Fiber Placement Device

Abstract

A fiber placement device provided with: an arrangement surface on which a reinforced fiber yarn is arranged and laminated; a yarn arrangement mechanism that presses and arranges the reinforced fiber yarn on the arrangement surface; and a heating mechanism that heats the arrangement surface. In one arrangement cycle, the yarn arrangement mechanism presses a reinforced fiber yarn group toward the arrangement surface heated in advance by the heating mechanism and moves by a prescribed length in a first axial direction to bond and fix the reinforced fiber yarn group onto the arrangement surface, and the arrangement surface moves in a second axial direction substantially orthogonal to the first axial direction. The arrangement cycle is repeatedly performed to array a reinforced fiber yarn in a desired shape on the arrangement surface. The heating mechanism is movable relative to the arrangement surface in the second axial direction. A region in which the reinforced fiber yarn is arranged in an nth arrangement cycle (n is a natural number of 2 or more) is heated in advance by the heating mechanism at the time of an n–1th arrangement cycle.

Description

[Technical field]

[0001] This application is based on and claims the benefit of priority to Patent Application No. 2020-059393, filed on March 30, 2020, the entire contents of which are incorporated herein by reference.

[0002] The present disclosure relates to a fiber placement apparatus used in the manufacture of fiber reinforced plastic products. [Background technology]

[0003] The following technique is known as a method for manufacturing a preform having a three-dimensional shape used in the manufacture of fiber-reinforced plastic products, which is made of reinforcing fibers such as glass fibers and carbon fibers. In this technique, a cut pattern having a two-dimensional shape corresponding to the shape of the desired preform is first cut out from a strip-shaped woven substrate made of reinforcing fibers. The cut pattern is pressed to form a preform having a three-dimensional shape. However, in this method, the woven substrate remaining after the cut pattern is cut out from the strip-shaped woven substrate is discarded. For this reason, this method has the problem of low yield of reinforcing fibers and high manufacturing costs.

[0004] One method for solving this problem is known as the fiber placement method. In the fiber placement method, multiple reinforcing fiber threads are placed only in the necessary places on a table and bonded to each other so that they form a two-dimensional shape corresponding to the shape of the desired preform. By pressing the reinforcing fiber threads arranged in such a two-dimensional shape, a preform having a three-dimensional shape is manufactured.

[0005] For example, Patent Document 1 discloses a fiber placement device that can place a reinforcing fiber thread on a table at high speed using this method. This device includes a thread pressing mechanism that can press the reinforcing fiber thread against the table, a thread supply mechanism that can supply the reinforcing fiber thread to the table, and a cutting blade that is positioned independently of the thread supply mechanism and can cut the reinforcing fiber thread by pressing the reinforcing fiber thread against the cutting edge using the thread pressing mechanism. By using this device, the reinforcing fiber thread can be placed on the table so as to have a desired two-dimensional shape. This improves the yield of the reinforcing fiber. Furthermore, this device allows the reinforcing fiber thread to be cut without slowing down the travel of the thread supply mechanism. This increases the speed of placement of the reinforcing fiber thread.

[0006] On the other hand, as for a technique for stacking further reinforcing fiber yarns on the arranged reinforcing fiber yarns, for example, Patent Document 2 discloses the following device. This device presses a reinforcing fiber substrate with a binder attached against a reinforcing fiber substrate layer stacked on a preform molding jig or against the preform molding jig by a heating and pressure roller. While the reinforcing fiber substrate is pressed by this heating and pressure roller, the binder melts and bonds the reinforcing fiber substrate.

[0007] As a technique for ensuring the heating time of the binder contained in the reinforcing fiber substrate being placed, for example, Patent Document 3 discloses the following device. This device includes a pressure roller for pressing the reinforcing fiber yarn against the lamination jig. This device preheats a part of the region of the lamination jig in the traveling direction of the pressure roller in addition to the reinforcing fiber yarn located upstream of the pressure roller. By using this device, the region where the reinforcing fiber yarn is placed can be preheated. As a result, by placing the reinforcing fiber yarn in the preheated region, the binder can be softened or melted by heating for a relatively short time, and the tact time required for manufacturing the preform can be shortened. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] International Publication No. 2016 / 047141 [Patent Document 2] JP 2011-57767 A [Patent Document 3] International Publication No. 2016 / 146902 Summary of the Invention [Problem to be solved by the invention]

[0009] In the device described in Patent Document 1, a suction table is used as a means for fixing the reinforcing fiber threads on the table. Therefore, the reinforcing fiber threads that are in direct contact with the suction table are fixed on the suction table. However, when a reinforcing fiber thread is to be placed on an area on the suction table where the reinforcing fiber threads are already placed, the reinforcing fiber threads cannot be fixed on the suction table. Therefore, in order to obtain a preform in which a plurality of reinforcing fiber threads are laminated using the above device, the following process is required. That is, after a layer of reinforcing fiber threads is arranged in a two-dimensional shape corresponding to the preform to be produced, the reinforcing fiber threads are transferred to another lamination table. Then, the reinforcing fiber threads are further laminated on the reinforcing fiber threads for a plurality of layers already laminated on the lamination table. Because such a process is performed, the technology of Patent Document 1 has a problem that the tact time required for manufacturing the preform is long, and the manufacturing cost increases.

[0010] In addition, in order to bond a reinforcing fiber substrate using the device described in Patent Document 2, it is necessary to heat the binder particles in the reinforcing fiber substrate to the melting point while the heating and pressurizing roll and the reinforcing fiber substrate guided to the heating and pressurizing roll are in contact with each other. Therefore, it is necessary to ensure sufficient contact time between the heating and pressurizing roll and the reinforcing fiber substrate. This limits the placement speed of the reinforcing fiber substrate, and the tact time required for manufacturing the preform is extended.

[0011] In the device described in Patent Document 3, a heating mechanism for preheating the lamination jig is mounted on a placement head including a pressure roll. The area preheated by the heating mechanism is limited to the area in the traveling direction of the pressure roll. Therefore, in order to sufficiently heat the area in the traveling direction of the pressure roll, the placement speed of the reinforcing fiber yarns could not be set high. As a result, the effect of reducing the takt time required for preform production was limited.

