MACHINE SYSTEM FOR MANUFACTURING A HYBRID COMPONENT

Description

[0001] The present invention relates to a method for producing a supporting structure as a hybrid component according to the preamble of claim 1 and a machine system according to the preamble of claim 12.

[0002] Load-bearing structures comprise a base structure and a reinforcing structure. Examples of base structures used include columns, plates, discs, domes, or ellipsoids of revolution. To achieve sufficient load-bearing capacity and rigidity of the base structures, the reinforcing structures, such as struts, plates, discs, or rods, are first manufactured in a complex manner. The struts and rods are then connected to the base structure to achieve sufficient load-bearing capacity and rigidity of the load-bearing structure as a combination of base structure and at least one reinforcing structure. Furthermore, the reinforcing structures can only be adapted to different geometries of base structures with considerable effort.

[0003] US 2014 / 0061974 A1 discloses a method for producing a three-dimensional object from a composite material. Two or more materials are extruded simultaneously as a composite material.

[0004] DE 10 2015 007 317 A1 describes a method for reinforcing a base structure with at least one reinforcement structure. The reinforcement structures are already manufactured in the required connection position, but the number of G machines is not optimally matched to the number of PE processing units. This results in high machine costs per manufactured support structure. The production of the support structures is therefore expensive.

[0005] DE 10 2014 006 706 A1 shows a method for producing a truss.

[0006] In the article "Process choice and production layout", Management & Development Center, April 11, 2008, pages 1-16, 11-04-2008, Found on the Internet: RL:https: / / web.archive.org / web / 20080411022735 / http: / / www.mdcegypt.com / Pages / Operation%20Management / Production%20 &%200peration%20Management / Facility%20Layout / Group%20Technology / Process%20choice%20and%20production%20layout1.asp, options for process selection are disclosed.

[0007] The object of the present invention is therefore to provide a method and a machine system for producing a hybrid component in which the supporting structure can be produced with low technical and financial expenditure per supporting structure.

[0008] This object is achieved by a method according to claim 1.

[0009] The basic structures provided per unit of time by just one G machine and the reinforcement structures for each basic structure produced by just one PE machine per unit of time can thus be optimally adapted to one another. The basic structures provided per unit of time by just one G machine differ significantly from the reinforcement structures for each basic structure produced by just one PE machine per unit of time, in particular the difference is greater than 20%, 30% or 50%. The cycle rate of the G machine therefore differs from the cycle rate of the PE machine. Due to the different numbers of G machines and PE machines in the machine system, the cycle rate of the G machine can be adapted to the cycle rate of the PE machine overall in the machine system.The cycle rate of a G-machine is the basic structures provided by a G-machine per unit of time, and analogously, the cycle rate of the PE machine is the reinforcement structures produced per unit of time for each basic structure. The sum of the cycle rates of the at least one G-machine present in the machine system essentially corresponds to the sum of the cycle rates of the at least one PE machine present. This advantageously optimizes the machine system's design, as longer, unnecessary waiting times for the manufactured basic structures prior to further processing in the PE machine can be avoided. The machine system is therefore cost-effective overall with regard to the support structures produced per unit of time, so that the support structures can advantageously be manufactured cost-effectively as hybrid components.The costs for manufacturing the support structure as a hybrid component can also be significantly reduced because the at least one reinforcement structure is already manufactured at the connection positions where the at least one reinforcement structure is to be connected or fastened to the base structure. This advantageously eliminates the need for complex subsequent arrangement of already manufactured reinforcement structures at the required connection positions.The hybrid component comprises at least one basic structure and at least one reinforcement structure, and the hybrid property of the hybrid component results from the different cycle rate with which the at least one basic structure is provided, in particular manufactured, by the G machine and the at least one reinforcement structure is manufactured with the PE machine, wherein the at least one basic structure and the at least one reinforcement structure generally have different structural properties, for example are formed from a different material, but the at least one basic structure and the at least one reinforcement structure can preferably also have identical structural properties.

[0010] In an additional embodiment, the base structure is produced with the at least one G-machine and / or a plurality of base structures are provided with the at least one G-machine and are transported to the at least one PE machine by the conveyor system and the reinforcement structures are produced on the base structures with the at least one PE machine.

[0011] In a supplementary embodiment, the basic structure is produced with the at least one G-machine by means of additive manufacturing, in particular 3D printing, preferably 3D printing as a powder bed process and / or free space process and / or liquid material process, and / or the basic structure is produced with the at least one G-machine by means of injection molding and / or the basic structure is made available with the at least one G-machine by removing the basic structure from a storage, in particular a magazine.

[0012] 3D printing is preferably carried out as a powder bed process using selective laser melting (SLM), selective laser sintering (SLS), selective head sintering (SHS), binder jetting and / or electron beam melting and / or 3D printing is carried out as a free-space process using fused deposition (FDM), laminated object modeling (LOM), cladding, wax deposition modeling (WDM), contour crafting, cold spraying and / or electron beam melting and / or 3D printing is carried out as a liquid material process using stereolithography (SLA), digital light processing (DLP) or liquid composite molding (LCM).

[0013] In an additional embodiment, the basic structure provided by the at least one G machine, in particular basic structures, is / are transported to the at least one PE machine by a conveyor system as a conveyor belt and / or robot.

[0014] In a further embodiment, after the production of the at least one reinforcement structure on the base structure, the base structure with the at least one reinforcement structure is transported back from the at least one PE machine to the at least one G machine using the conveyor system, and a further base structure is applied to the already produced reinforcement structure as an additional base structure using the at least one G machine. In a supplementary production step, at least one further additional reinforcement structure can be applied to the further base structure as an additional base structure by the PE machine or can be produced on the additional base structure, and for this purpose, the two interconnected base structures with the reinforcement structure are transported back from the G machine to the PE machine.These processes can also be repeated as often as desired, so that the supporting structure as the hybrid component can have any number of basic structures and reinforcement structures for each basic structure.

[0015] In a supplementary embodiment, the basic structures provided per unit of time by only one G machine are smaller than the reinforcement structures produced by only one PE machine per unit of time for each basic structure, and in the machine system the number of at least one G machine is greater than the number of at least one PE machine, in particular the machine system has only one PE machine, or the basic structures provided per unit of time by only one G machine are larger than the reinforcement structures produced by only one PE machine per unit of time for each basic structure, and in the machine system the number of at least one PE machine is greater than the number of at least one G machine, in particular the machine system has only one G machine.

