Ihlanganisa itheyiphu elukiwe, i-overmolding kanye nokukhiya ifomu, i-herone ikhiqiza ucezu olulodwa, igiya le-torque ephezulu njenge-demonstrator yezinhlelo zokusebenza eziningi.
Igiya-driveshaft ehlanganisiwe eyinhlanganisela.I-Herone isebenzisa amateyipu ahlanganisiwe ahlanganisiwe we-thermoplastic njengezandulela zenqubo ehlanganisa i-driveshaft laminate futhi ihlanganise izinto ezisebenzayo njengamagiya, ikhiqize izakhiwo ezihlangene ezinciphisa isisindo, ukubala ingxenye, isikhathi sokuhlanganisa kanye nezindleko.Umthombo wazo zonke izithombe |iqhawekazi
Ukuqagela kwamanje kudinga ukuphindwa kabili kwemikhumbi yezindiza zezentengiselwano eminyakeni engu-20 ezayo.Ukuze kuhlangatshezwane nalokhu, amanani okukhiqiza ngo-2019 amajeli abanzi axubile ahluka kusuka ku-10 kuye kwayi-14 ngenyanga nge-OEM ngayinye, kuyilapho ama-narrowbodies asevele enyukele ku-60 ngenyanga nge-OEM ngayinye.I-Airbus isebenzisana ngokukhethekile nabahlinzeki bempahla ukuze bashintshe izingxenye ezijwayelekile kodwa ezithatha isikhathi esiningi, izingxenye ze-prepreg zokubeka izandla ku-A320 ziye ezingxenyeni ezenziwe ngokushesha, izinqubo zesikhathi somjikelezo wemizuzu engama-20 njengokubunjwa kokudlulisa i-resin yokucindezela okuphezulu (HP-RTM), ngaleyo ndlela kusiza ingxenye. abahlinzeki bahlangabezana nokuphushela okwengeziwe ezindizeni eziyi-100 ngenyanga.Ngaleso sikhathi, imakethe yezokuthutha yasemadolobheni esafufusa ibikezela isidingo sezindiza ezi-3,000 zikagesi ezisuka zibheke mpo kanye nokufika (EVTOL) ngonyaka (ezingama-250 ngenyanga).
"Imboni idinga ubuchwepheshe bokukhiqiza obuzenzakalelayo obunezikhathi zokujikeleza ezifinyeziwe ezivumela futhi ukuhlanganisa imisebenzi, ehlinzekwa yizinhlanganisela ze-thermoplastic," kusho uDaniel Barfuss, umsunguli kanye nomlingani ophethe we-herone (Dresden, Germany), ubuchwepheshe obuyinhlanganisela nokukhiqiza izingxenye. ifemu esebenzisa izinto ezisezingeni eliphezulu ze-thermoplastic matrix kusuka ku-polyphenylenesulfide (PPS) kuya ku-polyetheretherketone (PEEK), i-polyetherketoneketone (PEKK) kanye ne-polyaryletherketone (PAEK)."Inhloso yethu enkulu ukuhlanganisa ukusebenza okuphezulu kwezinhlanganisela ze-thermoplastic (TPCs) nezindleko eziphansi, ukuze sikwazi ukwenza izingxenye ezifanelana nezinhlobonhlobo zezinhlelo zokusebenza zokukhiqiza eziwuchungechunge nezinhlelo ezintsha zokusebenza," kwengeza uDkt. Christian Garthaus, umsunguli wesibili we-herone nophethe. uzakwethu.
Ukufeza lokhu, inkampani isungule indlela entsha, eqala ngamateyipu afakwe ngokugcwele, aqhubekayo, eluka lamateyipu ukuze enze i-preform engenalutho ethi "organoTube" futhi ihlanganise ama-organoTubes abe amaphrofayili anezigaba ezihlukene kanye nezimo.Esinyathelweni senqubo esilandelayo, isebenzisa ukushisela kanye ne-thermoformability yama-TPC ukuhlanganisa izici zokusebenza ezifana namagiya ayinhlanganisela kuma-driveshafts, okokufaka ekugcineni kwamapayipi, noma ama-elementi okudlulisa ukulayisha abe yi-tension-compression struts.U-Barfuss wengeza ngokuthi kukhona inketho yokusebenzisa inqubo yokubumba eyingxubevange - eyakhiwe umphakeli we-ketone matrix u-Victrex (Cleveleys, Lancashire, UK) kanye nomphakeli wezingxenye u-Tri-Mack (Bristol, RI, US) - esebenzisa itheyiphu ye-PAEK encibilikayo ephansi yamaphrofayili kanye ne-PEEK yokunqwabelanisa, evumela into ehlanganisiwe, eyodwa kuyo yonke ukujoyina (bona okuthi “I-Overmolding ikhulisa ububanzi be-PEEK kuzinhlanganisela”).Uyanezela, "Ukuzivumelanisa kwethu nezimo kuvumela ukukhiya amafomu ejiyomethri, okukhiqiza izakhiwo ezihlanganisiwe ezingakwazi ukumelana nemithwalo ephakeme nakakhulu."
