A processing system for the automated manufacture of preforms

Abstract: A system (10) for the manufacture of reinforcing preforms for structural composite moulding is disclosed. The system (10) comprises two cells (C1,C2) each having a mould member (20,30) and an air supply system (40,50) and a robotic member (R) for supplying reinforcing materials to each of the mould members (20,30) and a material supply system (80) for providing reinforcing materials to said robotic member (R). The material supply system (80) includes a plurality of eyelet members (82) to reduce friction.

Description: The present invention relates to the manufacture of reinforcing preforms for structural composites, and more particularly to improving and optimizing the manufacturing process, including reducing friction in the material supply system and manufacturing preforms of various thicknesses. Methods and systems for making rigid three-dimensional reinforcement preforms used in resin transfer moulding (RTM) and structural reaction injection moulding (SRIM) processes for the manufacture of structural composites are well known. The manufacture and use of structural composite materials is becoming increasingly important today, particularly in components for the automotive industry. Structural composites are lighter in weight than conventional steel or metal components and can result in additional advantages, such as allowing fully automated, highly controllable processes, better part-to-part consistency, reduced waste or scrap, and equivalent or increased component performance. In general, the structural reinforcing preforms are made from a sprayed chopped material, such as glass and carbon fiber, which is held together by a binder and moulded into a precise form and shape. The preform in turn is then moulded into products, such as composite components (both structural and non-structural) and used in automobiles or other vehicles. The preform material is chopped and applied along with a powdered binder to a preform screen in a mould using a robotic routine. Positive air flow through the screen holds the chopped material on the screen surface. When the spraying is completed, the mould is closed and the preform is compressed to the desired thickness. Heated air is first drawn through the screen in order to melt the binder. Thereafter, cooled or ambient air is drawn through the preform setting the final shape. Once the preform is completed, it is removed from the mould and transferred to a component mould where the structural component is moulded. Although present automated preform processes and systems have been used to produce satisfactory structural composite products, a need exists to improve the processes and systems, particularly to reduce the cost, increase the output and reliability, and make components of various configurations and thicknesses. It is an object of the present invention to provide improved systems and processes for making rigid three-dimensional reinforcement preforms for resin transfer moulding (RIM) and structural reaction injection moulding (SRIM) processes for composite components and products. It is known from FR-A-2,639,867 according to the preamble of claim 1 to provide a system for the manufacture of reinforcing preforms for structural composite moulding, the system comprising a first cell including a first mould member, a second cell including a second mould member, a track member extending between said first and second cell members, a robotic member for supplying reinforcing materials to said first and second mould members, the robotic member being positioned on said track member and being adapted to move back and forth between said first and second cell members and a material supply system for providing reinforcing materials to said robotic member. According to the invention there is provided a system for the manufacture of reinforcing preforms for structural composite moulding, the system comprising a first cell including a first mould member, a second cell including a second mould member, a track member extending between said first and second cell members, a robotic member for supplying reinforcing materials to said first and second mould members, the robotic member being positioned on said track member and being adapted to move back and forth between said first and second cell members and a material supply system for providing reinforcing materials to said robotic member, wherein the material supply system comprises a plurality of eyelet members for guiding string reinforcing material to said robotic member, each of the eyelet members having a convergent divergent internal passageway which allows the string reinforcing material to be guided therethrough with minimal contact and friction and wherein a series of tubular members are used to enclose the string reinforcing material between the individual eyelets so as to allow the use of air pressure to help feed the string reinforcing material through the eyelet members, each of the tubular member being of sufficient diameter that it will not contact the string reinforcing material. Preferably, two separate arrangements of eyelet members may be provided for guiding said string reinforcing material through two separate curved path portions. The supply system may supply string reinforcing material from a bobbin to a chopper gun on the robotic member and a weight may be used to apply an appropriate tension to the string reinforcing material between the bobbin and the chopper gun. The weight may be positioned between the two separate arrangements of eyelet members. The system may further comprise a first air supply system for supplying air to said first mould member and a second air supply system for supplying air to said second mould member. The system may further comprise first and second sealing members in said first