[0012] An object of the present disclosure is to reduce the heating waiting time for melting or softening of the binder, thereby enabling high-speed arrangement of reinforcing fiber threads and shortening the time required to manufacture a preform. [Means for solving the problem]

[0013] The present disclosure has been made to address at least a portion of the above-mentioned problems, and can be realized in the following form.

[0014] (1) According to one embodiment of the present disclosure, a fiber placement device is provided. The fiber placement device includes a placement table having a placement surface on which reinforcing fiber yarns are placed and stacked, a thread placement mechanism that can place the reinforcing fiber yarns on the placement surface along a first direction by pressing the reinforcing fiber yarns against the placement surface and unwinding them, a heating mechanism that can heat a partial area of ​​the placement surface, and a control unit that controls the fiber placement device. The placement table and the thread placement mechanism are configured to be relatively movable in a second direction intersecting with the first direction. The placement table and the heating mechanism are configured to be relatively movable in the second direction. The control unit can repeatedly perform a placement cycle. The placement cycle includes a first process in which the thread placement mechanism places the reinforcing fiber yarns on the placement surface by a predetermined length along the first direction, and a second process in which the placement table is moved relatively in the second direction with respect to the thread placement mechanism. The control unit causes the heating mechanism to heat at least a portion of the region where the reinforcing fiber yarn is placed in the nth placement cycle by the time the (n-1)th (n is a natural number of 2 or more) placement cycle is completed. (2) In the fiber placement device of the above aspect, the control unit may be configured to cause the heating mechanism to heat all areas in which the reinforcing fiber yarn is placed in the n-th placement cycle by the time the (n-1)-th placement cycle is completed. (3) In the fiber placement device of the above aspect, the control unit may be configured to cause the heating mechanism to heat at least a part of the region where the reinforcing fiber yarn is placed in the n-th placement cycle during a period in which the (n-1)-th placement cycle is executed. (4) In the fiber placement device of the above embodiment, the heating mechanism may include a plurality of heating devices arranged along the first direction, each of which can be controlled independently, and the control unit may set a temperature of one of the plurality of heating devices that heats a region where the reinforcing fiber yarn is to be placed last in an n-th placement cycle to be higher than a temperature of one of the plurality of heating devices that heats a region where the reinforcing fiber yarn is to be placed first in an n-th placement cycle.

[0015] In order to address the above-mentioned problems, a fiber placement device according to the present disclosure has the following configurations (1) to (4). (1) A fiber placement device including at least a placement surface for placing and stacking reinforcing fiber yarns, a yarn placement mechanism for pressing and placing the reinforcing fiber yarns against the placement surface, and a heating mechanism for partially heating the placement surface, a repeatable arrangement cycle is provided in which the yarn arrangement mechanism is moved to a predetermined position, the yarn arrangement mechanism presses the reinforcing fiber yarn against the arrangement surface that has been preheated by the heating mechanism, the yarn arrangement mechanism is moved a predetermined length in a first axial direction, the reinforcing fiber yarn is adhered and fixed onto the arrangement surface, and the arrangement surface is moved in a second axial direction perpendicular to the first axial direction, the heating mechanism is configured to be movable relative to the placement surface along the second axial direction, and the heating mechanism is moved above a region where reinforcing fiber yarns are placed in the n-th placement cycle (n is a natural number of 2 or more) by the time the (n-1)th placement cycle (n is a natural number of 2 or more) is completed, thereby pre-heating the region. (2) A fiber placement device according to (1), characterized in that the heating mechanism is moved to an area where the reinforcing fiber yarn in the n-th placement cycle is to be placed, thereby preheating the entire area where the reinforcing fiber yarn in the n-th placement cycle is to be placed. (3) The fiber placement device according to (1) or (2), characterized in that the heating mechanism is moved to an area where the reinforcing fiber yarn in the n-th placement cycle is to be placed, and the area where the reinforcing fiber yarn in the n-th placement cycle is to be placed is pre-heated during the (n-1)-th placement cycle. (4) A fiber placement device according to any one of (1) to (3), characterized in that the heating mechanism comprises a group of heating devices divided into a plurality of regions along the first axial direction, and each of the group of heating devices is configured to be able to independently adjust the heating state.

[0016] The present disclosure may be realized in various forms other than a fiber placement device, such as a method for manufacturing a fiber placement device, a method for controlling a fiber placement device, a computer program for implementing the control method, a non-transitory recording medium on which the computer program is recorded, etc. Effect of the Invention

[0017] By using the fiber placement device of the present disclosure, the heat treatment for melting or softening the binder contained in the reinforcing fiber yarn and the placement operation of the yarn placement mechanism can be carried out separately, which makes it possible to place and stack the reinforcing fiber yarn on the placement surface at high speed, regardless of the waiting time for the binder to be heated. [Brief description of the drawings]

[0018] [Figure 1] FIG. 1 is a perspective view of an entire fiber placement device 100 according to an embodiment of the present disclosure. [Diagram 2] 1 is a view seen in the Y-axis direction for explaining the operation of a heating mechanism 50 of a fiber placement device 100 according to an embodiment of the present disclosure. FIG. [Diagram 3] FIG. 13 is a perspective view of the entire fiber placement device 100a which is a modified example of the first embodiment. [Figure 4] FIG. 1 is a perspective view of an entire fiber placement device 100b according to an embodiment of the present disclosure. [Diagram 5] FIG. 11 is an explanatory diagram showing a heating mechanism 50b of the fiber placement device 100c as viewed along the Y-axis direction. [Figure 6] 11 is an explanatory diagram for explaining the operation of a heating mechanism 50c of a fiber placement device 100c according to an embodiment of the present disclosure. FIG. [Figure 7] 13 is an explanatory diagram showing a heating mechanism 50c of the fiber placement device 100c as viewed along the Y-axis direction. FIG. [Figure 8A] FIG. 2 is an explanatory diagram for explaining a positional relationship between a yarn placement cycle by a yarn placement mechanism and a heating region by a heating mechanism in an embodiment of the present disclosure. [Figure 8B] FIG. 2 is an explanatory diagram for explaining a positional relationship between a yarn placement cycle by a yarn placement mechanism and a heating region by a heating mechanism in an embodiment of the present disclosure. [Figure 8C] FIG. 2 is an explanatory diagram for explaining a positional relationship between a yarn placement cycle by a yarn placement mechanism and a heating region by a heating mechanism in an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] A. First embodiment: A. Configuration and operation of the first embodiment: Hereinafter, specific embodiments of the present disclosure will be described with reference to the drawings. Note that the following description is for the purpose of facilitating understanding of the present disclosure and does not limit the present disclosure in any way. However, in order to be easily understood by those skilled in the art, references to preferred aspects and variations in each embodiment can also be interpreted as descriptions of a fiber placement device as a generic concept of the present disclosure.

