016] The number of material carriers per rotor can be selected, for example, depending on the width of the fiber material, the core profile cross-section, and / or the intended orientation of the fiber material relative to the core. For fiber materials with a narrow width or small thread diameter, a large number of material carriers can be provided, e.g., in a range between 10 and 500 per rotor. For fiber materials with a larger width, such as so-called prepreg tapes, a smaller number of material carriers can be provided, e.g., between 1 and 100 material carriers per rotor.

[0017] According to the invention, the rotor is designed as a divisible circular ring or in the shape of a circular segment. In particular, it can be provided that the rotor surrounds the axis of rotation as a continuous divisible circular ring or as a circular segment. Both shapes have the advantage that a core designed as a closed frame can be inserted into their winding space. This can be achieved particularly advantageously by an interruption in the circumference of a circular segment-shaped rotor. Furthermore, with a circular segment-shaped rotor it is possible to wind structures protruding from the core, since the rotor can be guided over these structures with the interruption. A rotor designed as a divisible circular ring also offers the advantage that a particularly high number of material supports can be provided due to the continuous circumference.A further advantage of a closed-shaped or annular rotor is that it forms a transmission device for the continuous transmission of a medium, such as compressed air or a plastic material, over the cross-sectional circumference of the core and / or for the transmission of electrical energy to components attached to the rotor, such as the material carriers or a heating device.

[0018] The winding device can in particular have at least one further rotatable rotor, wherein the rotors are arranged concentrically to one another. In general, a plurality of rotors can be provided, each of which is arranged concentrically to one another. This means in particular that they can rotate about the same axis of rotation, wherein the rotors can be arranged offset along the axis of rotation. In this way, the core can be wound particularly quickly, since each rotor can wind and thus produce a fiber layer. This means that several superimposed fiber layers can be produced simultaneously. In particular, if several material carriers are provided on each rotor, each rotor can advantageously wind a unidirectional fiber layer.

[0019] The tool system can, for example, be configured such that several rotors are provided that rotate parallel to one another in the same direction. In particular, when machining closed, frame-shaped cores, each rotor can, for example, deposit a fiber bundle on the core. Due to the presence of multiple rotors, several fiber bundles can be deposited flush next to one another on the core. This allows a fiber layer with several individual fiber bundles that lie flush next to one another to be formed quickly and efficiently. A unidirectional winding pattern can be formed particularly advantageously in this way.

[0020] In general, this process can be performed several times in succession. After a given number of consecutive passes, several preferably unidirectional fiber layers are formed. In this way, several continuous fiber layers can be formed from a few fiber strands, with one continuous fiber strand forming several superimposed layers.

[0021] As a result, a particularly high mechanical strength can be achieved in a fiber composite component which is formed from a fiber composite semi-finished product produced by means of the tool system according to the invention.

[0022] If the individual rotors rotate in opposite directions to each other, a cross-wound pattern is created with continuous fiber strands crossing each other.

[0023] The tool system may include a winding device positioning device for moving the winding device along the movement path.

[0024] The winding device positioning device can be implemented in particular as a guide arrangement with at least one first guide rail running in a first spatial direction, a second guide rail guided on the first guide rail and running in a second spatial direction, and a third guide rail guided on the second guide rail and running in a third spatial direction, and with a holder which is guided on the third guide rail and connected to the winding device.

[0025] This allows the winding device to be freely moved in three-dimensional space. This allows the winding device to be positioned reliably and easily, particularly relative to curved and frame-shaped cores.

[0026] As an alternative to the guide arrangement described above, the winding device positioning device can be formed by a robot having an arm kinematics movable in three spatial directions, wherein the arm kinematics has a mount connected to the winding device. The arm kinematics of the robot can, for example, have six axes of rotation that allow movement of the winding device along the core in a three-dimensional space.

[0027] The holder of the winding device positioning device connects it to the winding device. In particular, the winding device is connected to the winding device positioning device by the holder so that it can rotate about a holder axis. In this way, the orientation of the rotor's rotation axis relative to the core, in particular relative to the core cross-section, can also be changed. In this way, the path of the ribbon- or thread-like fiber material on the core can be advantageously varied. For example, a configuration advantageous for the strength of a component manufactured from the fiber composite semi-finished product to be produced can be achieved.

[0028] The at least two holding devices of the holding arrangement can be designed, in particular, as linearly displaceable clamping parts or as openable and closable clamps. These possible configurations can be used to construct a modular holding arrangement that can be easily adapted to the size and geometry of the core.

[0029] The tool system may further comprise a control device by means of which a rotational speed of the rotor, a feed direction and feed speed of the winding device along the movement path as well as a respective position of the holding devices can be adjusted.

[0030] The control device can, in particular, be functionally coupled to one or more of the components described above. For example, the control device can have functions for generating control commands, based on which at least one or more of the following actions are performed: - Setting a rotation speed of the rotor, e.g. by setting a speed of a motor driving the rotor, - Setting a feed direction and a feed speed, e.g. by actuating actuators assigned to the respective components of the winding device positioning device.