[0016] Expediently, different basic structures are produced with the G machine and / or different reinforcement structures are produced with the PE machine and / or the process is carried out using a machine system described in this patent application. The different basic structures produced by the G machine have, in particular, a different geometry and / or shape. These different geometries and / or shapes are known to a computing unit of the machine system, and based on these different geometries and / or shapes of the basic structure, at least one different reinforcement structure for each basic structure is applied to or produced on the basic structure using the PE machine. The different reinforcement structures therefore also have a different shape and / or geometry.This means that the method can also advantageously be used to produce different supporting structures or different hybrid components with the machine system by simply controlling the G machine and the PE machine differently from one computer unit.

[0017] In a further embodiment, no movement is carried out with the pultruded and / or extruded at least one reinforcing structure, in particular all reinforcing structures, after pultrusion and / or extrusion and laying on the base structure, relative to the base structure and / or the matrix of the pultruded and / or extruded reinforcing structure, in particular all reinforcing structures, hardens at the required connection position on and / or on the base structure and / or the pultrusion and extrusion are carried out simultaneously and / or continuously.

[0018] In a further embodiment, for the production of the at least one reinforcement structure, pultrusion is carried out as a first step and extrusion is carried out as a second step, so that the pultruded at least one reinforcement structure partially produced in the first step, in particular all of the reinforcement structures, is / are post-processed by extrusion in the second step and / or the at least one reinforcement structure, preferably all of the reinforcement structures, is / are produced, in particular continuously, by the pultrusion unit and / or extrusion unit being moved, in particular continuously, in space in a movement path at and / or in the region of the required connection position at a distance from the base structure. The distance is small, in the range of a few mm or cm.The pultrusion unit and / or extrusion unit is essentially moved to the required connection position, since after the at least one reinforcement structure emerges from the process unit, the reinforcement structure still has a small distance from the base structure.

[0019] Advantageously, the at least one reinforcement structure is produced as a straight or curved rod and / or the movement path is substantially a straight line and / or, preferably, a curved line and / or the pultrusion unit and / or extrusion unit is moved by a robot and / or after pultrusion and / or extrusion of each reinforcement structure, the composite material with the bevels and the matrix is ​​separated by a cutting unit and / or the at least one reinforcement structure is connected as the rod to the outside of more than 50%, 70%, 80% or 90% of its length to the base structure.

[0020] In a supplementary variant, at least one reinforcement structure is produced whose length is at least 2, 4, 5, 10 or 20 times greater than the diameter of this reinforcement structure and / or the cross-sectional shape of the at least one reinforcement structure, in particular of all reinforcement structures, is or are formed during extrusion and / or when placed on the base structure and / or the length of the reinforcement structure, in particular of all reinforcement structures, is or are formed by the length of the movement path of the pultrusion unit and / or extrusion unit and / or the at least one reinforcement structure, in particular all reinforcement structures, are produced without a cavity and / or without a hollow channel.When the at least one reinforcement structure is placed on the base structure, the composite material is not completely cooled and is therefore deformable, so that the composite material is adapted to the geometry of the base structure by deformation.

[0021] In a supplementary embodiment, the fibers and preferably the matrix are continuously conveyed first through the pultrusion unit and then through the extrusion unit and / or hybrid yarns with fibers and matrix are conveyed to the pultrusion unit or the fibers and the matrix are conveyed separately to the pultrusion unit and / or the fibers or the hybrid yarns are unwound from rolls and conveyed to the pultrusion unit and / or the at least one reinforcing structure, in particular all of the reinforcing structures, is / are produced such that at least one fiber, preferably a plurality of fibers, is / are arranged on an outer side of the at least one reinforcing structure, in particular all of the reinforcing structures, and / or the at least one reinforcing structure, in particular all of the reinforcing structures, is / are produced such thatso that at least one fiber, preferably a plurality of fibers, does / does not have a complete covering with the matrix and / or the at least one reinforcing structure, in particular all of the reinforcing structures, is / are produced such that the matrix is ​​arranged between the fibers. In the reinforcing structures, the fibers are firmly connected to one another by means of the matrix, since the matrix has hardened. The fibers are also arranged on the outside of the at least one reinforcing structure, so that the fibers are visible or tangible on the outside of the at least one reinforcing structure. In particular, the fibers are therefore not arranged in an inner region of the reinforcing structures and the matrix in an outer shell. Rather, the fibers and the matrix are distributed over the cross-sectional shape and the matrix is ​​also arranged between the fibers.Preferably, a reinforcing structure, in particular a rod, comprises, for example, at least two, three, five or ten fibers.

[0022] In an additional embodiment, the fibers are bonded to one another in a material-to-material ratio in the pultrusion unit during pultrusion by means of the matrix, in particular by heating and / or hardening the matrix and / or cooling and / or hardening the matrix during conveying from the pultrusion unit to the extrusion unit, so that the fibers are bonded to one another in a material-to-material ratio and / or the fibers and the matrix are conveyed by means of a conveying device, for example two conveying wheels, in particular by the conveying device acting on the fibers with the matrix during conveying the fibers with the matrix from the pultrusion unit to the extrusion unit and / or the fibers and the matrix are first bonded to one another in a material-to-material ratio by means of pultrusion, in particular by heating and / or hardening the matrix,are connected to one another and then, during extrusion in the extrusion unit, the cross-sectional shape of the at least one reinforcing structure is at least partially formed and / or the at least one reinforcing structure, in particular all reinforcing structures, is / are extruded with a maximum diameter between 1 mm and 30 mm, in particular between 2 mm and 20 mm.

[0023] In an additional embodiment, the fibers with the matrix are heated in the extrusion unit and / or the cross-sectional shape, preferably circular, elliptical or rectangular, of the at least one reinforcing structure is formed in the extrusion unit during extrusion and preferably due to the contact of the at least one reinforcing structure with the surface of the basic structure, the cross-sectional shape is formed again and / or the fibers with the matrix are first heated in the pultrusion unit, while the fibers with the matrix are conveyed from the pultrusion unit to the extrusion unit, the fibers cool down and are heated again in the extrusion unit of the fibers with the matrix and / or the fibers with the matrix are actively cooled in the pultrusion unit with a, preferably first, cooling device and / or the fibers with the matrix are cooled after conveying through the extrusion unit with a, preferably second,Cooling device, for example a fan, are actively cooled and / or the at least one reinforcement structure, in particular all reinforcement structures, are connected to the base structure by more than 70%, 80% or 90% of the length of the respective reinforcement structure, so that the length of the connection between the reinforcement structure and the base structure is greater than 70%, 80% or 90% of the length of the reinforcement structure.