[0020] The fiber placement device according to the present disclosure is a fiber placement device including at least a placement surface on which reinforcing fiber yarns are placed and layered, a yarn placement mechanism that presses and places the reinforcing fiber yarns on the placement surface, and a heating mechanism that partially heats the placement surface, and is capable of repeatedly performing a placement cycle in which the yarn placement mechanism is moved to a predetermined position, the reinforcing fiber yarns are pressed from the yarn placement mechanism toward the placement surface that has been preheated by the heating mechanism, the yarn placement mechanism is moved a predetermined length in a first axial direction, the reinforcing fiber yarns are adhered and fixed onto the placement surface, and the placement surface is moved in a second axial direction perpendicular to the first axial direction, and the heating mechanism is configured to be movable relative to the placement surface along the second axial direction, and the fiber placement device is characterized in that the heating mechanism is moved above a region where the reinforcing fiber yarns are placed in the n-th placement cycle by the time an (n-1)th placement cycle (n is a natural number of 2 or more) is completed, and the region is preheated.

[0021] Fig. 1 shows an overall perspective view of a fiber placement device 100 according to an embodiment of the present disclosure. Fig. 2 shows the heating mechanism 50 and the yarn placement mechanism 20 as viewed from the Y-axis + (plus) side of Fig. 1. Fig. 2 shows the positional relationship between the heating mechanism 50 and the yarn placement mechanism 20 of the fiber placement device 100 shown in Fig. 1. Note that the embodiment of the fiber placement device 100 shown in Figs. 1 and 2 is just an example, and the configuration of the fiber placement device in the present disclosure is not limited to each embodiment.

[0022] In this embodiment, the fiber placement device 100 comprises: a placement table 10 having a placement surface 10s for placing and stacking the reinforcing fiber thread 1; a thread placement mechanism 20 capable of pressing and placing the reinforcing fiber thread 1 against the placement surface 10s; a thread cutting mechanism 40 that is positioned independently of the thread placement mechanism 20 and cuts the reinforcing fiber thread 1 by pressing the reinforcing fiber thread 1 against a cutting edge by a thread pressing mechanism 21 provided inside the thread placement mechanism 20; a heating mechanism 50 that is positioned independently of the thread placement mechanism 20 and the thread cutting mechanism 40 and is capable of heating the placement surface 10s; and a control unit 60 that supervises the state of each of the above-mentioned mechanisms and controls the operation of each device according to a program provided by the user to place and stack the reinforcing fiber thread 1 on the placement surface 10s in the desired shape.

[0023] In the present disclosure, the fiber placement device 100 repeatedly performs the placement cycle described below. First, the fiber placement device 100 moves the thread placement mechanism 20 to a predetermined position. Specifically, the thread placement mechanism 20 is moved onto the placement surface 10s that has been preheated by the heating mechanism 50. The fiber placement device 100 presses the reinforcing fiber thread 1 unwound from the thread placement mechanism 20 onto the placement surface 10s, and then moves the thread placement mechanism 20 a predetermined length in a first axial direction (Y-axis direction in FIG. 1). After the reinforcing fiber thread 1 is fixed by being adhered onto the placement surface 10s, the fiber placement device 100 moves the placement table 10 in a second axial direction (X-axis direction in FIG. 1) perpendicular to the first axial direction. The fiber placement device 100 repeatedly performs the placement cycle described above. A specific configuration and operation of the fiber placement device 100 will be described below.

[0024] The reinforcing fiber thread 1 is a unidirectional fiber substrate containing at least reinforcing fibers and a resin component that exhibits adhesiveness when heated. The material and form of the reinforcing fiber thread 1 can be selected in various ways according to the handling during work and the required characteristics after molding. For example, the reinforcing fiber material can be carbon fiber, glass fiber, aramid, Kevlar, natural fiber, etc. The resin component material can be thermosetting epoxy or phenolic resin, or thermoplastic polyamide, polyether ether ketone, polyether ketone ketone, or polyether sulfone. The mixed state of the resin component with respect to the reinforcing fiber is not particularly limited. The inside of the reinforcing fiber bundle may be impregnated with a liquid resin component. The resin component may be applied in a thin film on the surface of the bundle. The powdered resin component may be attached to the surface of the bundle.

[0025] The placement table 10 has a placement surface 10s on which the reinforcing fiber yarns 1 are placed and layered. The placement table 10 is configured so as to be able to move relative to the yarn placement mechanism 20 in the X-axis direction.

[0026] Specifically, the placement table 10 has a placement surface 10s for arranging and arranging the reinforcing fiber yarns 1 into a desired peripheral shape. The placement table 10 has a placement surface moving mechanism 13. After the reinforcing fiber yarns 1 are placed on the placement surface 10s by the yarn placement mechanism 20 in the above-mentioned placement cycle, the placement surface moving mechanism 13 moves the placement table 10 in the X-axis direction relative to the yarn placement mechanism. Furthermore, in the case where the reinforcing fiber yarns 1 are placed and stacked on top of the reinforcing fiber yarns 1 in the desired peripheral shape, the placement cycle for the second layer and subsequent layers is performed by regarding the reinforcing fiber yarns 1 of the first layer as the placement surface 10s.

[0027] In the placement cycle, the placement table 10, the yarn placement mechanism 20, and the heating mechanism 50 may be configured to be relatively movable in the X-axis direction. Therefore, the placement surface moving mechanism 13 does not necessarily need to be provided on the placement table 10, and for example, the placement table 10 may be fixed, and the yarn placement mechanism 20, the yarn cutting mechanism 40, and the heating mechanism 50 may each be movable in the X-axis direction.

[0028] The yarn arrangement mechanism 20 can pay out the reinforcing fiber yarn 1 while pressing it against the arrangement surface 10s, and arrange the reinforcing fiber yarn 1 on the arrangement surface 10s along the Y-axis direction. The yarn arrangement mechanism 20 is configured to be movable relative to the arrangement table 10 in the X-axis direction.