and second mould members for preventing air flow from disturbing reinforcing materials in said mould members when said mould members are being closed. The system may further comprise at least one net-edge block member positioned between upper and lower parts of the first and second mould members wherein the first sealing member is positioned between said net-edge block member and the lower parts of the first and second mould members. The system may further comprise at least one net-edge block member positioned between upper and lower parts of the first and second mould members wherein the second sealing member is positioned between said net-edge block member and said upper parts of the first and second mould members. The system may further comprise a proportional valve for regulating the supply of reinforcing materials from said robotic member. The system may further comprise a means for programming said robotic member in order to supply reinforcing material to said first and second mould members in accordance with pre-specified routines and that said means for programming comprising software for programming said robotic member is off-line from said first and second mould members. Preferably, said software may comprise a ROBCAD system. The invention will now be described by way of example with reference to the accompanying drawing of which:- FIGURE 1 is a perspective schematic drawing of a multiple cell system for manufacturing reinforcing preforms according to the invention; FIGURE 2 is a schematic diagram of a system for reducing friction in the supply of string reinforcing materials to the applicator equipment; FIGURE 3 is an enlarged view of an eyelet used in the system for transferring reinforcing materials to the application equipment; FIGURE 4 is a partial cross-sectional diagram illustrating the mould for consolidating the preform in an open position; FIGURE 5 illustrates the mould as shown in Figure 4, but in a closed position; FIGURE 6 illustrates the moulding of a reinforcing preform with varying thickness; and FIGURE 7 is a schematic diagram of a system for varying the air flow to air ejectors used to remove items from the moulds. A system for the manufacture of a reinforcing preform is shown schematically in Figure 1 and referred to generally by the reference numeral 10. The system 10 consists of two cells C1 and C2, each of which is utilised to make a separate preform product. The cell C1 includes a two-piece mould which includes an upper mould portion 22 and a lower mould portion 24. Each of the mould portions includes a screen member provided in the precise shape of the upper or lower surface of the preform. The upper mould portion 22 is positioned on a moveable frame member 26 which is moveable along a set of tracks 28. Similarly, the mould of cell C2 includes an upper mould portion 32 and a lower mould portion 34 each of which has screen members. The upper mould portion 32 is positioned in a moveable frame member 36 which is moveable along a set of tracks 38. Each of the cells C1 and C2 has a separate suction fan F1 and F2, respectively, for providing the requisite air flow for the pre-forming operation. The air system 40 for cell C1 includes a fan mechanism 42 with an appropriate motor and blade system thereon (not shown), as well as a series of conduits 44 which circulate air to and from the mould. Similarly, air system 50 for cell C2 includes a fan mechanism 52 together with appropriate fan motor and blades (not shown), as well as a system of conduits 54 for circulation of the air flow into and through the mould. The use of separate suction fans F1 and F2 for each of the cells C1 and C2 insures that the process used in each cell is the same regardless of the stage of the preform process. The use of two suction fans allow consistent air flow rates and air velocities through the preforming tools at all times during the manufacture and operation. This insures that each cell is working in the same manner regardless of the stage of component fabrication on other cells in the system. By controlling the air velocity and air flow rate separately for each cell, this also insures repeatability from part-to-part and repeatability from cell-to-cell. A robot R is used to supply the reinforcing material to the mould to make the preforms in each of the cells C1 and C2. The robot R is an automated six-axis Cartesian coordinate robot of conventional type with a "chopper gun" 60 at the end of a moveable boom or arm 62. The robot R is positioned on a base 64 which is moveable along a track 66. The track 66 is positioned and provided to allow movement of the robot R back and forth between the two cells C1 and C2. In this manner, a single robot R can be used to make the preform in each of the moulds 20 and 30 in the two-cell system 10. An appropriate safety screen S of a conventional type is typically provided around the multiple cell system 10 in order to separate it from other machinery and systems in the variety of materials, including ceramic, micarta, stainless steel, steel, aluminum, or the like. The eyelets are used as a contact surface during the change of direction of the glass material in order to control the material and decrease the contact surface area and friction. The tube members are of sufficient diameter so that they will not contact the string reinforcing material as it is passing from the bobbin or doff to the robot. The tube members also allow the use of air pressure to help feed the string materials through the eyelets. This eliminates the need to manually feed the material through each individual eyelet. The present invention can be used with preformed materials such as glass, carbon, glass/carbon hybrids, and the like. The eyelets significantly reduce friction while allowing the string binder materials to be processed in existing chopper guns