用于复合材料的激光模板制造
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官能化复合材料的机器人注射成型

Anybrid可实现紧凑,灵活的混合喷射成型/用于较小系列和较大部件的包覆成型。
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Robin Robotized注塑机超模CFRP管

照片Credit:Anybrid GmbH

Anybrid GmbH(德国德累斯顿)是在图德累斯顿的轻质工程和聚合物技术(ILK)研究所的分拆。ILK与行业合作开发新的轻质技术,重点是钢筋聚合物复合材料。“我们两年前开发了这款机器化注塑机以生产混合组件,”曼德布奇首席商务官Michael Stegelmann说。混合组件是指用结构化 - 例如,复合管或金属电动车底盘 - 注塑成型塑料,以产生局部附着点,加强肋等。

这一过程称为超模或混合注射成型,在过去的5 - 6年中已经提出了很多关注,但在模压机中的更传统的形式钢模具,具有附着的注入单元。随着下面的图像和下面的视频,Anybrid基本上将该设置集小型化为在Kuka机器人上显示的红色和黑色的C形末端执行器和下面的视频。结果是革命性的,使挤出的挤压或挤出物包覆成型,因为它们离开成型模具或大结构,以便它们移动在装配线上移动。

罗宾

罗宾, short for “robotized injection molding”, was first presented in 2019 at the K show in Dusseldorf, Germany. “We then founded the company last year and are now working with customers to establish pilot production lines using the equipment,” says Stegelmann. The concept, he explains, is to reduce the mass of the injection molding machine by using small injection units and compact, inexpensive molding tools that can be quickly exchanged.

碳纤维增强聚合物组分减少了罗宾末端效应器的重量。照片Credit:Anybrid GmbH

“罗宾末端效应器包括由碳纤维复合材料制成的C架,在外面,您看到铝制框架,”Stegelmann解释。“该框架包含轻质锁定系统,在注射成型期间处理高达12吨的装载力,从模具的下侧带来。”罗宾还可以在大型结构上到达1米的悬臂。“这是我们在ILK中的专有技术 - 如何以正确的方式使用碳纤维和轻质材料。”

传统的注塑方法需要大型压力机和昂贵的模塑工具。因此,它仅限于大系列/大批量生产。相比之下,Robin可以在更大的部件上制造小型系列或多个不同的模制品。“原则是,我们在机器中拥有这种灵活性,我们可以使用几乎任何复合材料或结构,”Stegelmann Notes。

罗宾移动注塑成型使能功能化

Anybrid’s mobile injection molding approach provides an affordable means for a wide variety of functionalization — e.g., inserts for fasteners and LED lights, localized stiffeners and customized end-fittings — to composite pipes, tubes, profiles, plates and even larger structures, providing the flexibility needed for future manufacturing. Photo credit: Anybrid GmbH

“We try to minimize the size of the molds to reduce costs, so you just need a few thousand euros to build the mold,” Stegelmann explains. “This allows an integrated quick change-out system because only a small mold area has to be changed. The idea, for example, is that you have an assembly line with the possibility to quickly change the mold and do a different part on two different sides of the line. You can either use two Robin systems or one Robin system and quickly change the mold. So, you have high flexibility.”

这种尺寸的减小确实限制了可以包覆成型的区域。“目前,我们被注射射击的50-60克,”Stegelmann说。“我们开发了罗宾,重达140公斤,这使得可以使用更小,更实惠的自动化。我们现在正在专注于功能化管道和配置文件,并将较小的元素添加到更大的结构上。“

在包覆成型中实现了良好的联系

“这实际上是我们的背景,”Stegelmann说,参考了任何四个联合创始人。“我们在过去10年或15年的许多项目中完成了这一点,结合不同的材料并找到正确的粘合,我在挤出过程中做了博士学位,当你结合不同的材料时,它总是挑战。您总是需要一些额外的准备粘合等等离子体处理或激光处理,以改变表面结构,尤其是当将塑料或增强塑料粘合到金属上时。复合材料有点容易,因为您可以将聚合物矩阵与注塑材料和基板匹配。“

For example, in the overmolded tube shown below,Mitsui Chemicals Europe(Dusseldorf, Germany) supplied the carbon fiber-reinforced polypropylene (PP) unidirectional (UD) tapes andInemera(赫尔福德,德国)使用这些来生产复合管,然后复杂地包覆成型。“官能化与管道制成相同,”Stegelmann说。“我们用不合因和碳纤维增强的PP材料超出了它,也具有玻璃纤维增​​强剂。与罗宾,你可以用市场上的任何热塑性材料制造。“

The latter is why Anybrid assists its customers with testing. “We get customers that are not sure if their materials will bond to each other,” notes Stegelmann. “We ask them to send us some of the material and we then make some small, simple structures to test. We have a small mold for a stiffening rib that we can injection mold onto different plates. For example, if the customer sends us samples of some composite plates, we can overmold onto these with their injection molding materials. That's the first step, that we have a feasibility study of the bonding behavior of the different materials. After that, we can do some analysis and offer suggestions for optimization.”

潜在的应用

tubes and pipes functionalized using ROBIN

Robin用于用CFRP和其他材料进行官能化管道和管道。

“We are still exploring applications, but we are initially working with pipes and profiles,” says Stegelmann. “One of our ideas is to sequentially bring different structures onto these continuous, potentially very long shapes,” says Stegelmann. “So, elements can be applied directly to pipes. Such concepts are already being used by INOMETA and赫尔辛(德国德累斯顿)集成轴向连接系统和形状配件齿轮。这也可能在航空业中有趣,您需要各种僵硬增强功能,也许希望添加附件等功能。而且,例如,您可以具有纵梁或框架,但长度的变化很多。通过我们的技术,有可能保持高水平的自动化,只需改变您从一个部件到下一个部分的元素。“

“大组件,还有潜在的”ays Stegelmann. “Working at ILK for the last years, we developed many different hybrid components using steel, plastic and composites. We could see that overmolded clips on structural frames and chassis makes sense for assembly. And with the move to electric vehicles and hydrogen systems, we see that it is important to make assembly lines and processes as flexible as possible, to prepare for a variety of different components that may be needed in the future. With ROBIN, you can easily adjust local enhancements for assembly but also for stiffness of the structure, for example. However, we want to extend this capability beyond just automotive and aerospace. Our idea was to make this more affordable for small companies and enable this hybrid technology for smaller quantities in other fields and other applications.”

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