[0029] Specifically, the yarn arrangement mechanism 20 is attached to a slider mechanism 22 that is movable in the Y-axis direction (see arrow Ap11 in FIG. 1). As the slider mechanism 22 moves in the negative (minus) direction of the Y-axis, the yarn arrangement mechanism 20 moves in the Y-axis direction to above a desired yarn arrangement start position. At this time, the reinforcing fiber yarn 1 passes through a nip roller 101 provided in the yarn arrangement mechanism 20 and is held by a nip section 102 also provided in the yarn arrangement mechanism 20. The tip of the reinforcing fiber yarn 1 is guided to the bottom of the yarn pressing mechanism 21 by a final guide 23 provided in the yarn arrangement mechanism 20. Therefore, as the yarn arrangement mechanism 20 moves in the negative (minus) direction of the Y-axis, the reinforcing fiber yarn 1 is pulled out from a yarn payout section (not shown) upstream by an amount required for arrangement in the arrangement cycle.

[0030] Thereafter, the yarn pressing mechanism 21 descends in the negative (negative) direction of the Z axis and approaches the arrangement surface 10s, so that the end of the reinforcing fiber yarn 1 is pressed against the yarn arrangement start position on the arrangement surface 10s (see arrow Ap12 in FIG. 1). At this time, the yarn arrangement start position on the arrangement surface 10s and the arrangement intended area 11 for that arrangement cycle have been preheated by the heating mechanism 50. Therefore, the resin component contained in the reinforcing fiber yarn 1 pressed against the yarn arrangement start position and the arrangement intended area 11 on the arrangement surface 10s is heated and softened, and develops adhesiveness. As a result, the reinforcing fiber yarn 1 pressed against the arrangement surface 10s is adhered and fixed to the arrangement surface 10s by the adhesiveness.

[0031] By moving the yarn arrangement mechanism 20 a predetermined distance in the + (plus) direction of the Y-axis by the slider mechanism 22, the reinforcing fiber yarn 1 that has been pulled out from the yarn payout section is pressed against the arrangement surface 10s in sequence, and is adhered and fixed on the arrangement surface 10s (see arrow Ap11 in FIG. 1). At this time, the arrangement region 11 in which the reinforcing fiber yarn 1 is to be arranged has already been heated by the heating mechanism 50 as described above. Therefore, in order to adhere the reinforcing fiber yarn 1, it is not necessary to heat the arrangement region 11 immediately before arranging the reinforcing fiber yarn 1. Therefore, even if the yarn arrangement mechanism 20 is moved at high speed, the reinforcing fiber yarn 1 can be reliably adhered and fixed on the arrangement surface 10s.

[0032] The yarn cutting mechanism 40 includes a cutting blade 42 that cuts the reinforcing fiber yarn 1. The yarn cutting mechanism 40 is configured to be movable in the Y-axis direction and the Z-axis direction (see arrows Ap13 and Ap14 in FIG. 1).

[0033] After the reinforcing fiber yarn 1 is arranged and fixed on the arrangement surface 10s along the Y-axis direction (see arrow Ap11 in FIG. 1), the reinforcing fiber yarn 1 is cut by a cutting blade 42 of a yarn cutting mechanism 40 attached to a slider mechanism 41. The slider mechanism 41 is configured to be movable in the Y-axis direction independently of the slider mechanism 22 (see arrow Ap13 in FIG. 1). The yarn pressing mechanism 21 and the yarn cutting mechanism 40 rise in the + (plus) direction of the Z-axis and retreat from the arrangement surface 10s (see arrows Ap12 and A14 in FIG. 1). Thereafter, the arrangement table 10 is moved in the + (plus) direction of the X-axis along the arrangement surface moving mechanism 13 (see arrow Ap2 in FIG. 1).

[0034] The above-mentioned operations are called a series of “placement cycles.” By repeating these operations, the fiber placement device 100 can place the reinforcing fiber threads 1 in a desired two-dimensional shape on the placement surface 10s.

[0035] The heating mechanism 50 can heat a partial region of the placement surface 10s. The heating mechanism 50 is configured to be movable in the X-axis direction relative to the placement table 10. Specifically, the heating mechanism 50 is configured to be movable along a second axis direction (the X-axis direction in FIG. 1) relative to the placement surface 10s of the placement table 10. The heating mechanism 50 includes a movement mechanism 51, a temperature measurement unit 52, a heater 53, and a heater housing 54.

[0036] The heating method of the heater 53 of the heating mechanism 50 can be freely selected as long as it is a method that can heat the heating object without contacting it, such as a convection heating method using hot air, a radiation heating method using infrared rays, a lamp, a laser, etc. In this embodiment, from the viewpoints of the heating output per unit area of ​​the object (hereinafter referred to as the output density), the device cost, and the ease of output control, the heating method of the heater 53 of the heating mechanism 50 is radiation heating using infrared rays.

[0037] The higher the power density of the heating mechanism 50, the faster the placement cycle. On the other hand, a heater with a high power density also leads to an increase in the manufacturing cost of the fiber placement device 100. For this reason, the power density of the heater 53 of the heating mechanism 50 is set to 1 W / mm 2 The power density is preferably 1 W / mm 2 The following heaters 53 are readily available:

[0038] The heater housing 54 that holds the heater 53 is preferably structured to reflect infrared rays emitted from the heating mechanism 50 and radiate them in only one direction. By adopting such a configuration, it is possible to increase the output density of the heating mechanism 50. For example, the cross-sectional shape of the heater housing 54 may be an arch shape that heats only the area directly below it.

[0039] The moving mechanism 51 holds the heating mechanism 50 and moves it to a desired position on the arrangement surface 10s. The moving mechanism 51 can move the heating mechanism 50 in the X-axis direction relative to the arrangement surface 10s, independently of the yarn arrangement mechanism 20. This allows fine adjustment of the area to be heated in the X-axis direction.

[0040] The type of the moving mechanism 51 can be freely selected from a robot arm, a gantry crane, a parallel link, and the like. The moving mechanism 51 may be, for example, a slider mechanism extending from the slider mechanism 22 for moving the yarn placement mechanism 20. In addition, it is preferable that the moving mechanism 51 has sufficient support rigidity in consideration of the weight and inertia of the heating mechanism 50. By adopting such an embodiment, the heater 53 can be reliably placed in the intended placement area on the placement surface 10s in the next placement cycle.