[0031] The control commands can, for example, be present as a fixed sequence of signals in a data memory of the control device. For example, specific control commands for various known core geometries can be retrieved from the data memory. Alternatively, the control commands can also be generated based on variables detected by one or more sensors. For example, a distance sensor can be provided on the winding device to detect a position of the winding device relative to the core. In this way, an automated control or regulation system can be formed.

[0032] A further aspect of the invention relates to a method for producing a fiber composite semi-finished product comprising the following steps: - Winding a core held by a holding arrangement with at least two holding devices with a ribbon-like or thread-like fiber material by translationally moving a winding device along the core, wherein the winding device has at least one rotor rotating about a rotational axis, which is designed as a divisible circular ring or in the shape of a circular segment and which defines a winding space in which the core is arranged, at least one material carrier arranged stationary relative to the rotor, from which the fiber material is drawn off, and a guide bracket assigned to the respective material carrier, which protrudes from the rotor towards the rotational axis and guides the fiber material relative to the core, wherein the translational movement of the winding device is carried out in such a way that at least one directional component of the movement of the winding device coincides with the axis of rotation, wherein an outer contour of the winding device defines an enveloping surface during the movement along the core, which defines a working space of the winding device, - Moving one of the holding devices out of the working space of the winding device during the winding of a holding area of ​​the core at which the core is held by the respective holding device.

[0033] By wrapping the core in the winding space of the rotating rotor, it is possible to wrap the core, especially in closed-frame cores, with so-called "continuous fibers," i.e., a continuous fiber ribbon or thread. This increases the mechanical stability of a fiber composite component made from a fiber composite semi-finished product manufactured in the manner described above. This is particularly true because the mechanical properties of a fiber composite component depend on the fiber length, with the component strength increasing with increasing fiber length.

[0034] The core can, for example, be made of a foam-like material or a solid material. In general, the core can be made of a plastic material, a wood, metal or cork material or the like. Foam cores are particularly suitable for the production of fiber composite components in so-called sandwich construction. Here, the core remains in the semi-finished product after wrapping and can also remain in the fiber composite component made from it. Due to the generally low density of foam material, the mechanical properties of the semi-finished product / component are improved in this way with only a slight increase in weight. Cores made of solid material are particularly suitable for the production of fiber composite components in a monolithic construction, whereby the core is removed from the semi-finished product after wrapping or, if appropriate, after a fiber composite component has been produced from the semi-finished product.

[0035] The core may also have an open shape, e.g., rod-shaped, curved, or the like. Furthermore, the core may have a closed shape or form, e.g., an elliptical, circular, triangular, rectangular, or polygonal shape, or the like. In particular, the core may also be curved in multiple directions. The cores may, for example, have a rectangular, trapezoidal, triangular, circular, or elliptical cross-sectional shape.

[0036] The ribbon- or thread-like fiber material can be in the form of a roving, in particular a dry roving, a prepreg tape, or the like. Generally, dry fibers, in particular dry fibers coated with a binder material, e.g., a polymeric binder material, can be used.

[0037] When wrapping the core, a plurality of fiber layers is preferably formed. In particular, between 10 and 60 fiber layers, preferably between 15 and 50 fiber layers, and particularly preferably between 20 and 40 fiber layers can be formed. In these areas, high mechanical stability of a fiber composite component produced from a fiber composite semi-finished product manufactured in the manner described above is ensured with a low overall weight.

[0038] Particularly advantageously, in the method, a feed direction and a feed speed with which the winding device is moved along the core, as well as a rotation speed with which the rotor is rotated, can be coordinated with one another in such a way that a predetermined winding pattern is formed in each of the fiber layers.

[0039] For example, a unidirectional winding pattern can be created. To achieve this, the feed direction of the winding device along the core is not reversed during winding. Alternatively, crossed winding patterns can be created, in which the fiber material crosses over itself within a fiber layer.

[0040] In general, the feed direction, the feed speed and the rotation speed can also be coordinated in such a way that different or identical winding patterns are produced in different fiber layers.

[0041] Furthermore, it is also possible to coordinate the aforementioned variables defining the movement of the winding device in such a way that a winding pattern is produced in which the orientation of the fiber material relative to the core, in particular relative to a cross-sectional centerline of the core, varies within a fiber layer. For example, a winding pattern can be produced in which a unidirectional winding is present in a first longitudinal or circumferential section of the core, in which the bands or threads of the fiber material run along geodesic paths along the surface of the core, and in a second longitudinal or circumferential section of the core, a unidirectional winding is present in which the bands or threads of the fiber material run along non-geodesic paths along the surface of the core. In this context, other combinations of winding paths are of course also conceivable, in particular for crossed winding patterns.

[0042] Preferably, the adjustment of the feed direction, the feed speed and the rotation speed can be carried out in such a way that the predetermined winding pattern runs in such a way that at least one of the fiber strands has an orientation between 15 degrees and 89 degrees relative to a cross-sectional center line or to a curvature vector of the core, wherein the curvature vector runs between a center of curvature of the cross-sectional line at a certain point and the respective point of the cross-sectional center line.

[0043] The feed direction, feed speed, and rotation speed can be easily adjusted, e.g., using a control or regulating device. The resulting winding patterns, which can include different orientations of the fiber ribbons in certain sections, enable advantageous, simple adaptation of the fiber orientation to the specific mechanical requirements of a component manufactured from a fiber composite semi-finished product produced using the above-described process.

