pps proceeding - Abstract Preview
pps proceeding
Symposium: S08 - Process Monitoring, Control and Sensors
Poster Presentation
 
 

Development of a novel and adaptable injection unit for an automated and quality controlled manufacturing of RTM parts for aerospace applications

Hopmann Christian (1), Fecher Marc Linus (1), Boettcher Arne (1)*, Fischer Kai (1)

(1) IKV - Institute of Plastics Processing at RWTH Aachen University - Aachen - Germany

Fibre reinforced plastics (FRP) are increasingly being implemented in aircraft and automotive applications for structural lightweight components. A decisive problem for the high volume production of structural parts made of FRP with high fibre volume contents of up to 60 % is, that applied processes are only partly automated and have a low process robustness. Additionally the processes are typically not controlled and for a quality controlled qualification of the parts, time consuming post processes are necessary. In order to increase process robustness and reduce time consuming post processes a novel injection unit has beed developed by the Institute of Plastics Processing (IKV) at RWTH Aachen University together with Airbus Operations GmbH, Stade, and FILL GES.M.B.H., Gurten, Austria. This injection unit shall enable a fully automated and quality controlled manufacturing of Resin Transfer Moulding (RTM)- parts for aerospace applications. Therefore, different sensors will be integrated into the injection unit to fulfill the quality assurance: pressure sensors, thermocouples and dielectrical sensors. This allows for a measurement of all necessary process parameters and such process parameters which cannot be measured and controlled by common injection units or in-mould sensors. For example, the selected arrangement of the pressure sensors will enable the build-up of an online rheometer, which makes an injection of the resin system depending on the current viscosity possible. Furthermore, an online determination of the parts porosity and the permeability of the preform are envisaged. This paper explains the functionality of the developed injection unit with all integrated measurement systems. Additionally, current results of investigations regarding the verification and validation of the injection unit are presented and discussed.