[0041] The temperature measuring unit 52 measures the temperature of the placement surface 10s heated by the heater 53. In FIG. 2, an arrow As is shown pointing from the temperature measuring unit 52 to the placement surface 10s whose temperature is measured by the temperature measuring unit 52. The temperature measuring unit 52 is preferably capable of measuring the temperature of the placement surface 10s without contacting the placement surface 10s. Examples of such a method include infrared radiation temperature measurement, thermography, and optical measurement. The temperature measuring unit 52 is preferably capable of measuring a temperature range of 0°C to 500°C according to the temperature range to which the placement surface 10s can be heated. Furthermore, it is preferable that the response speed of the temperature measurement is high so that the temperature of the placement surface 10s can be appropriately managed even when the output density of the heater 53 is high. Specifically, the response speed is preferably 0.0001 to 1 second.

[0042] The control unit 60 controls the fiber placement device 100. The control unit 60 is a computer including a CPU, which is a processor, a RAM, and a ROM. The RAM includes a main memory and an auxiliary storage device. The CPU of the control unit 60 loads a computer program stored in the auxiliary storage device into the main memory and executes it to operate the fiber placement device 100.

[0043] The control unit 60 can repeatedly carry out the above-mentioned arrangement cycle. The arrangement cycle includes a first process and a second process. The first process is a process in which the yarn arrangement mechanism 20 arranges the reinforcing fiber yarn 1 on the arrangement surface 10s at a predetermined length along the Y-axis direction (see arrow Ap11 in FIG. 1). The second process is a process in which the arrangement table 10 is moved in the X-axis direction relative to the yarn arrangement mechanism 20 (see arrow Ap22 in FIG. 1). The control unit 60 causes the heating mechanism 50 to heat the arrangement region 12 in which the reinforcing fiber yarn 1 is to be arranged in the n-th arrangement cycle until the (n-1)-th arrangement cycle is completed.

[0044] Specifically, the control unit 60 moves the heating mechanism 50 above the area where the reinforcing fiber yarn 1 is placed in the nth placement cycle by the time the (n-1)th (n is a natural number greater than or equal to 2) placement cycle is completed, and heats the area facing the heating mechanism 50.

[0045] More specifically, the following process is executed. The moving mechanism 51 included in the heating mechanism 50 is movable in the X-axis direction independently of the slider mechanisms 22, 41. As a result, the heating mechanism 50 is movable in the X-axis direction relative to the yarn arrangement mechanism 20. The heating mechanism 50 is controlled to be located on the negative (-) side in the X-axis direction relative to the yarn pressing mechanism 21 included in the yarn arrangement mechanism 20. The temperature measurement unit 52 measures the temperature of the area on the arrangement surface 10s heated by the heating mechanism 50.

[0046] During or before the yarn arrangement mechanism 20 performs an arrangement cycle for arranging the reinforcing fiber yarn 1 in the arrangement region 11, the heating mechanism 50 moves above the arrangement region 12 in which the reinforcing fiber yarn 1 is to be arranged next after the arrangement region 11, and preheats the arrangement region 12. When the arrangement cycle for the arrangement region 11 is completed and the arrangement cycle for the arrangement region 12 is started, the arrangement region 12 has been heated to a predetermined temperature. Therefore, it is possible to start the arrangement cycle for the arrangement region 12 without waiting for the temperature of the arrangement region 12 to rise.

[0047] Thereafter, the above-mentioned arrangement cycle is repeated until the reinforcing fiber yarns are arranged so as to form a two-dimensional shape having the desired outer peripheral shape input to the control unit 60. As a result, a prototype of a reinforcing fiber sheet is formed in which a plurality of reinforcing fiber yarns 1 extending in the X-axis direction are aligned in the Y-axis direction.

[0048] In a conventional fiber placement device, the heating mechanism is mounted on the yarn placement mechanism. The heating mechanism is configured to heat the yarn pressing mechanism, the reinforcing fiber yarn guided to the yarn pressing mechanism, and a part of the placement surface on the moving direction of the yarn placement mechanism. In such an embodiment, heating for attaching the reinforcing fiber yarn to the placement surface is performed during the placement cycle for the region. Therefore, at the start of the placement operation, an initial heating waiting time is required to heat the placement surface so that the end of the reinforcing fiber yarn can be attached to the placement surface. In addition, during the placement operation, a continuous heating waiting time is required to heat the placement surface prior to the placement of the reinforcing fiber yarn. For this reason, when placing the reinforcing fiber yarn, the slider mechanism that moves the yarn placement mechanism can only move at a low speed in order to accommodate the continuous heating waiting time. In addition, in the initial stage of placement of the reinforcing fiber yarn, the slider mechanism needs to start moving at a very low speed in order to accommodate the initial heating waiting time. As a result, the tact time required for the placement cycle increases.

[0049] On the other hand, in the fiber placement device 100 according to the present disclosure, the planned placement area of ​​the reinforcing fiber yarn in the placement cycle is preheated in the immediately preceding placement cycle, so that the reinforcing fiber yarn can be placed without the above-mentioned initial heating waiting time and continuous heating waiting time, thereby making it possible to speed up the placement cycle.

[0050] In order to speed up the placement cycle, it is preferable that the entire area where the reinforcing fiber yarn is placed in the nth placement cycle is pre-heated by a heating mechanism 50 moved to the area where the reinforcing fiber yarn is placed in the nth placement cycle.

[0051] Specifically, it is preferable that the area in which the heating mechanism 50 can simultaneously heat the placement surface 10s can include an area defined by the width and length of the reinforcing fiber yarn that the yarn placement mechanism 20 can place on the placement surface 10s in one placement cycle. In this specification, the maximum width of the reinforcing fiber yarn that the yarn placement mechanism 20 can place on the placement surface 10s in one placement cycle is referred to as the "maximum placement width." The maximum length of the reinforcing fiber yarn that the yarn placement mechanism 20 can place on the placement surface 10s in one placement cycle is referred to as the "maximum placement length." The area in which the heating mechanism 50 can simultaneously heat the placement surface 10s is referred to as the "heatable area."