[0044] As already mentioned above, the core preferably forms a closed shape. The core generally determines the shape of the fiber composite semi-finished product. The fiber composite semi-finished products produced using the process described above are further processed, for example, into fiber composite components that can be used as structural components for aircraft. With closed cores, the structural components can be used, for example, as window frames, frames, or similar components in aircraft.

[0045] According to the invention, a method for producing a fiber composite component is further provided, the method comprising: - producing a fiber composite semi-finished product by carrying out a method according to one of the aforementioned embodiments, - Creating a layer of matrix material surrounding the fiber material, - Curing the matrix material of the resin layer.

[0046] The possible applications of a fiber composite component produced in this way have already been mentioned above.

[0047] With regard to directions and axes, in particular directions and axes relating to the course of physical structures, the course of an axis, a direction or a structure “along” another axis, direction or structure is understood to mean that these, in particular the tangents resulting at a respective point of the structures, each run at an angle of less than 45 degrees, preferably less than 30 degrees and particularly preferably parallel to one another.

[0048] With regard to directions and axes, in particular directions and axes relating to the course of physical structures, the term "transverse" to another axis, direction or structure is understood to mean that these, in particular the tangents resulting at a respective point of the structures, each run at an angle of greater than or equal to 45 degrees, preferably greater than or equal to 60 degrees and particularly preferably perpendicular to one another.

[0049] Herein, a "fiber material" or "fiber material" is generally understood to mean a material formed from a plurality of filamentary reinforcing fibers, such as carbon, glass, ceramic, aramid, boron, mineral, natural, or plastic fibers, or mixtures thereof. The fiber material can also be impregnated with a resin or matrix material, such as a thermosetting, thermoplastic, or elastomeric resin, or generally with a plastic resin or the like.

[0050] With regard to the fiber material, "ribbon- or thread-like" is understood in particular to mean that several individual fiber threads of the fiber material can be combined to form a strand, a strip, or a roving, in which the individual fibers are arranged, in particular, parallel to one another, along one another, wrapped around one another, or interwoven, or that several fiber threads are woven or connected to form a ribbon or strip. A fiber ribbon can, in particular, have a constant width and / or a constant basis weight.

[0051] A “unidirectional winding pattern”, a “unidirectional winding”, or a “unidirectional course” of the fiber material is generally understood here to mean that the strands, ribbons, strips or rovings forming a fiber layer do not cross and / or do not form undulations within this fiber layer.

[0052] The invention is explained below with reference to the figures of the drawings. The figures show: Fig. 1 is a perspective view of a tool system according to a preferred embodiment of the present invention; Fig. 2 a schematic representation of a movement of a winding device of the tool system along a movement path; Fig. 3 shows an example of a winding device according to an embodiment of the tool system according to the present invention; Fig. 4 a simplified sectional view of the Fig. 3 shown winding device, which in a section along the Fig. 3 drawn line BB; Fig. 5 shows a further embodiment of a winding device according to an embodiment of the tool system according to the present invention; Fig. 6 shows a first example of a winding device positioning device of the tool system; Fig. 7 shows a second example of a winding device positioning device of the tool system; Fig. 8 a plan view of an exemplary holding arrangement of the tool system; Fig. 9 a broken sectional view of the Fig. 8 shown holding arrangement, which in a section along the Fig. 8 drawn line CC, with a schematic representation of an example of a holding device; Fig. 10 is a schematic representation of a winding of a core with a fiber material according to an embodiment of the method for producing a fiber composite semi-finished product according to the present invention; Fig. 11 is a schematic representation of a winding of a core with a fiber material according to a further embodiment of the method for producing a fiber composite semi-finished product according to the present invention; Fig. 12 is a plan view of an example of a fiber composite semi-finished product that can be produced by means of a tool system and by a method according to the present invention and that has a core with an open mold; Fig. 13 is a plan view of another example of a fiber composite semi-finished product that can be produced by means of a tool system and by a method according to the present invention and that has a core with an open mold; Fig. 14 is a plan view of an example of a fiber composite semi-finished product that can be produced by means of a tool system and by a method according to the present invention and that has a core with a closed mold; Fig. 15 is a plan view of another example of a fiber composite semi-finished product that can be produced by means of a tool system and by a method according to the present invention and that has a core with a closed mold; Fig. 16 is a plan view of another example of a fiber composite semi-finished product that can be produced by means of a tool system and by a method according to the present invention and that has a core with a closed mold; Fig. 17 is a plan view of another example of a fiber composite semi-finished product that can be produced by means of a tool system and by a method according to the present invention and that has a core with a closed mold; Fig. 18 is an exposed perspective view of a portion of a core wrapped with a fiber material according to an embodiment of the method for producing a fiber composite semi-finished product according to the present invention, the fiber material extending according to a predetermined winding pattern shown by way of example; Fig. 19 is an exposed perspective view of a portion of a core wrapped with a fiber material according to an embodiment of the method for producing a fiber composite semi-finished product according to the present invention, the fiber material extending according to a predetermined winding pattern shown by way of example; Fig. 20 is an exposed perspective view of a portion of a core wrapped with a fiber material according to an embodiment of the method for producing a fiber composite semi-finished product according to the present invention, the fiber material extending according to a predetermined winding pattern shown by way of example; Fig. 21 a schematic highlighted sectional view of a fiber composite component produced according to an embodiment of a method according to the present invention.