Inqubo ye-herone iqala ngamateyipu e-thermoplastic e-carbon fiber-reinforced ngokugcwele ahlanganiswe abe ama-organoTubes futhi ahlanganiswe.“Saqala ukusebenzisana nalawa ma-organoTubes eminyakeni eyi-10 edlule, sakha amapayipi ahlanganisiwe asebenza nge-hydraulic ezondiza,” kusho u-Garthaus.Uchaza ukuthi ngenxa yokuthi awekho amapayipi amanzi ezindiza amabili ane-geometry efanayo, kuzodingeka isikhunta kulelo nalelo, kusetshenziswa ubuchwepheshe obukhona.“Besidinga ipayipi elingase licutshungulwe ukuze kutholakale igeometry yepayipi ngalinye.Ngakho-ke, umbono bekuwukwenza amaphrofayili ayinhlanganisela aqhubekayo bese i-CNC igoba lawa kumajiyometri afiswayo. ”
Fig. 2 Amateyipu angaphambi kokuluka alukiwe ahlinzeka ngama-preforms anomumo unetha abizwa nge-organoTubes ngenqubo yokwenza umjovo we-herone futhi anike amandla ukukhiqizwa komumo abahlukahlukene.
Lokhu kuzwakala kufana nalokho okwenziwa yi-Sigma Precision Components (Hinckley, UK) (bona "Ukulungisa kabusha ama-aeroengine ngamapayipi ayinhlanganisela") nge-carbon fiber/PEEK injini yokugqoka.“Babheka izingxenye ezifanayo kodwa basebenzisa indlela ehlukile yokuhlanganisa,” kuchaza uGarthaus."Ngendlela yethu, sibona amandla okukhula okusebenzayo, okufana ne-porosity engaphansi kuka-2% yezakhiwo ze-aerospace."
Garthaus' Ph.D.umsebenzi wethesis ku-ILK uhlolwe kusetshenziswa i-continuous thermoplastic composite (TPC) pultrusion ukuze kukhiqizwe amashubhu aluka, okubangele inqubo yokukhiqiza enelungelo lobunikazi eqhubekayo yamashubhu namaphrofayili e-TPC.Kodwa-ke, okwamanje, u-herone ukhethe ukusebenza nabahlinzeki bezindiza kanye namakhasimende esebenzisa inqubo eqhubekayo yokubumba.“Lokhu kusinikeza inkululeko yokwenza zonke izinhlobo zomumo, okuhlanganisa amaphrofayili agobile nalawo anezigaba ezihlukene, kanye nokusebenzisa amapheshana endawo kanye nokwehliswa kwe-ply,” uyachaza.“Sisebenzela ukwenza inqubo yokuhlanganisa amapheshana endawo bese siwahlanganisa nephrofayili eyinhlanganisela.Ngokuyisisekelo, yonke into ongayenza ngama-laminates ayisicaba namagobolondo, singayenzela amashubhu namaphrofayili. ”
Ukwenza lawa maphrofayili angenalutho e-TPC empeleni bekungenye yezinselelo ezinzima kakhulu, kusho uGarthaus.“Awukwazi ukusebenzisa ukwenza isitembu noma ukugoqa ngesinye i-silicone;ngakho-ke bekufanele sakhe inqubo entsha.”Kodwa le nqubo inika amandla ukusebenza okuphezulu kakhulu futhi okuhambisanayo nezingxenye ezisekelwe ku-shaft, uyaphawula.Iphinde yavumela ukusebenzisa ukubumba okuyingxubevange okwathuthukiswa yi-Victrex, lapho izinga lokushisa eliphansi le-PAEK lencibilika lihlanganiswa ngokweqile nge-PEEK, lihlanganisa i-organosheet nokubumba komjovo ngesinyathelo esisodwa.