[0024] In a further embodiment, the at least one reinforcement structure, in particular all of the reinforcement structures, is / are produced with plastic, preferably thermoplastic and / or thermosetting plastic and / or plastic as a reactive hotmelt or reactive hotmelt adhesive or reactive melt polymer, as the matrix and / or the at least one reinforcement structure, in particular all of the reinforcement structures, is / are produced with fibers as glass fibers, carbon fibers and / or aramid fibers and / or the at least one reinforcement structure, in particular all of the reinforcement structures, is / are produced exclusively from matrix and fibers and / or the at least one reinforcement structure, in particular all of the reinforcement structures, is / are producedsuch that the mass fraction or volume fraction of the fibers is at least 30%, 40%, 60% or 80% and / or the at least one reinforcing structure, in particular all of the reinforcing structures, is / are produced such that the mass fraction or volume fraction of the matrix is ​​less than 70%, 60%, 40% or 20% and / or the at least one reinforcing structure, in particular all of the reinforcing structures, is / are produced such that the at least one reinforcing structure is / are formed exclusively from the fibers and the matrix. Plastics as reactive hot melt or reactive hot melt adhesive or reactive melt polymer are plastics which preferably initially have thermoplastic properties and / or are a thermoplastic plastic, and after at least one change parameter, for example heating orHeating and / or exposure to moisture and / or irradiation with UV light and / or oxygen deprivation, as a result of a chemical change, in particular at least one chemical reaction, have thermosetting properties and / or are a thermosetting plastic. If a change parameter of heating or warming is used, the heating and / or warming in the pultrusion unit and / or extrusion unit can be used as a change parameter and after the subsequent cooling and hardening of the matrix on the base structure, the support structure, in particular the reinforcement structure, has sufficient load-bearing capacity and / or rigidity even when heated or warmed. Thermosetting plastics are 100% solid even when heated or warmed, i.e. the hardening cannot be reversed by heating.The warming and / or heating in the pultrusion unit and / or extrusion unit is carried out at temperatures between 60°C and 200°C, for example. In the case of a reactive hot melt, for example based on polymers, the chemical change is brought about by a connection between existing macromolecular chains (so-called cross links). Reactive hot melts are, for example, based on EVA (ethylene vinyl acetate) and polyester, or on PA (polyamide), or on polymers, or on PUR. Reactive hot melts can also contain substances that are not plastics or adhesives. In this respect, adhesives are also considered plastics. An essential property of the reactive hot melt or reactive hot melt adhesive is that they have a high melting point and are therefore not particularly hot.reactive melt polymer is thus that after hardening due to the action of the at least one change parameter, heating of the at least one reinforcing structure does not cause melting of the reactive hotmelt or the matrix from the reactive hotmelt, so that despite heating to temperatures normal for the application, for example to temperatures up to 200° C or 300° C, the load-bearing capacity and / or rigidity of the supporting structure is still guaranteed.

[0025] In a further embodiment, the at least one reinforcement structure, in particular all reinforcement structures, is / are manufactured such that the length of the fibers, in particular all fibers, in each reinforcement structure substantially corresponds to the length of the at least one reinforcement structure and / or the at least one reinforcement structure, in particular all reinforcement structures, cool and harden on the surface of the base structure. "Substantially" means that the length of the reinforcement structure corresponds to the length of the fibers in the respective reinforcement structure with a deviation of less than 30%, 20%, 10%, or 5%.

[0026] In a further embodiment, before the at least one reinforcement structure is placed on the surface of the base structure, the material of the base structure is removed locally on the surface of the base structure in the region of a later contact surface between the at least one reinforcement structure and the base structure.

[0027] Preferably, the basic structure is removed by machining, in particular with a tool, preferably a milling tool, and the tool is moved by a robot along the surface of the basic structure.

[0028] In an additional variant, a preferably elongated recess is incorporated into the base structure due to the removal of the material of the base structure, and the at least one reinforcing structure is subsequently inserted into the recess, so that a positive connection between the at least one reinforcing structure and the base structure is formed at the recess, particularly after the matrix has cooled and hardened. The recesses can, for example, be created during the production of the base structures with a 3D printer by appropriately controlling the 3D printer with a processing unit.

[0029] In a supplementary embodiment, before the at least one reinforcement structure is placed on the surface of the base structure, the surface of the base structure is heated locally in the region of a later contact surface between the at least one reinforcement structure and the base structure with a base structure heating device, in particular a laser or an infrared radiator.

[0030] In a further embodiment, the basic structure heating device is moved by a robot along the surface of the basic structure and / or due to the heating of the surface of the basic structure, the material of the basic structure changes its property locally in the region of a later contact surface between the at least one reinforcing structure and the basic structure, in particular becoming viscous and / or sticky and / or liquid, so that a material-to-material connection is formed between the matrix of the at least one reinforcing structure and the material of the basic structure, in particular after cooling.

[0031] In a supplementary embodiment, before the at least one reinforcing structure is placed on the surface of the base structure, a substance, in particular an adhesive and / or an adhesion promoter, is applied locally in the region of a later contact surface between the at least one reinforcing structure and the base structure using an addition device to improve the connection between the at least one reinforcing structure and the base structure.

[0032] Preferably, the adding device is moved by a robot along the surface of the base structure.

[0033] In a supplementary embodiment, the basic structure is first manufactured or provided and then the at least one reinforcement structure is manufactured.

[0034] Advantageously, the basic structure is produced using a different process than the at least one reinforcement structure.

[0035] A machine system according to the invention is designed according to claim 12.

[0036] The number of at least one G machine and the number of at least one PE machine is adapted to the cycle rate of the sum of the at least one G machine and the sum of the at least one PE machine in such a way that the sum of the cycle rates of the at least one G machine essentially corresponds, i.e. with a deviation of less than 60%, 50%, 40%, 30%, 20% or 10%, to the sum of the cycle rates of the at least one PE machine. The at least one G machine and the at least one PE machine are thus essentially constantly utilized during operation of the machine system for producing the support structure as the hybrid component. As a result, the machine system has low costs for producing each support structure.