[0053] In the figures, the same reference symbols denote identical or functionally identical components, unless otherwise stated.

[0054] Fig. 1 shows an embodiment of a tool system 1 for producing a fiber composite semi-finished product H (see Fig. 12-17) according to the present invention. The tool system 1 comprises a holding arrangement 10 with at least two holding devices 11 for holding a strip-shaped or thread-shaped fiber material F (see Fig. 3, Fig. 5, Fig. 10 and Fig. 11) core K to be wound and a winding device 20.

[0055] Fig. 3 shows an example of a possible structure of the winding device 20. The winding device has in particular at least one rotor 21 rotatable about a rotation axis 23, at least one material carrier 25, 26 arranged stationary relative to the rotor 21, 22 for providing the fiber material F and a guide bracket 27, 28 assigned to the respective material carrier 25, 26 and projecting from the rotor 21, 22 towards the rotation axis 23 for guiding the fiber material F.

[0056] As in Fig. As shown in Figure 5, the winding device 20 can have at least one further rotatable rotor 22. The further rotors 22 are each arranged concentrically to one another and concentrically to the rotor 21. It can be provided that the rotors 21, 22 are arranged offset along the rotation axis 23.

[0057] The at least one rotor 21, 22 is, as in Fig. 3, the core is formed in the shape of a circular segment, i.e., as a circular ring with an interruption. This design offers the advantage that the core can be inserted through the interruption into a winding space 24 defined by the rotor 21, 22.

[0058] As an alternative to a circular segment-shaped design, the rotor 21, 22, as shown in Fig. 5, is designed as a divisible circular ring. Here, the rotor is composed of several circumferential sections, each of which is releasably connected to one another, for example, by a snap-in connection, a clamp connection, a positive connection, or the like. With this design, material carriers 25, 26 can be arranged over the entire circumference, thereby increasing the amount of fiber material that can be deposited per unit time by means of the winding device 20.

[0059] In the variant of the winding device with several rotors 21, 22, the rotors 21, 22 can each be designed the same, e.g. in the shape of a circular segment or as a divisible circular ring, or differently. Fig. In the embodiment shown in Figure 5, both the rotor 21 and the rotor 22 are designed as a divisible circular ring.

[0060] The material carriers 25, 26 can advantageously be implemented as spools or rolls on which the fiber material F, e.g., in the form of rovings or pre-impregnated fiber ribbons, so-called prepregs, is wound. The material carriers 25, 26 are each arranged stationary relative to the respective rotor 21, 22 and are preferably connected thereto. When the rotor 21, 22 rotates about the rotational axis 23, the material carriers 25, 26 thus also rotate about the rotational axis 23. A plurality of material carriers 25, 26 can be provided per rotor 21, 22, for example, up to more than 100 per rotor 21, 22.

[0061] Each material carrier 25, 26 of a rotor 21, 22 is assigned a guide bracket 27, 28. The guide bracket 27, 28 ensures that the fiber material F is provided at a defined circumferential position of the rotor 21, 22 and at a defined radial position of the winding space 24. The fiber material F is thereby positioned relative to the core K by means of the guide bracket 27, 28.

[0062] The at least one rotor 21, 22 defines at least in sections a winding space 24 for receiving the core K. The winding space 24 extends in particular in the radial direction around the rotation axis 23 and over a width b20 of the rotor 21, 22 along the rotation axis 23, as is shown for example in Fig. 4. To produce the fiber composite semi-finished product H, the core K is, for example, as shown in the Fig. 2, Fig. 3 and Fig. 4, with a longitudinal section located in the winding space 24.

[0063] The winding device 20 is movable translationally along a movement path T such that a movement of the winding device 20 along the movement path T (see Fig. 2) has at least one directional component which coincides with the rotation axis 23 of the rotor 21, 22.

[0064] Fig. 2 shows, by way of example, a translational movement of the winding device 20 along a predetermined movement path T with a feed speed V20 and a feed direction T20. The movement path T can, for example, be the course of a cross-sectional center line KS of the core K. As a condition for positioning the winding device 20 relative to the core K, it can be provided that the rotation axis 23 runs within the winding space 24 along the cross-sectional center line KS of the core K.

[0065] As in Fig. 2, an outer contour 20a of the winding device 20 defines an envelope surface 29h during its movement along the movement path T. The outer contour 20a is in Fig. 2 is shown only schematically and is generally defined at each point of the movement path T by the circumferential line of a projection surface of the winding device 20, wherein the projection surface is obtained by projecting the winding device 20 onto a plane extending perpendicular to the respective point of the movement path T. The enveloping surface 29h defines a working space 29 of the winding device 20, as shown schematically in Fig. 2 is shown.

