Winning through light materials: Quality Assurance of Composite Materials in the automotive industry Fabric Machine

Date:2022-7-19 Author:Sam

In order to achieve the overall goal in 2030, automakers had to increase the quota of light materials in their vehicles from 30%to 70%to compensate for vehicle weight due to electric power systems and batteries. This is why a research prediction by the management consultant McKinsey, the automotive supply and factory engineering department will see the high -strength steel, aluminum and carbon fiber strong plastic \u0026 nbsp; (CFRP) \u0026 nbsp; A substantial increase. According to the trend of raw material prices, the revenue is likely to increase from 70 billion euros to more than 300 billion euros by 2030. Fiber composite forecasting increases by more than 5%. Fiber composite materials are perfectly applied to automakers due to their high intensity, weight ratio, and rigidity. The weight of each component can be reduced by 30%with carbon fiber composite materials. Because these materials are used in the automotive field and their output is increasing, the current demand is to improve the automation of the manufacturing process, such as RTM or wet molding molding. In the frequency of more and more, the mold pressure sensor is used to monitor the repetitiveness and quality of the product process. These manufacturers that use sensors to assist in production are optimized in advance during the manufacturing process of carbon fiber composite materials, and detected the secondary products \u0026 nbsp; (even completely avoided) \u0026 nbsp;
Composite materials have excellent mechanical characteristics and lightwear characteristics \u0026 nbsp;-\u0026 nbsp; This is why they are becoming more and more important. In the past, fiber enhanced plastic (FRP) \u0026 nbsp; mainly used in the aerospace field \u0026 nbsp; – \u0026 nbsp; but in order to adapt to the trend of improving efficiency and optimization resources, their application in the automotive industry is increasing. It is very important to use light structural materials to achieve the efficiency level prescribed by the law, reducing carbon dioxide emissions. The reason is clear: the lighter car consume less energy \u0026 nbsp;-\u0026 nbsp; this means less fuel.
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Quality guarantee in the field The production process of the engine coverThe importance of quality monitoring can be directly proved. To minimize the cycle, fast curing resin was used in this process. However, this means that the mold must be injected more quickly, so this is usually completed under high pressure. The internal pressure of the mold can be as high as 150 \u0026 nbsp; bar.
The engine covers a relatively large and heavier component on a car, so it has great potential to reduce weight by using light structures. The engine cover must face harsh requirements: its surface is divided into A -level, so the surface structure must be perfect \u0026 nbsp; – \u0026 nbsp; do not allow scratches or depression. At the same time, the mechanical characteristics of the engine cover must be ensured. The process monitoring of the mold pressure sensor enables it to identify the errors in the production process, so that the next step will not be performed on flawed parts. The high -cost production and materials of the engine cover make early recognition errors. This goal can be achieved through the process monitoring system. To this end, the COMONEO System (Comoneo) provides a complete measurement chain from sensors and connection technology to monitoring systems.

Modular pressure measurement guarantee the quality control of the HP-RTM process
pressure curve \u0026 nbsp;-\u0026 nbsp; \u0026 nbsp; \u0026 nbsp; \u0026 nbsp; \u0026 nbsp; \u0026 nbsp; \u0026 nbsp; \u0026 nbsp; ; Comoneo process monitoring system can visualize and evaluate \u0026 nbsp;-\u0026 nbsp; is a key factor for process optimization and production monitoring. (See Figure 1) on the staging stage of the stress curve such as vacuum, glue and curing. The abnormal display of the production of the engine cover in the pressure curve (Figure 2). The capture and records of pressure signals also ensure that the manufacturing components are tracked. Therefore, stress curve is a necessary tool for optimizing production and ensuring quality.

Take time to the first stage of the process. Vacuum and consistency are the key factor to ensure that the engine cover does not have bubbles. The vacuum is too weak or inconsistently indicates that the sealing function of the mold is insufficient. This will lead to a high proportion of air in the mold, which may cause air in the finished cover. The mold that does not take time can be detected from the pressure curve. The monitoring window placed on the stress curve can automatically detect the effect so that it can stop \u0026 nbsp; – \u0026 nbsp; before the production quality does not meet the standard, the production quality is \u0026 nbsp;. Benefit: prevent the cost of high material for sub -products \u0026 nbsp; (see Figure 2, curve 1). 6161AA型模腔压力传感器可帮助检测RTM过程的注塑误差。

The second stage includes injecting resin and curing mixture and cleaning prefabricated parts. When the resin reaches the position of the sensor, the pressure of the mold cavity continues to rise. This shows that the flow resistance increases during the filter layer of the resin to overcome the prefabricated parts. The rise in the pressure signal during the injection phase depends on the penetration rate of the prefabricated parts. The pressure gradient that deviates from normal pressure can indicate, such as differences in the direction of the prefabricated parts or in the direction of individual layers, or the foreign objects in the mold. Here, the special surveillance window ensures that the reference pressure rises \u0026 nbsp; (seeFigure 2, curve 2 and 3). If the evaluation results are traced back to the mixture, the injection molding pressure can be reset. The deviation provided by the reference curve is very small to eliminate the prefabricated part of the fault.
The complete mold injection process began at the third stage, and the pressure gradient increased sharply after the injection molding was completed. This may cause the mold to be half open, because most components are large and resin cannot be compressed. The result will be dependent on the wall thickness or \u0026 nbsp;-\u0026 nbsp; the worst case \u0026 nbsp; \u0026#8722; \u0026 nbsp; resin may leak. The pressure threshold of the mold pressure signal can quickly detect the pressure of the pressure and send signals to the hybrid pump, so as to switch from high injection pressure to relatively low pressure -reducing \u0026 nbsp; (see Figure 1). The fourth stage and the final stage of the HP-RTM process are mainly composed of a cured resin curing agent system. At this point, the mold pressure curve is affected by periodic fluctuations \u0026 nbsp; (in some cases) \u0026 nbsp; These are mainly affected by resin and its solidification characteristics. However, under normal circumstances, the sharp decline in the tip and pressure of the mold indicates that the volume of the resin has begun to shrink. This \”twisting\” time depends largely on the resin used, and it can be concluded that the resin system is correct. Therefore, it is a key factor for components to emphasize the current nature and quality. This \”twist\” can also be tracked in the monitoring window \u0026 nbsp; (see Figure 2, curve 4).

Summary


ComoNeo是以注塑成型过程生产效率最大化为目的的过程监测系统。
Integrated process production monitoring system and a process monitoring system based The tests were detected at the stage, paving the way for lean production and automation. This type of monitoring also helps early production optimization. The examples used include verification of simulation results, mold design and determining the best process settings. In addition, the quality test is performed for each part, and the quality data can be recorded automatically. In short, the advantages of integrated process monitoring are to improve cost efficiency and production quality. \u0026 Nbsp; – \u0026 nbsp; manufacturers of light materials for the automotive industry have benefited from these functions.


Qi Shile is a Swiss private enterprise, and is in the leading position of the industry in the field of dynamic measurement technology such as pressure, force, torque and acceleration. Its innovative sensor technology has promoted automotive development and industrial automation and many emerging industries. development of.