[0052] It is more preferable that the Y-axis dimension of the heatable area is equal to the maximum arrangement length. It is preferable that the X-axis dimension of the heatable area is about 1 to 10 times the maximum arrangement width. In such an embodiment, in addition to the arrangement planned area in the arrangement cycle next to the currently executed arrangement cycle, the arrangement planned area in the subsequent arrangement cycle can be heated. However, enlarging the heatable area increases the cost of the fiber placement device and makes it difficult to lay out the components other than the heating mechanism in the fiber placement device. For this reason, it is more preferable that the X-axis dimension of the heatable area is 5 times or less the maximum arrangement width.

[0053] Furthermore, it is preferable that the heating mechanism 50 preheats the region where the reinforcing fiber yarn 1 in the n-th arrangement cycle is to be arranged during the (n-1)-th arrangement cycle. Specifically, it is preferable that the heating mechanism 50 heats the next arrangement region 12 at least while the yarn arrangement mechanism 20 is performing an arrangement cycle for the arrangement region 11. By adopting such an embodiment, the time from heating to the arrangement of the reinforcing fiber yarn 1 can be shortened. Therefore, the energy utilization efficiency can be improved. As a result, the cost required for the arrangement of the reinforcing fiber yarn can be reduced.

[0054] In a mode in which the heating of the intended arrangement region 12 is completed before the implementation of the arrangement cycle in the intended arrangement region 11 and the heating of the intended arrangement region 12 is not performed during the implementation of the arrangement cycle in the intended arrangement region 11, the following problem occurs. The heat given to the intended arrangement region 12 is dissipated by thermal conduction into the arrangement surface 10s and by convection and radiation to the surrounding environment. Although the amount of heat dissipation varies depending on the temperature difference with the surroundings and the heat capacity and thermal conductivity of the arrangement surface 10s, in any mode, a part of the energy required for heating is lost by heat dissipation. In order to reduce the cost required for the arrangement of the reinforcing fiber yarn, it is preferable to use the energy required for heating to melt the binder with high efficiency. Therefore, it is preferable to heat the intended arrangement region 12 until the implementation of the arrangement cycle in the immediately preceding intended arrangement region 11.

[0055] A2. Modification of the first embodiment: 3 is a perspective view of the entire fiber placement device 100a which is a modification of the first embodiment. The fiber placement device 100a of this modification includes a heating mechanism 50a instead of the heating mechanism 50 included in the fiber placement device 100 of the first embodiment. Other points of the hardware configuration of the fiber placement device 100a are the same as those of the fiber placement device 100.

[0056] The heating mechanism 50a includes eight heating devices 501-508 arranged along the Y-axis direction. Each of the heating devices 501-508 includes a heater 53. Each of the heating devices 501-508 includes a temperature measuring unit 52, and can feedback-control the temperature of the heating target. Each of the heating devices 501-508 can be controlled independently. Specifically, the on / off and output of the heating devices 501-508 can be controlled independently.

[0057] The control unit 60 sets the temperature of the heating device that heats the region where the reinforcing fiber thread 1 is placed last in the n-th arrangement cycle among the heating devices 501-508 to be higher than the temperature of the heating device that heats the region where the reinforcing fiber thread 1 is placed first in the n-th arrangement cycle among the heating devices 501-508. More specifically, the set temperature of the heating device that heats the region where the reinforcing fiber thread 1 is placed first is set to the lowest among the heating devices 501-508. The set temperature of the heating device that heats the region where the reinforcing fiber thread 1 is placed last is set to the lowest among the heating devices 501-508. The set temperature of each heating device located between these two heating devices is set higher the closer it is to the heating device that heats the region where the reinforcing fiber thread 1 is placed last. In the example of FIG. 3, the heating device that heats the region where the reinforcing fiber thread 1 is placed first is the heating device 503, and the heating device that heats the region where the reinforcing fiber thread 1 is placed last is the heating device 508.

[0058] The shape of the reinforcing fiber sheet formed by the fiber placement device is close to the final shape of the product, and therefore the length of the reinforcing fiber yarns arranged in each arrangement cycle often differs. Hereinafter, the length of the reinforcing fiber yarns arranged in the Y-axis direction is also referred to as the "arrangement length." In the Y-axis direction, it is preferable to heat the parts where the reinforcing fiber yarns are arranged, while not heating the parts where the reinforcing fiber yarns are arranged. According to this modified example, such heating can be realized.

[0059] In this modification, the heating mechanism 50a includes eight heating devices 501 to 508. However, the number of heating devices included in the heating mechanism may be other numbers. However, the number of heating devices included in the heating mechanism is preferably 2 to 10.

[0060] In this modified example, the control unit 60 performs heating so that the output density of each heating device increases in order along the direction from - to + on the Y axis, as described above.

[0061] Of the two ends of the arrangement area 12 in the Y-axis direction, the closer the area is to the + end, the longer the time from when the heating mechanism 50a finishes heating until the reinforcing fiber yarn is arranged. Therefore, the closer the area is to the + end in the Y-axis direction, the greater the amount of heat dissipation, and the temperature at the time the reinforcing fiber yarn is arranged is significantly lower than when it is heated. By setting the output density of the multiple heating devices as described above, a temperature gradient that takes heat dissipation into consideration can be applied to the arrangement area. As a result, the reinforcing fiber yarn can be arranged in a state where each arrangement area is at an optimal temperature. In addition, excessive heating is not performed in the area close to the - end of the two ends of the arrangement area 12 in the Y-axis direction, so that unnecessary energy consumption can be avoided.

[0062] In this embodiment, the Y-axis direction is also referred to as the "first direction," and the X-axis direction is also referred to as the "second direction."

[0063] B. Second embodiment: A perspective view of a fiber placement device 100b as an embodiment different from the fiber placement device 100 according to the first embodiment is shown in Fig. 4. Moreover, a state in which a heating mechanism 50b of the fiber placement device 100b is viewed along the Y-axis direction is shown in Fig. 5.

[0064] The fiber placement device 100b includes a yarn placement mechanism 20b instead of the yarn placement mechanism 20 included in the fiber placement device 100 of the first embodiment. The fiber placement device 100b includes a heating mechanism 50b instead of the heating mechanism 50 included in the fiber placement device 100. Other points of the fiber placement device 100b are the same as those of the fiber placement device 100 of the first embodiment.

[0065] The yarn placement mechanism 20b has the same configuration as the yarn placement mechanism 20 of the first embodiment, except that a heating mechanism 50b is attached.