[0037] In a supplementary embodiment, the G-machine is a 3D printer and / or an injection molding machine and / or a storage device for the basic structures and / or the conveyor system is a conveyor belt and / or a robot.

[0038] In an additional variant, the machine system comprises a robot for moving the PE machine in a movement path in space and the PE machine is fastened to the robot so that the at least one reinforcement structure can be produced in the required connection position on the at least one base structure.

[0039] The machine system is expediently designed such that the basic structures provided per unit of time by only one G machine are smaller than the reinforcement structures for each basic structure produced by only one PE machine per unit of time, and the number of at least one G machine in the machine system is greater than the number of at least one PE machine, in particular the machine system has only one PE machine, or the machine system is designed such that the basic structures provided per unit of time by only one G machine are larger than the reinforcement structures for each basic structure produced by only one PE machine per unit of time, and the number of at least one PE machine in the machine system is greater than the number of at least one G machine, in particular the machine system has only one G machine.

[0040] The basic structure is expediently made of metal, in particular steel and / or aluminum, and / or of plastic, in particular fiber-reinforced plastic, and / or in a sandwich construction made of two different materials.

[0041] In a further variant, the basic structure is designed as a flat component, a plate, a disc, a partial spherical shell, a dome, a partial ellipsoid of revolution, a tub or a cup.

[0042] In an additional embodiment, the basic structure and / or the supporting structure is a load-bearing component, for example a beam, a column, a strut, a flange, a dome, a plate, a disc, a partial spherical shell, a shoe sole, a plate, a table top, a wall or a ceiling, for a wide variety of applications, in particular in everyday life, mechanical engineering, construction or electrical engineering.

[0043] In a supplementary embodiment, the at least one reinforcing structure is connected to a flat and / or curved surface of the base structure, preferably by producing the at least one reinforcing structure by means of extrusion and / or pultrusion on and / or on the flat and / or curved surface of the base structure.

[0044] In an expedient embodiment, the at least one reinforcement structure, preferably all reinforcement structures, is formed with plastic, preferably thermoplastic plastic and / or thermosetting plastic and / or plastic as a reactive hotmelt or reactive hotmelt adhesive or reactive melt polymer, as a matrix and / or the at least one reinforcement structure, preferably all reinforcement structures, are formed with fibers as glass fibers, carbon fibers and / or aramid fibers and / or the at least one reinforcement structure, preferably all reinforcement structures, is or are formed exclusively from fibers and matrix and / or the mass fraction or volume fraction of the fibers in the at least one reinforcement structure, preferably all reinforcement structures, is at least 30%, 40%, 60% or 80% and / or the mass fraction or volume fraction of the matrix in the at least one reinforcement structure,preferably all reinforcement structures, is less than 70%, 60%, 40% or 20% and / or the at least one reinforcement structure, preferably all reinforcement structures, are formed exclusively from the fibers and the matrix and / or the at least one reinforcement structure, preferably all reinforcement structures, are straight and / or curved and / or the length of the at least one reinforcement structure, preferably all reinforcement structures, is at least 2, 4, 5, 10 or 20 times greater than the diameter of the at least one reinforcement structure, preferably all reinforcement structures, and / or the at least one reinforcement structure, preferably all reinforcement structures, are formed without a cavity and / or on the at least one reinforcement structure, preferably all reinforcement structures,at least one fiber is arranged on the outside, or preferably several fibers are arranged, so that preferably the at least one fiber, preferably the several fibers, on the outside of the at least one reinforcing structure, preferably all reinforcing structures, is or are visible and / or tangible and / or at least one fiber, preferably several fibers, on the at least one reinforcing structure, preferably all reinforcing structures, does or do not have a complete covering with the matrix and / or the fibers are integrally connected to one another with the matrix arranged between the fibers.

[0045] The invention further comprises a computer program having program code means stored on a computer-readable data carrier for carrying out a method described in this patent application when the computer program is executed on a computer or a corresponding computing unit.

[0046] The invention also includes a computer program product with program code means stored on a computer-readable data carrier for carrying out a method described in this patent application when the computer program is executed on a computer or a corresponding computing unit.

[0047] In the following, embodiments of the invention are described in more detail with reference to the accompanying drawings.

[0048] It shows: Fig. 1 a simplified longitudinal section of a process unit as a PE machine with a pultrusion unit and extrusion unit for carrying out the process, Fig. 2 a side view of the process unit during the implementation of the process, Fig. 3 a cross section of a basic structure before the application of a reinforcement structure, Fig. 4 the cross section of the basic structure according to Fig. 3 after applying the reinforcement structure, Fig. 5 a cross section of basic structures and reinforcement structures in a first embodiment, Fig. 6 the cross section of basic structures and reinforcement structures in a second embodiment, Fig. 7 a plan view of a basic structure and reinforcement structures in a third embodiment, Fig. 8 a perspective view of the basic structure with reinforcement structures according to Fig. 7 , Fig. 9 a plan view of a basic structure and reinforcing structures in a fourth embodiment, Fig. 10 a perspective view of the basic structure with reinforcing structures according to Fig. 9 , Fig. 11 a plan view of a basic structure and reinforcing structures in a fifth embodiment, Fig. 12 a perspective view of the basic structure with reinforcing structures according to Fig. 11 , Fig. 13 a side view of a basic structure and reinforcing structures in a sixth embodiment, Fig. 14 a perspective view of the basic structure with reinforcing structures according to Fig. 13 , Fig. 15 a perspective view of a basic structure in a seventh embodiment, Fig. 16 a perspective view of a basic structure with reinforcement structure according to Fig. 15 , Fig. 17 a perspective view of a basic structure with reinforcement structure and an additional basic structure according to Fig. 15 , Fig. 18 a perspective view of a basic structure with reinforcement structure and an additional basic structure and an additional reinforcement structure according to Fig. 15 , Fig. 19 a highly simplified representation of a machine system in a first embodiment and Fig. 20 a highly simplified representation of a machine system in a second embodiment.