Esinye isici esiphawulekayo sokusebenzisa i-organoTube braided tape preforms ukuthi akhiqiza udoti omncane kakhulu."Ngokweluka, sinemfucuza engaphansi kuka-2%, futhi ngenxa yokuthi iyitheyiphu ye-TPC, singasebenzisa le mali encane yemfucuza ekubuyiseleni ngokweqile ukuze sithole izinga lokusetshenziswa kwezinto ezibonakalayo kuze kufike ku-100%," kugcizelela u-Garthaus.
UBarfuss noGarthaus baqale umsebenzi wabo wokuthuthukisa njengabacwaningi e-Institute of Lightweight Engineering and Polymer Technology (ILK) eTU Dresden."Lesi ngesinye sezikhungo ezinkulu zaseYurophu zezinhlanganisela nemiklamo eyi-hybrid lightweight," kuphawula uBarfuss.Yena noGarthaus basebenze lapho cishe iminyaka eyi-10 ngentuthuko eminingi, okuhlanganisa ukuqhubeka kwe-TPC pultrusion kanye nezinhlobo ezahlukene zokujoyina.Lowo msebenzi wagcina usugxilile kulokho manje osekuyi-herone TPC process technology.
"Sibe sesifaka isicelo kuhlelo lwaseJalimane lwe-EXIST, okuhloswe ngalo ukudlulisela ubuchwepheshe obunjalo embonini futhi sixhase amaphrojekthi we-40-60 unyaka ngamunye emikhakheni eminingi yocwaningo," kusho uBarfuss."Sithole uxhaso lwezinsizakusebenza, abasebenzi abane kanye nokutshalwa kwezimali esinyathelweni esilandelayo sokukhulisa."Bakha iqhawekazi ngoMeyi 2018 ngemuva kokubukisa eJEC World.
Ngo-JEC World 2019, i-herone yayikhiqize inqwaba yezingxenye zokubonisa, okuhlanganisa ne-lightweight, high-torque, i-integrated gearshaft, noma i-gearshaft."Sisebenzisa i-carbon fiber/PAEK tape organoTube eboshwe ngama-engeli adingwa yingxenye futhi sihlanganise lokho kube ishubhu," kuchaza u-Barfuss.“Sibe sesishisa ishubhu ku-200°C bese siliguqa ngegiya elenziwe ngokujova i-PEEK emfushane ye-carbon fiber-reinforced ku-380°C.”I-overmolding yenziwe kusetshenziswa i-Moldflow Insight evela ku-Autodesk (San Rafael, Calif., US).Isikhathi sokugcwalisa isikhunta sathuthukiswa saba amasekhondi angu-40.5 futhi satholwa kusetshenziswa umshini wokubumba umjovo we-Arburg (Lossburg, Germany) ALLROUNDER.
Lokhu kweqisa akunciphisi nje kuphela izindleko zokuhlanganisa, izinyathelo zokukhiqiza kanye nempahla, kodwa futhi kuthuthukisa ukusebenza.Umehluko ongu-40°C phakathi kwezinga lokushisa elincibilikayo le-PAEK shaft kanye nalelo giya le-PEEK eligubuzelwe ngokweqile linika amandla ukuhlangana kokuncibilika okuhlangene phakathi kwakho kokubili ezingeni lamangqamuzana.Uhlobo lwesibili lwendlela yokuhlanganisa, ukukhiya ifomu, kufinyelelwa ngokusebenzisa ingcindezi yomjovo ukuze kanyekanye i-thermoform i-shaft ngesikhathi i-overmolding ukuze kwakhiwe i-contour yokuvala ifomu.Lokhu kungabonakala ku-Fig. 1 ngezansi ngokuthi "i-injection-forming".Idala isiyingi sikathayela noma i-sinusoidal lapho igiya lihlanganiswa khona ngokuphambene nesigaba esiyisiyingi esibushelelezi, okuholela kufomu lokukhiya ngokwejometri.Lokhu kuthuthukisa nakakhulu amandla e-gearshaft ehlanganisiwe, njengoba kubonisiwe ekuhlolweni (bona igrafu ngezansi kwesokudla).Fig.1. Ithuthukiswe ngokubambisana ne-Victrex kanye ne-ILK, i-herone isebenzisa ingcindezi yomjovo ngesikhathi i-overmolding ukuze idale i-contour yokuvala ifomu ku-gearshaft ehlanganisiwe (phezulu).Le nqubo yokwenza umjovo ivumela i-gearshaft ehlanganisiwe enokukhiya ifomu (ijika eliluhlaza kugrafu) ukuba gcina i-torque ephakeme uma iqhathaniswa ne-gear-driveshaft ehlanganiswe ngokweqile ngaphandle kokukhiya (ijika elimnyama kugrafu).
