Continuous Fiber Application Synchronization for Automated Thermoplastic Impregnation
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Solution Overview
Problem
Existing methods for applying continuous fibers impregnated with thermoplastic materials to structurally loaded components, particularly in the automotive sector, are expensive and not suitable for automated production due to the need for manual handling and alignment of pre-cut fibers.
Innovation Solution
A method and arrangement that uses a straightening device to align and tension continuous fibers, synchronizing their speed and acceleration with the moving object, ensuring slip-free application through real-time regulation, and employing a conveying material to maintain tension and alignment, allowing for automated and reproducible application of impregnated fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If continuous fibers are cut into sections and manually handled, then the fibers can be applied to components, but the production process becomes expensive and not automated
Solution Approach 1:
The continuous fiber is impregnated with thermoplastic material in advance before application to the component. This preliminary impregnation allows the fiber to be handled as a self-contained unit during automated application, eliminating the need for manual sectioning and handling of dry fibers.
Solution Approach 2:
The invention uses continuous fiber strands that are fed continuously through the application device and onto the moving component. This continuous feed mechanism replaces discrete manual placement of fiber sections, enabling automated production while maintaining consistent fiber application quality.
2Productivity
If fibers are applied manually, then positioning can be controlled, but production speed and efficiency are reduced
Solution Approach 1:
The system uses sensors to detect the position and speed of the moving component in real-time, and this feedback is used to control the feed rate and positioning of the continuous fiber through the application device, ensuring accurate fiber placement even at high production speeds.
Solution Approach 2:
The invention replaces manual mechanical positioning with an automated system that uses controlled tension, guide rollers, and synchronization mechanisms to precisely position the continuous fiber relative to the moving component, enabling both high speed and high precision.
3Reliability
If thermoplastic material is used for impregnation, then fibers can be connected to component, but material may harden prematurely
Solution Approach 1:
The system controls the temperature of the impregnated fiber continuously during application, keeping the thermoplastic material in a softened state that allows proper bonding to the component. Temperature is raised during application to prevent premature hardening, then allowed to harden after the fiber is in place.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the efficient and reproducible application of impregnated continuous fibers to moving objects, ensuring they are applied in a tensioned state without premature hardening of the thermoplastic material, enhancing production reliability and allowing for 3D configurations, which is not achievable with traditional methods.
Implementation Method 1
a conveying material acts on the continuous fiber, via which the continuous fiber is aligned
Implementation Method 2
allow the thermoplastic material to be melted by heating and thus to be connected to the component
Data Source
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AI summary
The method involves depositing the continuous fiber (16) on a moving object (12) unidirectionally and before curing of thermoplastic material. The object is moved by a handling device and both velocity- and acceleration characteristic of the moving object is transferred to the applied continuous fiber. The continuous fiber is guided in a slip-free manner in an impregnation device (20) on a rotor. An independent claim is included for an arrangement for applying impregnation provided continuous fiber on a moving object.