[0066] The heating mechanism 50b is provided in the yarn arrangement mechanism 20b. When the yarn arrangement mechanism 20b is moved in the Y-axis direction by the slider mechanism 22, the heating mechanism 50b is moved in the Y-axis direction together with the yarn arrangement mechanism 20b. In this embodiment, the size of the heating mechanism 50b in the Y-axis direction is smaller than that of the heating mechanism 50 in the first embodiment so as not to interfere with the operation of the yarn arrangement mechanism 20b. Therefore, the size of the area on the arrangement surface 10s that can be heated by the heating mechanism 50b in the Y-axis direction is shorter than the maximum arrangement length. The heating mechanism 50b is configured to heat a part of the arrangement surface 10s on the +Y-axis direction side and a part of the arrangement surface 10s on the -X-axis direction side as viewed from the yarn pressing mechanism 21.

[0067] The heating mechanism 50b heats the arrangement surface 10s directly below the heating mechanism 50b while the yarn arrangement mechanism 20 is moving in the Y-axis direction in the above-mentioned arrangement cycle. The arrangement surface 10s directly below the heating mechanism 50b is a planned arrangement area on the negative side in the X-axis direction with respect to the currently arranged reinforcing fiber yarn 1, and is a planned arrangement area in the next arrangement cycle.

[0068] In this embodiment, the heating mechanism 50b is made smaller, and the cost of the device and the running cost can be reduced. In addition, even if the placement surface 10s has a three-dimensional shape, the next placement area can be heated. Therefore, this is suitable as a device for manufacturing small parts with complex shapes.

[0069] C. Third embodiment: A perspective view of a fiber placement device 100c as yet another embodiment is shown in Fig. 6. Moreover, a heating mechanism 50c of the fiber placement device 100c is shown in Fig. 7 as viewed along the Y-axis direction.

[0070] The fiber placement device 100c includes a heating mechanism 50c instead of the heating mechanism 50 included in the fiber placement device 100 of the first embodiment. Other points of the fiber placement device 100c are the same as those of the fiber placement device 100 of the first embodiment.

[0071] The heating mechanism 50c is provided over the entire length of the arrangement surface 10s in the Y-axis direction. The heating mechanism 50c is attached to the slider mechanism 22. The distance in the X-axis direction between the heating mechanism 50c and the yarn arrangement mechanism 20 is constant. Therefore, in this fiber placement device 100c, the heating mechanism 50c heats the area where the reinforcing fiber yarn is arranged a certain number of cycles (for example, 1 to 5 cycles) after the area arranged by the yarn arrangement mechanism 20 in a certain arrangement cycle. The fiber placement device 100c does not include the movement mechanism 51 of the fiber placement device 100. Therefore, the cost of the fiber placement device 100c is low.

[0072] In addition, as long as the heating mechanism 50c is independently movable with respect to the placement surface 10s, the object to which the heating mechanism 50c is fixed is not limited to the slider mechanism 22. The heating mechanism 50c may be fixed, for example, to a frame member that supports the slider mechanism 22 or other members via a bracket.

[0073] D. Relationship between planned placement area and heating area: 8A to 8C are explanatory diagrams showing heating regions. In all of the examples shown in Fig. 8A to 8C, a reinforcing fiber yarn 1 is arranged on an arrangement surface 10s, and an arrangement cycle is repeated to further stack the reinforcing fiber yarns. The lower part of Fig. 8A to 8C shows numbers 1 to (n+3) indicating the order of arrangement cycles for arranging the reinforcing fiber yarns that form the first layer. All of Fig. 8A to 8C show a state in the middle of the (n-1)th arrangement cycle (n is any integer equal to or greater than 2).

[0074] In FIGS. 8A to 8C, the region 14 surrounded by the thick dashed line is the region where the reinforcing fiber yarn 1 is to be arranged. In FIGS. 8A to 8C, the hatched region is the region where the reinforcing fiber yarn 1 has already been arranged. In FIGS. 8A to 8C, the region 15 surrounded by the thin dashed line is the region where the reinforcing fiber yarn 1 is to be arranged in the placement cycles after the nth cycle. In FIGS. 8A to 8C, the regions with a checkered pattern are the heating regions 16, 17, 18 that are heated when the (n - 1)th (n is an arbitrary integer of 2 or more) placement cycle is performed.

[0075] At any point until the completion of the (n - 1)th placement cycle, at least a part of the planned placement region 15 of the reinforcing fiber yarn in the placement cycles after the nth cycle is heated.

[0076] In the present disclosure, it is sufficient that a part of the planned placement region 15 of the placement cycles after the nth cycle is heated during the (n - k)th (k is a natural number satisfying k < n) placement cycle. In the example of FIG. 8A, the heating region 16 in the (n - 1)th placement cycle is configured to straddle a part of the planned placement regions from the (n + 1)th to the (n + 3)th cycles, respectively.

[0077] In order to speed up the placement cycle, it is preferable to preheat the entire planned placement region. In the example of FIG. 8B, the heating region 17 in the (n - 1)th placement cycle is the entire planned placement regions from the (n + 1)th to the (n + 3)th cycles.

[0078] In order to reduce the energy loss due to heat dissipation from the preheated region, it is preferable to heat the planned placement region of the reinforcing fiber yarn in the next placement cycle. In the example of FIG. 8C, the heating region 18 in the (n - 1)th placement cycle is the entire planned placement regions from the nth to the (n + 2)th cycles.

[0079] E. Other Embodiments: E1. Other Embodiment 1: In the first embodiment, the entire arrangement region 12 in which the reinforcing fiber yarn 1 is to be arranged in the n-th arrangement cycle is heated simultaneously by the heating mechanism 50. However, the region in which the reinforcing fiber yarn is to be arranged in the n-th arrangement cycle may be heated by multiple heat treatments.

[0080] E2. Alternative embodiment 2: In the first and third embodiments, the control unit 60 causes the heating mechanism 50 to heat all the regions in which the reinforcing fiber threads 1 are arranged in the n-th arrangement cycle until the (n-1)-th arrangement cycle is completed (see also Figs. 8B and 8C). However, as shown in the example of Fig. 8A, it is also possible to have a mode in which a part of the regions in which the reinforcing fiber threads 1 are arranged in the n-th arrangement cycle is heated by the heating mechanism 50 until the (n-1)-th arrangement cycle is completed.