without modification of them. The roving from the doffs or bobbins 70 is broken up or "chopped" by the chopper gun 60 into small pieces of material in the order of 10-50 mm in length, depending on the precise processing system utilized. The preferred applicator or chopper gun is supplied by Applicator System AB and includes two separate chopper members, a surface veil chopper and a reinforcement chopper. A pneumatic motor drives the surface veil chopper with the feed and knife rollers connected with a drive belt. If a veil layer of fine chopped material, in the order of 9-10 mm in length, is desired, a single-ended roving is used. This allows the fibers to defibrillate or filamentise, yielding a uniform veil mat layer. The addition of the chopped veil mat layer assists in removing the part from the mould and can be advantageous to enhance surface quality of the moulded part if required. One of the advantages of the applicator chopper device is that it has a large processing window and high output capability that significantly reduces preferred fabrication times when compared with traditional chopper guns. The chopper gun also preferably processes glass rovings of 2200 to 3500 TEX, rovings of 2400 TEX are preferably used in the preform process. The chopper gun utilizes electric servo motors to control the speed of both the feed and knife rollers, thus allowing continuously variable fiber output and fiber length during the preforming process. Fiber output and length control can be changed during the process to eliminate fiber-bridging issues and radii and to obtain net-shape edge characteristics. A variable air pressure system 110 is utilized, as shown in Figure 7. This allows adjustment of the air ejector input pressure which changes the output force of the chopper gun and allows different materials to be processed and different characteristics to be achieved in the sprayed preform. A conventional pneumatic proportional valve 112 is connected to the two air ejectors 114 and 116 in the chopper gun. The pneumatic proportional or solenoid valve 112 is controlled by a system computer 120 or the robot R. By allowing continuously variable air ejector pressure to be controlled in this manner, various materials not previously able to be processed in the preform system or various unique combinations of materials can be used. In addition, the preform characteristics can be enhanced, including net-shape edge definition. The input air pressure and subsequent output air flow from the ejector can be specified by the machine operator depending upon the material being processed or the desired preform characteristics. In this regard, a rigid three-dimensional preform having various thicknesses of material at various portions of the preform component can be manufactured. A representative preform product 150 in this regard is shown in Figure 6. With this system, a "tailor-blanking" process can be utilized which allows the formation of components having the desired thickness for structural rigidity where desired, but allowing the use of thinner portions of the component where the rigidity is not necessary or required. Any conventional roving can be utilized with the present invention, such as fiberglass roving produced by Owens-Corning. Also, the glass roving 15 preferably has a sizing on it which improves the bonding and handling characteristics. In order to form the preformed product, deposition screen members shaped in the form of the preform are provided in the lower mould portions 24 and 34 of the moulds 20 and 30 respectively. The reinforcing roving materials such as string binders, are chopped by the chopper gun 60 and applied along with a thermal plastic or thermoset powder binder to the preformed screens using a robotic routine. Positive air flow through the preform deposition screen members holds the chopped materials on the screen surface during the entire spray-up routine. If desired, as mentioned above, a surface veil can be applied first on the screen. A surface veil enhances the surface quality of the moulded part and also can be used to prevent flow of the binder through the deposition screen and into the air circulation system. For formation of the preform, the robot R is positioned adjacent the appropriate cell, for example C1, and used to spray the chopped glass and binder to the desired thickness on the preformed screen. When the spray-up is complete, the moveable frame member 26 with the upper mould portions 22 is automatically moved in position over the lower mould portion 24 and the tool is closed. The upper mould portion has a similar consolidation screen member which is shaped to form the finished preform. Ambient temperature air flow through the preform screen is terminated and heated air is drawn through the screens in order to melt the binder on the chopped materials and hold them together. At the same time, the mould is closed compressing the chopped material into the desired size and configuration. After the binder has been cured or melted, the heated air flow is stopped and cooled or ambient air is drawn through the preform thereby cooling or freezing the binder and setting the final shape of the preforms. Once the mould or tool is opened, the finished preform is removed from the mould and then used as a reinforcement member in the formation of a composite component or product. With a multi-cell system 10, as shown in Figure 1, two preforms can be manufactured with use of a single robot R. In this manner, once the chopped glass and binder are finished being applied to the screen in cell C1, and the mould is started to be closed and the preform consolidated, the robot R can be moved along track 66 to its station at cell C2 in order to spray form a second preform. In this manner a plurality of preforms can be produced consecutively from system 10, with a preform