[0066] The holding devices 11 of the holding arrangement 10 for holding the core K are each coupled to the winding device 20 in such a way that they can be moved out of the working space 29 of the winding device 20 during the translational movement of the winding device 20. In particular, each individual holding device 11 is detachable from the core K that it holds and can be moved out of the working space 29 of the winding device 20. As a result, the winding device can be moved in a continuous direction over the entire extent of the core K. This is particularly important for cores K with a closed shape and complex geometry, as is shown for example in the Fig. 14 to 17, or generally advantageous for cores K with a curved cross-sectional line KS. When winding with fiber material F, the core K can be firmly clamped or fixed in the holding arrangement 10 and the winding device 20 can be moved along the core K. While the winding device 20 is winding a holding area along the cross-sectional line KS of the core K, in which a holding device 11 engages the core, the holding device 11 can be moved out of the working space 29 of the winding device 20 during the wrapping of this area.

[0067] In this way, it is possible to wrap the core K without rotating it itself. This results in a simple design of the tool system 1. At the same time, the core can be wrapped with a plurality of fiber layers FL, each of which has a unidirectional winding pattern M, as shown in the Fig. 18 to 21, which will be discussed in more detail below.

[0068] As in the Fig. As further shown in Figures 3 to 5, the winding device 20 may further comprise a drive device 30 that drives the rotor 21, 22 such that it rotates at a rotational speed ω about the rotation axis 23. The direction of rotation is advantageously reversible. The drive device 30 may be designed as an electric motor, a pneumatic motor, a hydraulic motor, or the like.

[0069] Furthermore, the winding device 20 can have a stator 31 on which the rotor 21, 22 is guided. For example, it can be provided that the rotor 21 is arranged offset from the stator 31 along the rotation axis 23 and is guided on an axial section of the stator 31. This has the advantage that the inner diameter d20 of the rotor 21 can be selected to be large. In this way, on the one hand, the circumference of the rotor 21 is enlarged, whereby more material carriers 25, 26 can be arranged on it, and furthermore, the winding space 24 is enlarged, whereby cores K with a larger cross-sectional area and greater curvature can be processed. However, the rotor 21 can also be guided on an inner circumferential surface of the stator 31. The stator 31 can, in particular, be designed in the shape of a circular segment.

[0070] Preferably, an induction coil 32 can be provided on the winding device 20, by means of which components sitting on the rotor 21, such as the material carriers 25, 26, can be supplied with electrical energy. This can be used, for example, to operate an optionally provided heating device (not shown) for heating the fiber material F. With the heating device, it is possible to cure and / or solidify a resin impregnation optionally provided on the fiber material F during the winding process. This improves the adhesion of the fiber material to the core K, ensuring that the fiber material remains in the desired position relative to the core. This increases the quality of the fiber composite semi-finished product. The heating device can also be provided separately from the winding device 20 and guided along the core K together with it.

[0071] As in the Fig. 3 and Fig. 5, the winding device 20 may have a distance sensor 33 for detecting a position of the winding device 20 relative to the core K. The distance sensor 33 may be implemented, for example, by an infrared sensor, an ultrasonic sensor, or the like, and is preferably arranged on the stator 31.

[0072] The tool system 1 can in particular comprise a winding device positioning device 40 (see Fig. 1) for moving the winding device 20 along the movement path T.

[0073] Fig. 6 shows, by way of example, the kinematic relationships of a winding device positioning device 40 implemented as a guide arrangement 41. In the Fig. In the embodiment of the tool system 1 shown in Figure 1, the winding device positioning device 40 is implemented as a guide arrangement 41.

[0074] As in Fig. 6, the guide arrangement 41 has at least one first guide rail 42 extending in a first spatial direction X. A second guide rail 43 extending in a second spatial direction Y is guided on this. In particular, the second guide rail 43 is guided on the first guide rail 42 such that the second guide rail 43 is translationally movable in the first spatial direction X, as shown in Fig. 6 is indicated by the arrow PX.

[0075] Furthermore, a third guide rail 44 is guided on the second guide rail 43, which runs in a third spatial direction Z. In particular, the third guide rail 44 is guided on the second guide rail 43 in such a way that the third guide rail 44 is movable in a translational manner in the second spatial direction Y, as shown in Fig. 6 is indicated by the arrow PY.

[0076] A holder 45 is guided on the third guide rail 44 and is connected to the winding device 20. The holder 45 is guided on the third guide rail 44 in such a way that the holder 45 is translationally movable in the third spatial direction Z, as shown in Fig. 6 is indicated by the arrow PZ.

[0077] On the guide rails 42, 43, 44, guide tracks, e.g. in the form of guide grooves, guide lugs or the like, can be formed in each case for guiding the respective other rail 42, 43, 44 or the holder 45, into which a guide section of the respective guided rail 42, 43, 44 or the holder 45 engages.

[0078] As an alternative to a guide arrangement 41, the winding device positioning device 40 can be operated by a robot 50 (see Fig. 7). For this purpose, the robot 50 has an arm kinematics 51 that can be moved in the three spatial directions X, Y, and Z. Fig. Figure 7 shows an example of the kinematic relationships of a possible arm kinematics 51. A first arm 52 running in a spatial direction Y is mounted rotatably about its longitudinal axis, as in Fig. 7 by the arrow PY. A second arm 53 connected to the first arm 52 by a joint 52g is pivotable about a pivot axis extending perpendicular to the longitudinal axis of the first arm 52, as shown in Fig. 7 is indicated by the arrow PZ. A third arm 54 is also guided translationally on the second arm 53, with a holder 55 connected to the winding device 20 being arranged at an end portion of the third arm 54.