[0049] In Fig. 1 and 2 , a process unit 5 for producing a reinforcement structure 1 is shown. The process unit 5 comprises a pultrusion unit 6 and an extrusion unit 7 and forms a PE machine 42. In the pultrusion unit 6, a pultrusion channel 9 is formed and in a direction from right to left as shown in Fig. 1 The pultrusion channel 9 initially has a conically tapered section and then a section with a constant diameter. On the pultrusion channel 9 in the section with the constant diameter, a pressure is applied in a direction as shown in Fig. 1 from right to left and in a conveying direction of hybrid yarns 21 or of the reinforcement structure 1 to be produced or produced, first a first heating device 8 is arranged and then a first cooling device 10. A cooling channel 11 is formed on the first cooling device 10, through which a cooling fluid is passed to cool the partially produced reinforcement structure 1. The extrusion unit 7 comprises an extrusion channel 15 and the extrusion channel 15 comprises a first conically tapered section and a second section with a constant diameter. A second heating device 16 is formed on the second section of the extrusion channel 15 with the constant diameter. The first and second heating devices 8, 16 are preferably designed as an electrical resistance heater.In the conveying direction of the reinforcement structure 1 to be produced through the extrusion channel 15, the conically tapered section of the extrusion channel 15 is formed first, followed by the section of the extrusion channel 15 with the constant diameter. A conveyor device 12 is formed between the pultrusion unit 6 and the extrusion unit 7. The conveyor device 12 comprises a first conveyor wheel 13 and a second conveyor wheel 14, which are driven by an electric motor (not shown). The partially manufactured reinforcement structure 1 is arranged between the two conveyor wheels 13, 14, so that the partially manufactured reinforcement structure 1 is pulled out of the pultrusion unit 6 by the conveyor device 12 and pushed into the extrusion unit 7 by the conveyor device 12.

[0050] The pultrusion unit 6 and the extrusion unit 7 are provided with a connecting part 20, for example a Fig. 1 only partially shown housing. Furthermore, a feed part 23 with three guide bores 24 is attached to the connecting part 20. A hybrid yarn 21 is wound on each of three rolls 22. The hybrid yarn 21 consists of a fiber as a glass fiber and further comprises the matrix made of a thermoplastic. The matrix as the thermoplastic is arranged in the hybrid yarn 21 as a fibrous matrix or as a matrix fiber. The hybrid yarn 21 is flexible and can thus be unwound from the roll 22. Furthermore, a second cooling unit 17 is attached to the extrusion unit 7. The second cooling unit 17 comprises a blower 18 and a cooling pipe 19. By means of the blower 18, ambient air is guided through the cooling pipe 19, specifically to the area of ​​the reinforcement structure 1 immediately after leaving the extrusion unit 7.A cutting unit 25 serves to cut off the reinforcement structure 1 extruded on the extrusion unit 7 as required and thereby to produce an end of the reinforcement structure 1.

[0051] During the manufacture of the reinforcement structure 1 from the composite material 29 with the fibers and the matrix, the composite material 29 is prepared as shown in Fig. 1 first through the pultrusion unit 6 and then through the extrusion unit 7 by means of the conveyor device 12, however, both processes take place simultaneously due to the length of the rods 2 and the distance between the pultrusion unit 6 and the extrusion unit 7. During the conveying of the composite material 29, the hybrid yarn 21 is thus unwound from the three rollers 22 and introduced into the conically tapered section of the pultrusion channel 9. At the second section of the pultrusion channel 9 with the constant diameter, the three hybrid yarns 21 are heated with the first heating device 8 so that the thermoplastic of the matrix melts at the hybrid yarns 21 and thereby the glass fibers in the three hybrid yarns 21 are firmly bonded to one another by means of the matrix made of the thermoplastic as a pultrusion process.Subsequently, the composite material 29 with the fibers and the matrix is ​​conveyed or moved to the section of the pultrusion channel 9 with the first cooling device 10, so that the composite material 29 with the glass fibers and the thermoplastic is cooled and thereby hardened. After the composite material 29 emerges from the fibers and the matrix, the composite material 29 with the matrix is ​​conveyed or guided from the already partially manufactured reinforcement structure 1 by the conveyor device 12 into the extrusion unit 7. Due to the cooling of the composite material 29 with the fibers in the first cooling device 10, the composite material 29 with the fibers can be conveyed by the conveyor device 12.In the extrusion unit 7, the composite material 29 with the fibers and the matrix is ​​slightly heated again by the second heating device 16 at the section of the extrusion channel 15 with the constant diameter, to such an extent that the final shaping of the cross-sectional shape of the reinforcement structure 1 to be produced is formed at the end region in the conveying direction of the extrusion channel 15. The in . Fig. 1 The left end of the extrusion channel 15 has a circular or square cross-sectional shape, so that reinforcement structures 1 with a circular or square cross-section are produced by the process unit 5. After the reinforcement structures 1 exit the extrusion channel 15 of the extrusion unit 7, ambient air is directed as cooling air to the rod 2 by the blower 18 through the cooling pipe 19, so that a faster cooling of the reinforcement structures 1 can be achieved.

[0052] The reinforcement structures 1 produced by the method are designed as straight or curved bars 2. The bars 2 are produced by the process unit 5 at the required connection position on a base structure 4, so that the process unit 5 on a movement path 26 as a straight line 27 or curved line 27 by means of movement arms 28 of a Fig. 2 The movement path 26 as a straight line 27 or curved line 27 essentially corresponds to the longitudinal axis of the reinforcement structure 1 produced by the process unit 5. After the production of the bars 2 and the placement of the bars 2 or the reinforcement structures 1 on the surface of the base structure 4, no relative movement of the produced bars 2 to other bars 2 already produced or still to be produced or to the base structure 2 is required, since the bars 2 are already produced by the process unit 5 at the required connection position on the base structure 4. As a result, the costs for the production of a support structure 3 with the base structure 4 and reinforcement structures 1 by means of the process unit 5 can be significantly reduced. Fig. 2 The rollers 22 and the hybrid yarns 21 are not shown. The reinforcement structure 1 consists of rods 2 made of the composite material 29, namely with fibers as glass fibers and the matrix as a thermoplastic material.

[0053] In a further, not shown embodiment of the process unit 5, the fibers, e.g. glass, aramid or carbon fibers, are wound on the rollers 22 and the matrix as the thermoplastic plastic is stored separately in a container with a container heater in a heated state and conveyed to the pultrusion unit 6 by means of a matrix conveyor device (not shown). The pultrusion unit 6 and the extrusion unit 7 can also be designed as just one component, for example by carrying out the extrusion, i.e. the final shaping of an outer side 33 of the rod 2, immediately after the pultrusion, without the conveyor device 12 being arranged between the extrusion unit 7 and the pultrusion unit 6.