[0081] It is preferable that the heating of the region where the reinforcing fiber thread 1 is initially placed in the n-th placement cycle is completed by the time the (n-1)-th placement cycle is completed. That is, it is preferable that the temperature of the region where the reinforcing fiber thread 1 is initially placed in the n-th placement cycle is raised to the target temperature by the time the n-th placement cycle is started.

[0082] E3. Alternative embodiment 3: 8C, the control unit 60 causes the heating mechanism 50 to heat the region where the reinforcing fiber thread 1 is placed in the nth placing cycle during the period when the (n-1)th placing cycle is being executed. However, the control unit 60 may also cause the heating mechanism 50 to heat the region where the reinforcing fiber thread 1 is placed in a placing cycle after the nth placing cycle during the period when the (n-1)th placing cycle is being executed.

[0083] E4. Alternative embodiment 4: In a modification of the first embodiment, the heating mechanism 50a includes a plurality of heating devices 501-508 arranged along the Y-axis direction, each of which can be controlled independently. The control unit 60 sets the temperature of the heating device 508, which heats the region where the reinforcing fiber thread 1 is placed last in the n-th arrangement cycle, among the plurality of heating devices 501-508, higher than the temperature of the heating device 503, which heats the region where the reinforcing fiber thread 1 is placed first. However, the regions where the reinforcing fiber thread 1 is placed in the n-th arrangement cycle may all be heated to the same target temperature.

[0084] The present disclosure is not limited to the above-mentioned embodiment, and can be realized in various configurations without departing from the spirit of the present disclosure. For example, the technical features of the embodiments corresponding to the technical features in each aspect described in the Summary of the Invention can be appropriately replaced or combined to solve some or all of the above-mentioned problems or to achieve some or all of the above-mentioned effects. Furthermore, if a technical feature is not described as essential in this specification, it can be appropriately deleted. [Explanation of symbols]

[0085] 1...Reinforced fiber yarn 2…Reinforced fiber 3. Resin component 10...Placement stand 10s…Placement surface 11... Area in which reinforcing fiber yarn is to be arranged in the arrangement cycle 12... Planned area for placement of reinforcing fiber yarn in the next placement cycle 13…Placement surface movement mechanism 14...Area having a desired two-dimensional shape 15... Planned area of ​​reinforcing fiber yarn in nth placement cycle 16...Heating area 17...Heating area 18...Heating area 20...Yarn arrangement mechanism 20b…Yarn arrangement mechanism 21... Yarn pressing mechanism 22...Slider mechanism 23…Final Guide 40... Yarn cutting mechanism 41...Slider mechanism 42…Cutting edge 50...Heating mechanism 50a...Heating mechanism 50b…Heating mechanism 50c...Heating mechanism 51...Movement mechanism 52...Temperature measurement section 53…Heater 54…Heater housing 60...Control unit 100...Fiber placement device 100a...Fiber placement device 100b...Fiber placement device 100c…Fiber placement device 101...Nip roller 102…Nip section 501~508…Heating device Ap11: Arrow indicating the direction of operation of the yarn arrangement mechanism 20 in the first process Ap22: Arrow indicating the direction of movement of the placement table 10 in the second process

Claims

1. 1. A fiber placement device, comprising: A placement table having a placement surface on which the reinforcing fiber yarns are placed and stacked; a yarn arrangement mechanism that can arrange the reinforcing fiber yarn on the arrangement surface along a first direction by unwinding the reinforcing fiber yarn while pressing the reinforcing fiber yarn against the arrangement surface; A heating mechanism capable of heating a partial area of ​​the placement surface; A control unit that controls the fiber placement device, The placement table and the yarn placement mechanism are configured to be relatively movable in a second direction intersecting the first direction, The placement table and the heating mechanism are configured to be relatively movable in the second direction, The control unit can repeatedly perform the arrangement cycle, The arrangement cycle is A first process of arranging the reinforcing fiber yarn on the arrangement surface by the yarn arrangement mechanism along the first direction at a predetermined length; and a second process of moving the placement table relative to the yarn placement mechanism in the second direction, The heating mechanism is movable relative to the placement table independently of the yarn placement mechanism; The control unit causes the heating mechanism to heat at least a portion of the region where the reinforcing fiber yarn is placed in the n-th placement cycle by the time the (n-1)-th placement cycle (n is a natural number of 2 or more) is completed.

2. 2. The fiber placement device of claim 1, The control unit causes the heating mechanism to heat all areas in which the reinforcing fiber yarn is placed in the n-th placement cycle by the time the (n-1)-th placement cycle is completed.

3. 3. The fiber placement device according to claim 1, The control unit causes the heating mechanism to heat at least a portion of an area where the reinforcing fiber yarn is placed in the n-th placement cycle during a period in which the (n-1)-th placement cycle is executed.

4. 1. A fiber placement device, comprising: A placement table having a placement surface on which the reinforcing fiber yarns are placed and stacked; a yarn arrangement mechanism that can arrange the reinforcing fiber yarn on the arrangement surface along a first direction by unwinding the reinforcing fiber yarn while pressing the reinforcing fiber yarn against the arrangement surface; A heating mechanism capable of heating a partial area of ​​the placement surface; A control unit that controls the fiber placement device, The placement table and the yarn placement mechanism are configured to be relatively movable in a second direction intersecting the first direction, The placement table and the heating mechanism are configured to be relatively movable in the second direction, The control unit can repeatedly perform the arrangement cycle, The arrangement cycle is A first process of arranging the reinforcing fiber yarn on the arrangement surface by the yarn arrangement mechanism along the first direction at a predetermined length; and a second process of moving the placement table relative to the yarn placement mechanism in the second direction, The control unit causes the heating mechanism to heat at least a part of the region in which the reinforcing fiber yarn is placed in the n-th placement cycle by the time the (n-1)-th placement cycle (n is a natural number of 2 or more) is completed, the heating mechanism includes a plurality of heating devices arranged along the first direction, each of which can be independently controlled; the control unit sets the temperature of a heating device, among the plurality of heating devices, that heats a region where the reinforcing fiber yarn is placed last in an n-th placement cycle, to be higher than the temperature of a heating device, among the plurality of heating devices, that heats a region where the reinforcing fiber yarn is placed first in an n-th placement cycle.

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