[0079] The holder 45, 55 connects the winding device 20 to the winding device positioning device 40 in such a way that the winding device 20 is rotatable about a holder axis 56. For example, the winding device 20 can have a bolt 34 that is rotatably mounted on the holder 45 about the holder axis 46, as shown in Fig. 3 is shown as an example. Alternatively, it can be provided that the winding device 20 is connected to the holder 45, 55 in a rotationally fixed manner, and the holder 45, 55 is connected to the third guide rail 44 or the third arm 54 so as to be rotatable about a rotation axis 46, 56.

[0080] As already described, the tool system comprises a holding arrangement 10 with at least two holding devices 11. The holding devices 11 can, for example, as shown in Fig. 1, be designed as linearly displaceable clamping parts 12. These are preferably arranged on an end section 14e of a translationally displaceable carrier 14, as shown in Fig. 1. Particularly advantageously, two supports 14 can be arranged opposite each other in such a way that their longitudinal axes 14a extend along one another and the end sections 14a, on which the clamping parts 12 or clamping jaws are arranged, face each other. In this way, a core K can be clamped and thus held between two opposing clamping parts 12.

[0081] Drive devices 70, e.g., in the form of linear motors, chain drives, hydraulic drives, or the like, can be provided for the translational movement of the supports 14. The translational movement of the supports 14 also allows them to be moved out of the working space 29 of the winding device 20.

[0082] In this way, a modular holding arrangement can be constructed that can be easily adapted to the size and geometry of the core.

[0083] The at least two holding devices 11 can also be designed as openable and closable clamps 13, as in the Fig. 8 and Fig. 9. The clamps 13 can be attached, for example, to the end sections 14e of the Fig. 1 shown support 14. Furthermore, the clamps 13 can be mounted on angled holding arms 15 of a Fig. 8 and Fig. 9 can be arranged in the holding arrangement 10 shown as an example.

[0084] The Fig. The holding arrangement 10 shown in Figure 8 has a plurality of angled holding arms 15. Each of the holding arms 15 has, in particular, a first support 16, a second support 17 guided thereon and extending transversely thereto, and a support part 18 guided on the second support 17, on which a respective clamp 13 is arranged.

[0085] The first supports 16 can be fastened with a first end portion 16a to a ring 19 rotatable about a rotation axis D19, as in Fig. 9. Alternatively, each carrier 16 may be rotatably mounted at the first end portion 16a.

[0086] The second supports 17 are each guided on the associated first support 16 in such a way that they are translationally displaceable along the first support 16, as indicated by the arrow P16 in Fig. 9 is indicated.

[0087] The support parts 18 are each guided on the associated second carrier 17 in such a way that they can be displaced translationally along the second carrier 17, as indicated by the arrow P17 in Fig. 9 is indicated.

[0088] Due to these adjustment possibilities of the supports 16, 17 and the support part 18 relative to each other, the holding arrangement 11 can be flexibly adapted to complex-shaped cores K.

[0089] The holding device 11, designed as a clamp 13, is arranged at an end section 18e of the respective support part 18. The clamp 13 can preferably have two pivotable clamping jaws 13a, 13b, between which the core K can be clamped. Fig. 9, the clamping jaws 13a, 13b are shown as solid lines in a position in which they hold the core K, and as dashed lines in a pivoted position in which they release the core K.

[0090] As in Fig. 8, the holding arrangement 11 can be realized such that the first supports 16 of the angled holding arms 15 each extend radially from the ring 19.

[0091] This allows a modular holding arrangement to be constructed that can be easily adapted to the size and geometry of the core.

[0092] As in Fig. 1, the tool system 1 can have a control device 60, by means of which the rotational speed ω of the rotor 21, 22, the feed direction T20 and the feed speed V20 of the winding device 20 along the movement path T, as well as a respective position of the holding devices 11, can be adjusted. The control device 50 can, in particular, have functions for generating control commands, based on which respective servomotors, e.g., the drive motor 30 of the winding device 20 or the drive devices 70 of the holding arrangement 10, are actuated.

[0093] Fig. 10 shows an example of a step of a method for producing the fiber composite semi-finished product H according to the present invention. In the Fig. In the step shown in Figure 10, the core K held by a holding arrangement 10 is wrapped with a ribbon-like or thread-like fiber material F. In particular, the core K is held by at least two holding devices 11 of the holding arrangement 10. The holding arrangement 10 can be designed in one of the ways described above.

[0094] The winding of the core K takes place by translationally moving a winding device 20 along the core K. The winding device 20 can be designed in particular as described above. The core K is arranged in the winding space 24 defined by the rotor 21, 22. The rotor 21 rotates at a rotational speed ω about the rotation axis 23 and is moved at a feed speed V20 in a feed direction T20 along the core K. The fiber material F is drawn off from the respective material carriers 25, 26 and guided to the core K via the guide brackets 27, 28.

[0095] The translational movement of the winding device 20 takes place in such a way that at least one directional component of the movement of the winding device 20 coincides with the rotation axis 23.

