Industrial concept for the automated production of small batch series preforms for Carbon Fiber Reinforced Plastic (CFRP) components

Abstract

Modern helicopters often rely on components made from carbon fiber reinforced plastic to save weight in big structural components with simple geometries. There is great potential for further weight savings in smaller more complex structures. Low quantities, a high variability in geometry and freeform surfaces are characteristics of such components. Therefore a manual layup of the preforms is generally chosen for production. An automated process could help to exhaust the full lightweight potential and increase accuracy of the preforms. For small batch series a full automation is not cost effective. Using the example of an aerodynamic freeform component the Center for Lightweight Production Technology investigated an automated preforming concept. The concept incorporates manual sub-processes to support the automation without compromising the quality of the preform. A platform based tool that can easily be integrated in existing robotic cells is developed to meet the industrial needs for low machine costs. The flexibility of a platform based solution ensures short downtimes and enables the production of preforms with varying geometries. The embedment of the concept at industrial level will be discussed.