[0054] In a further embodiment not shown, instead of thermoplastic as the matrix, a thermosetting plastic or a plastic as a reactive hot melt or reactive hot melt adhesive or reactive melt polymer is used. The thermosetting plastic is stored separately in a container and fed to the extrusion unit 7 and / or the pultrusion unit 6 by means of a matrix conveyor. The thermosetting plastic is hardened by means of irradiation or the addition of chemical additives. The hardening of the plastic as a reactive hot melt or reactive hot melt adhesive or reactive melt polymer is carried out in particular by heating as a change parameter during processing of the matrix in the pultrusion unit 6 and / or in the extrusion unit 7.As an alternative, the plastic can also be cured as a reactive hot melt by moisture and / or UV light and / or oxygen deprivation. When curing by UV light, after the at least one reinforcement structure 1 has been placed on the base structure 4, the at least one reinforcement structure 1 is irradiated with UV light using a UV light source (not shown).

[0055] Pre-processing devices 34, 36, 38 as a tool 34 as a milling tool 35, a basic structure heating device 36, for example a laser 37 or an infrared radiator 38, and an addition device 39 for adhesive 31 are attached to the process unit 5 (only in Fig. 2 shown). The tool 34, the base structure heating device 36 and the addition device 39 are movable relative to the process unit 5 by mechanical means, so that the pre-processing devices 34, 36, 38 can be arranged in the required position on different movement paths 26 with different surfaces of base structures 4. Before placing the reinforcement structure 1 produced on the process unit 5 onto the surface of the base structure 4, an elongated recess 32 ( Fig. 3 ) with any cross-sectional shape, depending on the geometry of the milling tool 35, are milled into the base structure 4. The recesses 32 have an undercut, so that after cooling and hardening of the composite material 29 with the fibers and the matrix within the recess 32, a positive connection of the rods 2 as a reinforcement structure 1 on the base structure 1, for example plates 30, is formed.

[0056] Subsequently, the surface of the base structure 4 in the region of the recess 32 is heated with the base structure heating device 36 so that the matrix of the composite material 29 can bond to the material of the base structure 4 and, after cooling and hardening of the composite material 29 and the base structure 4, a firm bond exists between the base structure 4 and the reinforcement structure 1.

[0057] Subsequently, adhesive 31 is applied to the surface of the base structure 4 in the region of the recess 32 using the addition device 39 in order to firmly bond the reinforcement structure 1 to the base structure 4 after the reinforcement structure 1 has been placed on the base structure 4 and the adhesive 31 has hardened. In general, depending on the material of the base structure 4, only the base structure heating device 36 or only the addition device 39 is operated. If the base structure 4 is made of metal, for example steel or aluminum, only the addition device 39 and not the base structure heating device 36 is operated. If the base structure 4 is made of thermoplastic, only the addition device 39 and not the base structure heating device 36 is operated.

[0058] In Fig. 5 A cross section of basic structures 4 and reinforcing structures 1 as a supporting structure 3 or hybrid component 3 is shown in a first exemplary embodiment. The basic structures 4 have a straight surface and the basic structures 4 and reinforcing structures 1 are formed in layers one above the other. For example, a layer of the basic structure 4 is produced with a 3D printer and then the reinforcing structure 1 with the process unit 5. The rods 2 can also be formed without a distance a between two adjacent rods 2 in a direction perpendicular to the plane of the drawing. Fig. 5 be extruded onto the surface of the base structure 4, so that the reinforcement structure 1 can also have a disc-shaped geometry.

[0059] In Fig. 6 A cross-section of base structures 4 and reinforcement structures 1 as a support structure 3 is shown in a second exemplary embodiment. The base structures 4 have a curved surface, and the base structures 4 and reinforcement structures 1 are formed in layers one above the other, so that the reinforcement structures 1 are also curved.

[0060] In Fig. 7 is a plan view of the basic structure 4 and reinforcement structures 1 as hybrid component 3 and in Fig. 8 a perspective view of the base structure 4 with reinforcing structures 1 in a third embodiment. The base structure 4 has a straight surface, so that the reinforcing structures 1 are also straight. The reinforcing structures 1 have parallel to the plane of the drawing of Fig. 7 a distance a. The rod-shaped reinforcement structures 1 have a length L as the longitudinal extension in a longitudinal axis of the reinforcement structures 1.

[0061] In Fig. 9 is a plan view of the basic structure 4 and reinforcement structures 1 as supporting structure 3 and in Fig. 10 a perspective view of the base structure 4 with reinforcing structures 1 in a fourth embodiment. The base structure 4 has a straight surface, so that the reinforcing structures 1 are also straight. The reinforcing structures 1 have parallel to the plane of the drawing of Fig. 9 a distance a.

[0062] In Fig. 11 is a plan view of the basic structure 4 and reinforcement structures 1 as hybrid component 3 and in Fig. 12 a perspective view of the base structure 4 with reinforcing structures 1 in a fifth embodiment. The base structure 4 has a straight surface, so that the reinforcing structures 1 are also straight. The reinforcing structures 1 have parallel to the plane of the drawing of Fig. 7 a distance a, and furthermore, individual extruded rods 2 are materially joined to one another without a distance a by moving the process unit 5 along a corresponding movement path 26. To materially join the rods 2, they are extruded in such a way that the matrix has not yet cooled and / or the already extruded rods 2 are heated for the materially bonded connection.

[0063] In Fig. 13 is a side view of the basic structure 4 and reinforcement structures 1 as supporting structure 3 and in Fig. 14 A perspective view of the base structure 4 with reinforcing structures 1 in a sixth exemplary embodiment is shown. The base structure 4 has a curved surface, so that the reinforcing structures 1 are also curved. The reinforcing structures 1 are partially arranged in recesses 32 of the base structure 4.

