Composites in Automotive 1.11.2013 Prof. Dr.-Ing. Dipl.-Wirt. Ing Thomas Gries
Contents Carbon Fibre Textile Manufacturing Resin Impregnation Simulation / Quality Assurance Recycling Textile solutions for mobility NRW / RWTH / ITA 2
From the fibre to the product 3
Demand [t] Global demand for carbon fibre 140000 120000 100000 80000 60000 40000 20000 0 2008 2009 2010 2011 2012 2015 2020 Year 4
Carbon Fibre
Carbon fibres @ ITA Production capabilities Scale laboratory discontinious quasi-continious continious Equipment Thermal Analysis Chamber Oven Laboratory Line Pilot Line Quantities 5 10 cm 1 m 100 m bobbin Dec. 2012 6
MegaCarbon Recource-efficient and highly productive production of carbon fibres for a wide application spectrum Objectives: Increase of production speed Increase of capacity of the new production plants Lowering the power demand Polymerisation Spinning Solution Spinning Procedure Stabilisation Carbonisation Finishing 7
Textile Manufacturing
FRP Steel Textile Manufacturing Tailored Blank Tailored Tube Assembly Line Tailored NCF Tailored Braid Preformcenter 9
Production technology for Tailored-NCF Enhancement of multi-axial warp-knitting machinery Warp-knitting machine Source: LIBA Maschinenfabrik 10
Resin Impregnation BMW M3 Large scale production 70 /day 1000 /day Minutes Seconds 11
State Of The Art - Prepreg 12
New Technologies at RWTH Gap Impregnation IKV Discharge of Matrix Spread of Matrix Preform Mould Flow front Frame Matrix 13
Simulation/ Quality Assurance
Modelling Textile characterization Friction coefficient Geometry Shearability Modelling Kinematic simulation Level Macro (Meso, Micro) Validation Digital Image Correlation (DIC) 15
Real Time Quality Assurance Falcon (Fibre Automatic Live Control) 16
Recycling
The value chain Starting materials UD- and nonwoven Tapes Simulation and Design Thermoforming and Function integration Multi-Material- Component Automobile sector Goal: Cost effective concept for mass production of composites 11ic0003_Short presentation_2012.pptx Slide Nr. 3 20.01.2012 18 CAMISMA 2012 All rights reserved
Textile solutions for mobility Quelle BMW 19
Lightweight construction with FRP Textile fabrics Braiding technologie Tailored NCF 3D-Fabric Braiding of a hub Crashabsorber 3D-Preforming Prepregging ITA-Preformcenter FRP convertible roof Simulation Coating ficility 20
Smart Textiles and integration of functions Textile bus systems Sensor systems Conductive paths Conductive fabrics Sensor rope Sensor wear Textile integrated illumination Heated textiles LEDs on textiles Illuminated structures Source: ITCF Denkendorf Heated fabric Source: Sefar Heated fabric Source: TITV Greiz 21
Technical fibres for innovative materials Additives in thermoplastic fibres Piezoelectric fibres PSU Polysulfon PEEK Polyether ether-keton PEI Polyetherimid Luminescent fibres High temperature fibres PVDF- Fibres Fibre integration High modulus fibres Hybrid fibres Carbon fibre Source: Zoltec Glass fabric Hybrid yarn Thermoplastic FRP frontend Source: Ticona 22
Recycling of FRP Opening of fibres Yarn formation Laboratory Card Laboratory Card Ring spinning Opening roller Formation of nonwovens Bonding of Nonwovens Aerodynamic web formation web on screen Consolidation of nonwovens Recycled nonwoven 23
RWTH Aachen Campus New form of cooperation between industry and university: 15 relevant clusters Exchange of research results, employees, further resources Biggest European technology campus 2 Bill investment ITA till 2020 Source: rha reicher haase + associierte 19
Aachen Composites Engineers - ACEs Integrated solutions for textile composites Production technology Textile technology Plastic processing Automotive applications Component design Objectives Interdisciplinary innovations and enhancements of: Products, processes, production machines Design, simulation and measurement technique Technology and know-how transfer between research and industry Technologies for composite structures in automotive applications Source: ACEs 20
RWTH Aachen University and ITA RWTH Aachen University 4500 scientists 2300 service personnel 36,000 students 750 Mill. budget 40 % research projects Institut für Textiltechnik (ITA) 80 scientists 55 service personnel 190 graduate research assistants 50 students majoring in textile technology per year 14,3 Mill. budget 90 % research projects 21
TFI: Institut für Bodensysteme an der RWTH Aachen e.v. Organisation Our Strengths: Fibres Textile structures Production technology Application Textile Engineering Fibre Reinforced Composites Medicine / Smart Textiles Man Made Fibre Technology 22