[0096] During the winding process, the method further comprises moving one of the holding devices 11 out of the working space 29 of the winding device 20. The holding device 11 is moved out during the winding of a holding area K11 of the core K, at which the core K is held by the respective holding device 11.

[0097] As cores K, cores K with a curved or angled cross-sectional center line KS can be used, as for example in the Fig. 13 to 17. However, the method is also applicable to cores K with a straight cross-sectional center line KS, as in Fig. 12 shown.

[0098] The process is particularly advantageous for closed or frame-shaped cores K, as in the Fig. 14 to 17. The cores can, for example, have an elliptical shape, see Fig. 14, a rectangular, see Fig. 15, a circular, see Fig. 16, or a polygonal shape, see Fig. 17, have.

[0099] Since the holding devices 11 are moved out of the working space 29 of the winding device 20 during the winding of the holding area K11 of the core, even closed cores K can be wrapped with a fiber material F in a simple manner.

[0100] The ribbon- or thread-like fiber material F can, for example, be in the form of a roving, i.e., a bundle or strand of preferably parallel-arranged filaments or continuous fibers. Fiber or fiber braid ribbons pre-impregnated with a matrix material can also be used.

[0101] In the method according to the invention for producing the fiber composite semi-finished product H, a plurality of fiber layers FL are preferably formed when winding the core K. For closed cores K, this can be achieved, for example, by moving the winding device 20 with rotating rotor 21, 22 several times around the entire circumference UK of the core K. For open cores K, the formation of several fiber layers FL can be achieved by reversing the feed direction T20 of the winding device 20 at predetermined reversal points P1, P2.

[0102] Another particularly advantageous possibility for producing several fiber layers FL is in Fig. 11. In this case, a winding device 20 is moved along the core K, which has a first rotor 21, which deposits a first fiber layer FL1 lying against the core K, and a second rotor 22, which deposits a second fiber layer FL2 lying against the first fiber layer FL1, on the core K. As in exemplary Fig. 11, the rotors 20, 21 can have rotational speeds ω21, ω22 with different directions of rotation and speed values

[0103] In general, a plurality of fiber layers FL can be produced, for example the number of fiber layers can be in the range between 10 and 60, preferably in a range between 15 and 50 and particularly preferably in a range between 20 and 40.

[0104] In the method for producing the fiber composite component, the feed direction T20, the feed speed V20 at which the winding device 20 is moved along the core K, and the rotational speed ω at which the rotor 21, 22 is rotated can generally be coordinated with one another such that a unidirectional winding pattern M is formed in each of the fiber layers FL. The feed direction T20, the feed speed V20, and the rotational speed ω can generally be coordinated with one another such that different winding patterns M can be achieved in sections along the core K.

[0105] The Fig. Figures 18 to 20 each show examples of different unidirectional winding patterns M when wrapping the core with two fiber ribbons F1, F2 per fiber layer FL. Feed direction T20, feed speed V20 and rotation speed ω can be adjusted to one another, for example, so that the core, as shown in Fig. 18 is wound spirally. Furthermore, tuning can be carried out in such a way that, as in Fig. 19, a parallel-radial winding pattern M is generated. The feed direction T20, the feed speed V20 and the rotation speed ω can also be coordinated in such a way that the core, as shown in Fig. 20 shown is wrapped parallel-angled.

[0106] According to the invention, a method for producing a fiber composite component B (see Fig. 21). Accordingly, a fiber composite semi-finished product H is first manufactured using the method described above. Subsequently, a layer of matrix material is created that surrounds the fiber layers FL, and this matrix material is cured to form a resin layer. Fig. 21 shows, by way of example and schematically, a highlighted cross-sectional view of a fiber composite component B produced in this way, with a plurality of fiber layers FL made of a band-shaped fiber material F and with a resin layer S. List of reference symbols 1 tool system 10 Holding arrangement 11 Holding devices of the holding arrangement 12 clamping parts 13 brackets 14 carriers 14e End section of the respective beam 15 angled holding arms 16 first support of the respective angled support arm 17 second support of the respective angled support arm 18 Support part of the respective angled holding arm 19 rings 20 winding device 20a Outer contour of the winding device 21 first rotor 22 additional rotor 23 Rotation axis 24 changing rooms 25, 26 Material carrier 27, 28 guide bracket 29 Working area of ​​the winding device 29h envelope area 30 drive device 31 Stator 32 Induction coil 33 Distance sensor 34 bolts 40 Winding device positioning device 41 Management arrangement 42 first guide rail of the guide arrangement 43 second guide rail of the guide arrangement 44 third guide rail of the guide arrangement 45, 55 bracket 50 robots 51 Arm kinematics 52 first arm 53 second arm 54 third arm 60 Control device 70 drive devices of the holding arrangement B Fiber composite component b20 Width of the rotor d20 inner diameter of the rotor D19 rotation axis F Fiber material F1 first sliver F2 second fiber band FL fiber layers FL1 first fiber layer FL2 second fiber layer H Fiber composite semi-finished product K Kern KS Cross-sectional centerline of the core M wrap pattern PX, PY, PZ arrow P1, P2 reversal points P16 Arrow T trajectory T20 Feed direction of the winding device UK Core circumference V20 Feed speed of the winding device ω, ω21, ω22 Rotational speed of the rotor