[0064] In the Fig. 15 bis 18 A seventh embodiment of the basic structure 4 and reinforcement structure 1 is shown as a hybrid component 3. The Fig. 15 The basic structure 4 shown is manufactured or made available by a G-machine 41, for example, manufactured by a 3D printer 44, manufactured by an injection molding machine, or taken from a storage 45 as a magazine 46, that is, merely made available. Fig. 15 The basic structure 5 shown, which is produced, for example, as a honeycomb structure, is Fig. 15 The basic structure 4 shown is transported to the PE machine 42 by a conveyor system 43, for example a conveyor belt 47 or robot 48. In the PE machine 42, the reinforcing structures 1 are applied by the process unit 5 as the pultrusion and extrusion unit 6, 7. In this case, a plurality of rods 2 are placed next to one another without any spacing on the top side of the Fig. 15 shown basic structure 4 and connected to the basic structure 4. Subsequently, the Fig. 16 The hybrid component 3 shown as the supporting structure 3 is transported back to the G-machine 41 as the 3D printer 44 or the injection molding machine. Here, an additional layer of the basic structure 4 is applied to the Fig. 16 reinforcement structure 1 shown in Figure 1. After this manufacturing step, the supporting structure 3 has the Fig. 17 After this manufacturing step, the geometry shown in Fig. 17 The hybrid component 3 shown is then transported to the PE machine 42 by means of the conveyor system 43, and the reinforcement structure 1 is then applied. The manufacturing process can also be carried out in such a way that the hybrid component 3 is already produced as shown in Fig. 16 represents the final finished product and no further manufacturing steps are performed. The manufacturing method described in the seventh embodiment preferably also applies analogously to the first to sixth embodiments.

[0065] In Fig. 19 A first embodiment of a machine system 40 is shown. A total of five 3D printers 44 as G-machines 41 are combined with a PE machine 42, as a process unit 5 on a robot, to form the machine system 5. The cycle rate of each 3D printer 44 corresponds approximately to one-fifth of the cycle rate of the PE machine 42. The sum of the cycle rates of the 3D printers 44 thus essentially corresponds to the cycle rate of the single PE machine 42. The basic structures 4 produced by the G-machine 41 are transported to the PE machine 42 by the conveyor system 43, for example a conveyor belt 47 and / or a robot 48. At the PE machine 42, the reinforcement structure 1 is applied to the basic structure 4, so that the support structure 3 can be finally produced as the hybrid component 3 and is then removed at a removal point 49.

[0066] In Fig. 20 A second embodiment of the machine system 40 is shown. An injection molding machine 50 as the G machine 41 is combined with three PE machines 42. The cycle rate of a PE machine 42 corresponds approximately to one-third of the cycle rate of the injection molding machine 50. The injection molding machine 50 can, for example, produce thirty basic structures 4 in ten minutes, and a PE machine 42 can apply or produce one reinforcement structure 1 for each basic structure 4 on ten basic structures 4 in ten minutes, i.e., produce ten reinforcement structures 1 in ten minutes. The sum of the cycle rates of the PE machines 42 thus corresponds to the cycle rate of the injection molding machine 50. During operation of the machine system 40, both the injection molding machine 50 and the PE machines 42 are constantly fully utilized. The conveyor system 43 is designed accordingly to transport the basic structures 4 from the injection molding machine 50 to the PE machines 42.

[0067] Overall, the method according to the invention for reinforcing the basic structure 4 offers significant advantages. The reinforcing structures 1 are produced from the composite material 29 with fibers and a matrix. During production, the process unit 5 is moved along a longitudinal axis of the reinforcing structure 1 to be produced, in particular the rod 2, as a straight or curved movement path 26, so that the rods 2 can be produced from the composite material 29 at the required connection position already on the surface of the basic structure 4 and the costs for producing the supporting structure 3 are thereby significantly reduced. When using the hybrid yarn 21, the proportion of the matrix and the fibers in the rods 2 is constant. By using a different number of hybrid yarns 21 orFibers for producing a rod 2, it is also possible to produce rods 2 with different diameters. Furthermore, the rods 2 can also be produced with different cross-sectional shapes. For this purpose, the end of the extrusion channel 15 has a . Fig. 1not shown, so that bars 2 can be easily manufactured not only as circular shapes but also as elliptical bars 2 or rectangular bars 2 or square bars 2 in cross-sectional shape. Adapting the geometry and / or shape of the reinforcement structures 1 to different base structures 4 with a wide variety of geometries can be achieved simply and inexpensively by the robot simply moving the process unit 5 along an adapted movement path 26. For this purpose, the robot either has sensors for detecting the geometry of the base structure 4 and / or the geometry of the base structure 4 is stored in a computing unit of the robot. Based on the data on the geometry of the base structure 4, the computing unit can calculate the movement path 26 for a predetermined position for the at least one reinforcement structure 1.The adaptation of the geometry of at least one reinforcement structure 1 to the geometry of the base structure 4 can thus be carried out exclusively by programming and / or data processing, because any desired movement paths 26 in space can be executed with the robot. The adaptation or modification of the geometry and / or shape of the base structures 4 can be carried out exclusively by programming and / or data processing during production with the G-machine, in particular a 3D printer, by means of a corresponding control of the G-machine with a computing unit.

[0068] In the machine system 40, the number of G machines 41 is optimally adapted to the number of PE machines 42. This means that, due to the existing total cycle rates of the G machines 41 and PE machines 42, both the G machines 41 and the PE machines 42 are essentially constantly utilized during the production of the hybrid components 3. This advantageously results in low machine costs for each hybrid component 3 for the production of the hybrid components 3. Unnecessary downtimes of a G machine 41 or a PE machine 42 can thus be advantageously avoided to a large extent. The hybrid components 3 can be used for a wide variety of applications, for example in mechanical engineering as support structures 3 or in everyday applications, for example as plates for eating or as shoe soles.The term supporting structure 3 is therefore to be interpreted broadly as a hybrid component 3 and a special load-bearing effect of the supporting structure 3 or the hybrid component 3 is not necessarily required.

Claims

1. Method for producing a supporting structure (3) as a hybrid component (3) with a basic structure (4) and with at least one reinforcing structure (1), comprising the steps of: - producing the at least one reinforcing structure (1) for in each case one basic structure (4), which is a machine for providing the basic structure, - providing the basic structure (4) with a G-machine (41), - connecting the at least one reinforcing structure (1) to the base structure (4), so that the at least one reinforcing structure (1) is connected to the base structure (4) in a connecting position and the base structure (4) together with the at least one reinforcing structure (1) forms the supporting structure (3), wherein, the production of the at least one reinforcing structure (1) for a respective base structure (4) is carried out by producing the at least one reinforcing structure (1) from a composite material with fibres and a matrix by means of pultrusion and / or by means of extrusion, and and a pultrusion unit (6) and / or an extrusion unit (7) is / are moved in space as a PE machine (42) for producing the reinforcing structure (1), so that the at least one reinforcing structure (1), after pultrusion and / or extrusion, is / are pultruded and / or extruded onto the base structure (4) at the required connection position in each case, and the at least one reinforcing structure (1) is / are and the at least one reinforcing structure (1) is connected to the base structure (4) by more than 50% with respect to the length of the respective reinforcing structure (1), so that the length of the connection between the reinforcing structure (1) and the base structure (4) is greater than 50% of the length of the reinforcing structure (1) and the method is carried out with a machine system (40) and in the machine system (40) the number of the at least one G machine (41) and the number of the at least one PE machine (42) are different and the basic structure (4) provided by the at least one G machine (41) is transported to the at least one PE machine (42) with a conveyor system (43).