"Abantu abaningi bathola ukuhlangana okuncibilikisiwe okuhlangene ngesikhathi sokugcwala ngokweqile," kusho uGarthaus, "kanti abanye basebenzisa ukukhiya amafomu kuma-composites, kodwa ukhiye uwukuhlanganisa kokubili kube yinqubo eyodwa, ezenzakalelayo."Uchaza ukuthi emiphumeleni yokuhlolwa ku-Fig. 1, kokubili i-shaft ne-circumference egcwele yegiya kwakuboshiwe ngokuhlukana, bese kuzuliswa ukuze kufakwe ukugunda.Ukwehluleka kokuqala kugrafu kumakwa yisiyingi ukukhombisa ukuthi okwegiya le-PEEK elibunjwe ngokweqile ngaphandle kokukhiya ifomu.Ukwehluleka kwesibili kumakwa yindilinga eshwabene efana nenkanyezi, okubonisa ukuhlolwa kwegiya eligubuzelwe ngokweqile eline-form-locking."Kulokhu, unokujoyina okuhlangene nokukhiyiwe," kusho u-Garthaus, "futhi uthola cishe ukwenyuka ngo-44% kumthwalo we-torque."Inselelo manje, uthi, ukuthola i-form-locking ukuze ilayishe kusenesikhathi ukuze iqhubeke nokwandisa i-torque le-gearshaft ezoyibamba ngaphambi kokuhluleka.
Iphuzu elibalulekile mayelana ne-contour form-locking efinyelelwa yi-herone ngokwakhiwa kwayo komjovo ukuthi ifanelana ngokuphelele nengxenye ngayinye futhi ukulayishwa kwaleyo ngxenye kufanele imelane.Isibonelo, ku-gearshaft, i-form-locking i-circumferential, kodwa ku-tension-compression struts engezansi, i-axial.“Yilokhu esikuthuthukisile kuyindlela ebanzi,” kusho uGarthaus."Indlela esihlanganisa ngayo imisebenzi nezingxenye incike kuhlelo lokusebenza lomuntu ngamunye, kodwa lapho singakwenza okwengeziwe, singonga isisindo nezindleko ezengeziwe."
Futhi, i-ketone eqiniswe ngefayibha emifushane esetshenziswa ezintweni ezisebenza ngokuchichima njengamagiya inikeza izindawo zokugqokwa ezinhle kakhulu.I-Victrex ikufakazele lokhu futhi empeleni, imaketha leli qiniso ngezinto zayo ze-PEEK ne-PAEK.
U-Barfuss uveza ukuthi i-gearshaft edidiyelwe, ehlonishwe ngendondo ye-JEC World Innovation ka-2019 esigabeni se-aerospace, “iwukuboniswa kwendlela yethu, hhayi nje inqubo egxile esicelweni esisodwa.Besifuna ukuhlola ukuthi singakwelula kangakanani ukukhiqizwa nokusebenzisa izakhiwo ze-TPC ukukhiqiza izakhiwo ezisebenzayo, ezihlanganisiwe. "Inkampani njengamanje ithuthukisa izinduku zokucindezelwa kwe-tension, ezisetshenziswa ezinhlelweni ezifana nama-struts.
Umdwebo 3 I-tension-compression strutsUkwakheka komjovo kunwetshwa kuma-struts, lapho i-herone ibumba ngokweqile into yokudlulisa umthwalo wensimbi esakhiweni sengxenye isebenzisa i-axial form-locking ukuze kwandiswe amandla okujoyina.
Isici esisebenzayo se-tension-compression struts iyingxenye yesixhumi esibonakalayo esisansimbi edlulisa imithwalo iye futhi isuke kumfoloko yensimbi iye eshubhuni eyinhlanganisela (bona umfanekiso ngezansi).Ukwakhiwa komjovo kusetshenziselwa ukuhlanganisa ingxenye yesingeniso yomthwalo wensimbi kumzimba we-strut oyinhlanganisela.