Claims

[1] Tool system (1) for producing a fiber composite semi-finished product (H), comprising: - a holding arrangement (10) with at least two holding devices (11) for holding a core (K) to be wound with a band- or thread-like fibre material (F), - a winding device (20) with at least one rotor (21, 22) rotatable about a rotational axis (23), which is designed as a divisible circular ring or in the shape of a circular segment and which at least partially defines a winding space (24) for receiving the core (K), at least one material carrier (25, 26) arranged stationary relative to the rotor (21, 22) for providing the fiber material (F), and a guide bracket (27, 28) assigned to the respective material carrier (25, 26) and projecting from the rotor (21, 22) toward the rotational axis (23) for guiding the fiber material (F), wherein the winding device (20) is movable translationally along a movement path (T) such that a movement of the winding device (20) along the movement path (T) has at least one directional component that coincides with the rotational axis (23), wherein an outer contour (20a) of the winding device (20) defines an enveloping surface (29h) during the movement along the movement path (T), which defines a working space (29) of the winding device (20), wherein the holding devices (11) are each coupled to the winding device (20) in such a way that they can be moved out of the working space (29) of the winding device (20) during the translatory movement of the winding device (20), wherein the tool system (1) has a winding device positioning device (40) for moving the winding device (20) along the movement path (T), wherein the winding device positioning device (40) is designed as a guide arrangement (41) with at least one first guide rail (42) running in a first spatial direction (X), a second guide rail (43) guided on the first guide rail (42) and running in a second spatial direction (Y), and a third guide rail (44) guided on the second guide rail (43) and running in a third spatial direction (Z), and with a holder (45) which is guided on the third guide rail (44) and is connected to the winding device (20). [2] Tool system (1) according to claim 1, wherein the winding device (20) has at least one further rotatable rotor (22), wherein the rotors (21, 22) are arranged concentrically to one another. [3] Tool system (1) according to claim 1 or 2, wherein the holder (45, 55) connects the winding device (20) to the winding device positioning device (40) so as to be rotatable about a holder axis. [4] Tool system (1) according to one of the preceding claims, wherein the at least two holding devices (11) are designed as linearly displaceable clamping parts (12) or as openable and closable clamps (13). [5] Tool system (1) according to one of the preceding claims, wherein the tool system (1) comprises a control device (60) by means of which a rotational speed (ω) of the rotor (21, 22), a feed direction (T20) and feed speed (V20) of the winding device (20) along the movement path (T) as well as a respective position of the holding devices (11) can be adjusted. [6] Process for producing a fiber composite semi-finished product (H) comprising the following steps: - Winding a core (K) held by a holding arrangement (10) with at least two holding devices (11) with a ribbon-like or thread-like fiber material (F) by translationally moving a winding device (20) along the core (K), wherein the winding device (20) has at least one rotor (21, 22) rotating about a rotation axis (23), which is designed as a divisible circular ring or in the shape of a circular segment and which defines a winding space (24) in which the core (K) is arranged, at least one material carrier (25, 26) arranged stationary relative to the rotor (21, 22), from which the fiber material (F) is drawn off, and a guide bracket (27, 28) assigned to the respective material carrier (25, 26) and projecting from the rotor (21, 22) towards the rotation axis (23), which guide bracket guides the fiber material (F) relative to the core (K), wherein the translational Moving the winding device (20) is carried out in such a way,that at least one directional component of the movement of the winding device (20) coincides with the rotation axis (23), wherein an outer contour (20a) of the winding device (20) defines an envelope surface (20h) during the movement along the core (K), which defines a working space (29) of the winding device (20), wherein the tool system (1) has a winding device positioning device (40) for moving the winding device (20) along the movement path (T), wherein the winding device positioning device (40) has a guide arrangement (41) with at least one first guide rail (42) running in a first spatial direction (X), a second guide rail (43) guided on the first guide rail (42) and running in a second spatial direction (Y), and a third guide rail (44) guided on the second guide rail (43) and running in a third spatial direction (Z), and with a holder (45),which is guided on the third guide rail (44) and connected to the winding device (20), - Moving one of the holding devices (11) out of the working space (29) of the winding device (20) during the winding of a holding area (K11) of the core (K) at which the core is held by the respective holding device (11). [7] Method according to claim 6, wherein the band- or thread-shaped fiber material (F) is present as a roving, a prepreg tape or the like. [8] Method according to claim 6 or 7, wherein a plurality of fiber layers (FL) are formed when the core (K) is wound. [9] Method according to claim 8, wherein a feed direction (T20) and a feed speed (V20) with which the winding device (20) is moved along the core (K), as well as a rotation speed (ω) with which the rotor (21, 22) is rotated, are coordinated with one another in such a way that a predetermined winding pattern (M) is formed in each of the fiber layers (FL). [10] Method according to one of claims 6 to 9, wherein the core (K) forms a closed shape. [11] Method for producing a fiber composite component, comprising: - producing a fiber composite semi-finished product (H) by carrying out a method according to one of claims 6 to 10, - producing a layer of matrix material surrounding the fibre material (F), - Curing the matrix material of the resin layer (S).

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