2. Method according to claim 1, characterised in that the basic structure (4) is produced with the at least one G-machine (41) and / or a plurality of basic structures (4) are made available with the at least one G machine (41) and are transported with the conveyor system (43) to the at least one PE machine (42) and the reinforcing structures (1) are produced on the basic structures (4) with the at least one PE machine (42).

3. Method according to claim 1 or 2, characterised in that the at least one reinforcing structure (1) is connected to the base structure (4) by more than 70%, 80% or 90% with respect to the length of the respective reinforcing structure (1), so that the length of the connection between the reinforcing structure (1) and the base structure (4) is greater than 70%, 80% or 90% of the length of the reinforcing structure (1).

4. Method according to one or more of the preceding claims, characterised in that the basic structures (4) provided per unit of time by only one G machine (41) have a difference from the reinforcing structures (1) produced per unit of time by only one PE machine (42) for one basic structure (4) in each case, which difference is greater than 20%, 30% or 50%.

5. Method according to one or more of the preceding claims, characterised in that the basic structure (4) provided by the at least one G machine (41), in particular basic structures (4), is or are transported to the at least one PE machine (42) by a conveyor system (43) in the form of a conveyor belt (47) and / or robot (48).

6. Method according to one or more of the preceding claims, characterised in that after the production of the at least one reinforcing structure (1) on the base structure (4), the base structure (4) with the at least one reinforcing structure (1) is transported back from the at least one PE machine (42) to the at least one G machine (41) by the conveyor system (43) and a further base structure (4) is applied to the already produced reinforcing structure (1) as an additional base structure (4) by the at least one G machine (41).

7. Method according to one or more of the preceding claims, characterised in that the basic structures (4) provided by only one G machine (41) per unit of time are smaller than the reinforcing structures (1) produced by only one PE machine (42) per unit of time for one basic structure (4) in each case and the number of at least one G machine (41) in the machine system (40) is greater than the number of at least one PE machine (42), in particular the machine system (40) has only one PE machine (42) or the basic structures (4) provided by only one G machine (41) per unit of time are greater than the reinforcing structures (1) produced by only one PE machine (42) per unit of time for one basic structure (4) in each case and the number of at least one PE machine (42) in the machine system (40) is greater than the number of at least one G machine (41), in particular the machine system (40) has only one G machine (41).

8. Method according to one or more of the preceding claims, characterised in that different basic structures (4) are produced with the G machine (41) and / or different reinforcing structures (1) are produced with the PE machine (42) and / or the method is carried out with a machine system (40) according to one or more of claims 12 to 15.

9. Method according to one or more of the preceding claims, characterised in that no movement relative to the base structure (4) is or are carried out with the pultruded and / or extruded at least one reinforcing structure (1) after pultrusion and / or extrusion and placement on the base structure (4) and / or the matrix of the pultruded and / or extruded reinforcing structure (1) hardens at the required bonding position on and / or to the base structure (4) and / or the pultrusion and extrusion are carried out simultaneously and / or continuously.

10. Method according to one or more of the preceding claims, characterised in that for the production of the at least one reinforcing structure (1), pultrusion is carried out as the first step and extrusion is carried out as the second step, so that the at least one reinforcing structure (1) partially produced by pultrusion in the first step is or are reworked by extrusion in the second step and / or the at least one reinforcing structure (1), preferably all reinforcing structures (1), is or are produced, in particular continuously, by moving the pultrusion unit (6) and / or extrusion unit (7), in particular continuously, in space in a movement path (26) at the required connection position at a distance from the base structure (4).

11. Method according to one or more of the preceding claims, characterised in that the at least one reinforcing structure (1) is connected as a rod (2) in its length to the base structure (4) by more than 50%, 70%, 80% or 90% on the outside (33).

12. Machine system (40) for producing a supporting structure (3) as a hybrid component (3) with a basic structure (4) and with at least one reinforcing structure (1), comprising: - at least one G machine (41) for providing the basic structure (4), - at least one PE machine (42) with a pultrusion unit (6) and / or an extrusion unit (7) for producing the at least one reinforcing structure (1), characterised in that the number of the at least one G machine (41) and the number of the at least one PE machine (42) are different and the machine system (40) comprises a conveyor system (43) for transporting the basic structure (4) from the G machine (41) to the PE machine (42) and the machine system (40) is set up to carry out a method according to one or more of claims 1 to 11.

13. Machine system according to claim 12, characterised in that the G-machine (41) is a 3D printer (44) and / or an injection moulding machine and / or a storage (45) for the basic structures (4) and / or the conveyor system (43) is a conveyor belt (47) and / or a robot (48).

14. Machine system according to claim 12 or 13, characterised in that the machine system (40) comprises a robot for moving the PE machine (42) in a movement path in space and the PE machine (42) is attached to the robot so that the at least one reinforcing structure (1) can be produced in the required connection position on the at least one base structure (4).

15. Machine system according to one or more of claims 12 to 14, characterised in that the machine system (40) is designed in such a way that the basic structures (4) provided per unit of time by only one G machine (41) are smaller than the reinforcing structures (1) produced per unit of time by only one PE machine (42) for one basic structure (4) in each case, and in the machine system (40) the number of at least one G machine (41) is greater than the number of at least one PE machine (42), in particular the machine system (40) has only one PE machine (42), or the machine system (40) is designed in such a way that the basic structures (4) provided per unit of time by only one G machine (41) are greater than the reinforcing structures (1) produced per unit of time by only one PE machine (42) for one basic structure (4) in each case, and in the machine system (40) the number of the at least one PE machine (42) is greater than the number of the at least one G machine (41), in particular the machine system (40) has only one G machine (41).