Continuous Fiber Preform Shaping to Prevent Wrinkles
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Solution Overview
Problem
Existing systems for forming fiber semi-finished products often result in wrinkling, undulation, and non-parallelism, leading to inhomogeneities and undesirable weakening of the workpiece, particularly during continuous or quasi-endless processing.
Innovation Solution
A forming device with hold-down devices and forming tools that provide support and restrict the movement of the fiber semi-finished product, using guide surfaces and contact surfaces to prevent wrinkling and ensure continuous formation without interruptions, allowing for the production of fiber semi-finished products with defined shapes such as L, U, Z, or omega profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the fiber semi-finished product is pushed through the forming device using conventional rollers, then the material can be continuously processed, but the material wrinkles and creases during forming
Solution Approach 1:
Instead of pushing the material through the forming section as in conventional devices, the invention inverts the approach by having the material pulled through the forming section by a pulling device located downstream. This reversal of the force direction eliminates the pushing action that causes wrinkling and creasing, while maintaining continuous processing capability.
Solution Approach 2:
The invention introduces a pulling device as an intermediary element that mediates the material transport through the forming section. This pulling device, positioned downstream, provides a controlled tensile force that draws the material through the forming section without the compressive pushing forces that cause surface defects, thereby resolving the contradiction between continuous processing and surface quality.
2Shape
If the fiber semi-finished product is formed into complex profiles, then the product shape is improved, but the material becomes inhomogeneous and weakened
Solution Approach 1:
The invention applies dynamic control to the forming process by using a pulling device that can adjust the pulling force and speed. This dynamic approach allows the material to be progressively formed into complex profiles while maintaining uniform tension and preventing localized stress concentrations that would cause inhomogeneity and weakening. The continuous pulling action ensures uniform deformation throughout the material.
3Adaptability or versatility
If the material is processed in smaller sections, then the forming freedom is improved, but the processing time and effort increase
Solution Approach 1:
The invention implements continuous action by having the pulling device continuously draw the fiber semi-finished product through the forming section without interruptions. This continuous pulling process maintains constant forming freedom for complex profiles while eliminating the need to stop and reposition material sections, thereby significantly improving processing efficiency compared to section-by-section processing.
Data Source
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AI summary
The invention relates to a shaping device and a system for the continuous shaping of a semi-finished fiber product and a method for shaping a semi-finished fiber product. According to the invention, the semi-finished fiber product is supported flatly from a first side and is at least locally further restricted in its freedom of movement, for example pressed on and/or guided, on another side of the semi-finished fiber product opposite the first side. The further restriction takes place in relation to the guide surface at at least one constant location and/or area past which the semi-finished fiber product is guided, in particular by means of a gap which is stationary relative to the guide surface and through which the semi-finished fiber product is guided. For this purpose, shaping tools and guide surfaces defined thereby are used for support, and hold-down devices and their contact surfaces are used for further restriction. The further restriction is carried out in particular transversely to a feed direction of the semi-finished fiber product through the shaping device. In comparison with the prior art, the further restriction and the flat guidance result in a reduction and in particular in the prevention of the formation of undulations and wrinkles.