“Umhlomulo omkhulu esiwunikezayo ukwehlisa inani lezingxenye,” uyaphawula.“Lokhu kwenza ukukhathala kube lula, okuyinselelo enkulu ekufakeni izicelo zezindiza.Ukukhiya amafomu sekuvele kusetshenziswe ezinhlanganisela ze-thermoset ngepulasitiki noma insimbi, kodwa akukho ukubopha okuhlangene, ukuze ukwazi ukuthola ukunyakaza okuncane phakathi kwezingxenye.Indlela yethu, nokho, ihlinzeka ngohlaka oluhlangene olungenakho ukunyakaza okunjalo. ”
UGarthaus ubalula ukubekezelela umonakalo njengenye inselele kulezi zingxenye."Kufanele uthinte ama-struts bese uhlola ukukhathala," uyachaza."Ngenxa yokuthi sisebenzisa izinto ze-matrix ezisebenza kahle kakhulu ze-thermoplastic, singafinyelela ukubekezelela ukulimala okungama-40% uma kuqhathaniswa nama-thermosets, futhi nanoma yimaphi ama-microcracks avela kumthelela akhula kancane ngokulayisha ukukhathala."
Ngisho noma ama-strits okubonisa abonisa okokufaka kwensimbi, i-herone okwamanje ithuthukisa isisombululo se-all-thermoplastic, esivumela ukuhlangana okuhlangene phakathi kwe-composite strut body kanye nento esethulo yomthwalo."Uma sikwazi, sikhetha ukuhlala siyinhlanganisela yonke futhi silungise izakhiwo ngokushintsha uhlobo lwe-fiber reinforcement, okuhlanganisa i-carbon, ingilazi, i-fiber eqhubekayo nefushane," kusho u-Garthaus.“Ngale ndlela, sinciphisa ubunkimbinkimbi nezinkinga zesixhumi esibonakalayo.Isibonelo, sinezinkinga ezincane kakhulu uma kuqhathaniswa nokuhlanganisa ama-thermosets nama-thermoplastics. "Ngaphezu kwalokho, isibopho esiphakathi kwe-PAEK ne-PEEK sihlolwe yi-Tri-Mack ngemiphumela ebonisa ukuthi inama-85% wamandla we-laminate ye-CF/PAEK eyisisekelo futhi iqine ngokuphindwe kabili kunezibopho zokunamathela zisebenzisa i-industry-standard epoxy film adhesive.
U-Barfuss uthi i-herone manje inabasebenzi abayisishiyagalolunye futhi ishintsha kusukela kumhlinzeki wokuthuthukiswa kobuchwepheshe kuya kubahlinzeki bezingxenye zezindiza.Isinyathelo sayo esikhulu esilandelayo ukuthuthukiswa kwefekthri entsha eDresden.“Ekupheleni kuka-2020 sizobe sinemboni yokuhlola ekhiqiza izingxenye zochungechunge lokuqala,” usho kanje."Sesivele sisebenzisana nama-OEM endiza nabaphakeli ababalulekile beTier 1, sibonisa imiklamo yezinhlobo eziningi zezinhlelo zokusebenza."
Le nkampani futhi isebenza nabahlinzeki be-eVTOL nabahlanganyeli abahlukahlukene e-US Njengoba iqhawekazi livuthwa izicelo zendiza, futhi izuza ulwazi lokukhiqiza ngezicelo zempahla yezemidlalo okuhlanganisa amalulwane nezingxenye zamabhayisikili."Ubuchwepheshe bethu bungakhiqiza izingxenye eziningi eziyinkimbinkimbi ngokusebenza, isikhathi somjikelezo kanye nezinzuzo zezindleko," kusho uGarthaus.“Isikhathi sethu somjikelezo sisebenzisa i-PEEK imizuzu engama-20, uma kuqhathaniswa nemizuzu engama-240 sisebenzisa i-autoclave-cured prepreg.Sibona insimu ebanzi yamathuba, kodwa okwamanje, ukugxila kwethu kukwenza izicelo zethu zokuqala zikhiqize futhi sibonise ukubaluleka kwezingxenye ezinjalo emakethe.”
I-Herone izobe futhi yethula ku-Carbon Fiber 2019. Funda kabanzi mayelana nomcimbi ku-carbonfiberevent.com.
Kugxilwe ekuthuthukiseni ukwakheka kwezandla okungokwesiko, abakhiqizi be-nacelle kanye ne-thrust reverser baphonsa iso ekusetshenzisweni okuzayo kwe-automation kanye nokubumba okuvaliwe.
Isistimu yezikhali zendiza izuza ukusebenza okuphezulu kwekhabhoni/epoxy ngokusebenza kahle kokubumba kokucindezelwa.
Izindlela zokubala umthelela wezinhlanganisela ezinawo endaweni ezungezile zivumela ukuqhathanisa okuqhutshwa yidatha nezinto ezivamile endaweni yokudlala.
Isikhathi sokuthumela: Aug-19-2019