being formed optimally every 3-4 minutes. It is a fully automated preforming process requiring little or no operator intervention. The full process automation is accomplished by the robotics and by automating machine control. The process automation provides repeatability in part-to-part consistency as required in high volume automotive applications of composites. As indicated, either thermal plastic or thermoset binder materials can be used in order to manufacture the preform. The use of each of these materials is known in the art and each has its own advantages and disadvantages. For example, thermoset binding materials appear to prevent binder migration in the moulded parts, but require higher temperatures and longer holding time to obtain complete cares and to eliminate binder "tackiness" in the preform. Once the preforms are finished, they are used to make composite products, particularly by resin transfer moulding (RTM) or structural reaction injection moulding (SRIM) processes. For each of the particular size and configuration of preform components or products, the application process of the robot R needs to be programmed. The movement of the chopper gun relative to the preform screen needs to be controlled in order to provide the requisite amount of chopped material and binder at the requisite position on the screen. In order to prevent the programming process of the robot being done manually on the screens in the mould s and thus creating down time of the cell for that purpose, the robotic program is automatically generated offline by a robotic software program, such as ROBCAD. In this manner, using a computerized process, virtually the entire path and programming of the robot R for making the preform can be programmed in the laboratory or facility and then adjusted or fine tuned at the actual cell site in order to manufacture the requisite shape of the preform. Due to robotics and programmable chopper guns, blanks of varying glass content and thickness can be manufactured to suit the component design requirements. The programs for robotic applicators are automatically generated based upon part geometry, equipment constraints, material constraints, and desired part characteristics. The programs are tested within the ROBCAD software to insure that all positions are executable by the robot and free of object collisions. Previous methods require that the operator program the robot either in the teach mould on the machine, that is on the cell, or use an offline programming software. Generation of a robotic program for material deposition with minimal operator intervention is allowed. This reduces robotic programming lead time and automates the robotic programming process. The software produces the required spray-up routine for the moveable arm 62 and chopper gun 60 on the robot R. For the veil mat, the fiberglass material can be chopped or broken up into fine pieces, such as 9-10 mm in length. For the remainder of the preform material, the fiberglass can be broken or chopped into pieces, approximately 25-50 mm in length. The material used for moulding the structural composite components is typically a polyester or polyurethane material or an epoxy. In the mould the material is injected through the preform and completely around it forming the final product. It is also possible to provide a hybrid material for forming the preform. For example, fiberglass and carbon string materials can be broken or chopped up simultaneously or concurrently forming the spray-on material. Doffs or bobbins of each of these materials can be used, together with one or two chopping wheels or knives in the chopper gun or applicator 60. During the consolidation process, the upper mould sections or portions 22 and 32 of moulds 20 and 30, respectively, are closed onto the lower moulding tools or portions 24 and 34, respectively. Due to the consistent air flow through the deposition screens in the moulds, higher velocity air flows are created when the two mould portions are being closed for consolidation of the preform. High velocity air flow adjacent the edges of the part can cause the deposit material to move from its original location, however, creating gaps in the sprayed materials or uneven edges. In order to prevent the high velocity air flow from disturbing the material at the edges of the formed preform, seals 120 and 130 are provided, as shown in Figures 4 and 5. Seals 120 is provided between the net-edge block 140 and the lower mould portion 24, 34. The second seal 130 is provided between the net-edge block 140 and the upper mould portion 22, 32. The net-edge blocks 140 are provided around the outer perimeter of the preform 150 in order to contain the sprayed materials and provide a net edge which does not have to be cut or framed afterwards. The blocks 140 are provided in the requisite shape to form the perimeter of the preform and are secured to the moulds with screws, bolts, or other fastener members. The seals 120 and 130, which preferably are made from an elastomeric material, prevent high velocity air from entering into the internal portion of the mould (mould cavity) when the two mould portions are being closed. Seal 120 prevents high velocity air flow from entering the mould cavity and disturbing the preform between the net-edge block 140 and the lower mould portion, while the seal 130 is provided to prevent high velocity air flow from entering into the mould cavity between the net-edge block and the upper mould portion. While the invention has been described in connection with one or more embodiments, it is to be understood that the specific mechanisms and techniques which have been described are merely illustrative of the principles of the invention. Numerous modifications may be made to the methods and apparatus described without departing from the scope of the invention.

Claims: A system (10) for the manufacture of reinforcing preforms for structural composite moulding, the system (10) comprising a first cell (C1) including a first mould member (20), a second cell (C2) including a second mould member (30), a track member (66) extending between said first and second cell members (C1 and C2), a robotic member (R) for supplying reinforcing materials to said first and second mould members (20 and 30), the robotic member (R) being positioned on said track member (66) and being adapted to move back and forth between said first and second cell members (C1 and C2) and a material supply system (80) for providing reinforcing materials to said robotic member (R) characterised in that the material supply system (80) comprises a plurality of eyelet members (82) for guiding string reinforcing material (72) to said robotic member (R), each of the eyelet members (82) having a convergent divergent internal passageway (92) which allows the string reinforcing material (72) to be guided therethrough with minimal contact and friction and that a series of tubular members (96) are used to enclose the string reinforcing material (72) between the individual eyelets (82) so as to allow the use of air pressure to help feed the string reinforcing material through the eyelet members (82), each of the tubular member (96) being of sufficient diameter that it will not contact the string reinforcing material(72). A system as claimed in claim 1 wherein two separate arrangements of eyelet members (82) are provided for guiding said string reinforcing material (72) through two separate curved path portions (94). A system as claimed in claim 1 or in claim 2 wherein the supply system supplies string reinforcing material (72) from a bobbin (70) to a chopper gun (60) on the robotic member (R) and a weight (100) is used to apply an appropriate tension to the string reinforcing material (72) between the bobbin and the chopper gun(60). A system as claimed in claim 3 when dependent upon claim 2 wherein the weight (100) is positioned between the two separate arrangements of eyelet members (82). A system as claimed in any of claims 1 to 4 wherein the system further comprises a first air supply system (40) for supplying air to said first mould member (20) and a second air supply system (50) for supplying air to said second mould member (30). A system as claimed in any of claims 1 to 5 further comprising first and second sealing members (120 and 130) in said first and second mould members (20, 30) for preventing air flow from disturbing reinforcing materials in said mould members (20, 30) when said mould members (20, 30) are being closed. A system as claimed in claim 6 further comprising at least one net-edge block member (140) positioned between upper and lower parts (22,32) and (24,34) of the first and second mould members (20 and 30) wherein the first sealing member (120) is positioned between said net-edge block member (140) and the lower parts (24, 34) of the first and second mould members (20 and 30). A system as claimed in claim 6 or in claim 7 further comprising at least one net-edge block member (140) positioned between upper and lower parts (22,32) and (24,34) of the first and second mould members (20 and 30) wherein the second sealing member (130) is positioned between said net-edge block member (140) and said upper parts (22, 32) of the first and second mould members (20 and 30). A system as claimed in any of claims 1 to 8 further comprising a proportional valve (112) for regulating the supply of reinforcing materials from said robotic member (R). A system as claimed in any of claims 1 to 9 wherein the system further comprises a means for programming said robotic member (R) in order to supply reinforcing material to said first and second mould members (20, 30) in accordance with pre-specified routines and that said means for programming comprising software for programming said robotic member is off-line from said first and second mould members (20, 30).

Inventors: CHAVKA NORMAN GERALD, DAHL JEFFREY SCOTT, JOHNSON CARL FREDERICK, KLEVEN ERIC DANIEL, CHAVKA, NORMAN GERALD, DAHL, JEFFREY SCOTT, JOHNSON, CARL FREDERICK, KLEVEN, ERIC DANIEL
Applicants: FORD GLOBAL TECH INC, FORD GLOBAL TECHNOLOGIES, INC.
Application year: 2001
Main classification: B29B11
IPC codes: B29C43, B29C70, B29K105