ʻO ka hui pū ʻana i ka lipine braided, overmolding a me ka hoʻopaʻa ʻana, hana ʻo herone i hoʻokahi ʻāpana, kiʻekiʻe-torque gear-driveshaft ma ke ʻano he mea hōʻike no ka laulā o nā noi.
ʻO ka huila hui pū ʻia.Hoʻohana ʻo Herone i nā lipine prepreg composite thermoplastic i hoʻopaʻa ʻia ma ke ʻano he preforms no kahi kaʻina hana e hoʻohui i ka driveshaft laminate a overmolds i nā mea hana e like me nā gears, e hana ana i nā hale i hui pū ʻia e hōʻemi i ke kaumaha, helu hapa, ka manawa hui a me ke kumukūʻai.Puna no nā kiʻi a pau |herone
Manaʻo nā kuhi o kēia manawa no ka pālua ʻana o nā ʻauwaʻa mokulele kalepa i nā makahiki he 20 e hiki mai ana.No ka hoʻokō ʻana i kēia, ʻokoʻa ka nui o ka hana ma 2019 no nā jetliners widebody composites-intensive mai 10 a 14 i kēlā me kēia mahina no OEM, aʻo nā narrowbodies ua piʻi i 60 i kēlā me kēia mahina no OEM.Ke hana pū nei ʻo Airbus me nā mea hoʻolako e hoʻololi i nā ʻāpana kuʻuna a paʻa i ka manawa, hoʻonohonoho lima i nā ʻāpana prepreg ma ka A320 i nā ʻāpana i hana ʻia ma o ka wikiwiki, 20-minuke kaʻina manawa pōkole e like me ke kiʻekiʻe-pressure resin transfer molding (HP-RTM), no laila ke kōkua nei i ka ʻāpana. hui nā mea hoʻolako i kahi pahu hou aku i nā mokulele 100 i kēlā me kēia mahina.Eia nō naʻe, ke wānana nei ka mākaʻikaʻi o ke kaona a me ka mākeke kaʻa i ka pono no 3,000 mau mokulele mokulele a me ka pae ʻana (EVTOL) i kēlā me kēia makahiki (250 i kēlā me kēia mahina).
"Pono ka ʻoihana i nā ʻenehana hana automated me nā manawa pōkole pōkole e hiki ai ke hoʻohui i nā hana, i hāʻawi ʻia e nā thermoplastic composites," wahi a Daniel Barfuss, ka mea hoʻokumu a me ka hoa hoʻokele o ka herone (Dresden, Kelemānia), kahi ʻenehana composites a me nā ʻāpana hana. paʻa e hoʻohana ana i nā mea matrix thermoplastic kiʻekiʻe mai ka polyphenylenesulfide (PPS) i ka polyetherketone (PEEK), polyetherketoneketone (PEKK) a me ka polyaryletherketone (PAEK)."ʻO kā mākou pahuhopu nui ʻo ka hoʻohui ʻana i ka hana kiʻekiʻe o nā thermoplastic composites (TPCs) me ka haʻahaʻa haʻahaʻa, e hiki ai i nā ʻāpana i hoʻopili ʻia no kahi ʻano ākea o nā noi hana serial a me nā noi hou," wahi a Kauka Christian Garthaus, ka mea hoʻokumu ʻelua o ka herone a me ka hoʻokele. hoa pili.
No ka hoʻokō ʻana i kēia, ua hoʻomohala ka hui i kahi ala hou, e hoʻomaka me ka hoʻopiha piha ʻana, nā lipine fiber mau, e ulana i kēia mau lipine e hana i kahi hollow preform "organoTube" a hoʻohui i nā organoTubes i nā profile me nā ʻāpana keʻa a me nā ʻano.Ma ke kaʻina hana aʻe, hoʻohana ia i ka weldability a me ka thermoformability o nā TPC e hoʻohui i nā mea hana e like me ka hui pū ʻana ma luna o nā driveshafts, nā hoʻopili hope ma nā paipu, a i ʻole nā mea hoʻoili hoʻoili i loko o nā struts-compression struts.Hoʻohui ʻo Barfuss aia ke koho e hoʻohana i kahi kaʻina hana hoʻoheheʻe hybrid - hoʻomohala ʻia e ka mea hoʻolako ketone matrix Victrex (Cleveleys, Lancashire, UK) a me nā mea hoʻolako ʻāpana ʻo Tri-Mack (Bristol, RI, US) - e hoʻohana ana i ka lipine hoʻoheheʻe haʻahaʻa PAEK no nā kiʻi. a me PEEK no ka hoʻoheheʻe ʻana, e hiki ai i kahi mea i hoʻohui ʻia, hoʻokahi mea ma o ka hui ʻana (e ʻike i ka "Hoʻonui ka Overmolding i ka laulā o PEEK i loko o nā composites")."ʻO kā mākou hoʻololi ʻana e hiki ai i ka geometrical form-locking," i hoʻohui ai ʻo ia, "e hana ana i nā hale i hoʻohui ʻia e hiki ke kū i nā ukana kiʻekiʻe."
Hoʻomaka ke kaʻina hana herone me nā lipine thermoplastic i hoʻopaʻa ʻia i ka fiber carbon fiber i hoʻopaʻa ʻia i loko o nā organoTubes a hoʻohui ʻia."Ua hoʻomaka mākou e hana me kēia organoTubes 10 mau makahiki i hala aku nei, e hoʻomohala ana i nā paipu hydraulic composite no ka mokulele," wahi a Garthaus.Ua wehewehe ʻo ia no ka loaʻa ʻole o ʻelua paipu hydraulic mokulele i ka geometry hoʻokahi, pono e hoʻoheheʻe ʻia no kēlā me kēia me ka hoʻohana ʻana i ka ʻenehana i loaʻa."Pono mākou i kahi paipu i hiki ke hana ʻia ma hope o ka hoʻokō ʻana i ka geometry paipu pākahi.No laila, ʻo ka manaʻo ʻo ia ka hana ʻana i nā profile composite mau a laila hoʻohuli ʻo CNC i kēia i loko o nā geometries i makemake ʻia.
Fig. 2 Hoʻolako ʻia nā lipine prepreg i ulana ʻia i nā ʻano ʻupena i kapa ʻia he organoTubes no ke kaʻina hana ʻana o ka herone a hiki ke hana i nā ʻano like ʻole.
Ua like kēia me ka mea a Sigma Precision Components (Hinckley, UK) e hana nei (e ʻike i ka "Redressing aeroengines with composite pipes") me kona kapa kalapona/PEEK engine."Ke nānā nei lākou i nā ʻāpana like akā hoʻohana i kahi ʻano hoʻohui like ʻole," wehewehe ʻo Garthaus."Me kā mākou hoʻokokoke, ʻike mākou i ka hiki ke hoʻonui i ka hana, e like me ka liʻiliʻi o 2% porosity no nā hale aerospace."
ʻO Garthaus' Ph.D.ʻimi ʻia ka hana thesis ma ka ILK me ka hoʻohana ʻana i ka pultrusion thermoplastic composite (TPC) no ka hana ʻana i nā paipu i ulana ʻia, a ua hopena i kahi kaʻina hana hoʻomau patented no nā paipu TPC a me nā kiʻi.Eia naʻe, i kēia manawa, ua koho ʻo herone e hana pū me nā mea hoʻolako mokulele a me nā mea kūʻai aku e hoʻohana ana i kahi kaʻina hana hoʻoheheʻe ʻole."Hāʻawi kēia iā mākou i ke kūʻokoʻa e hana i nā ʻano like ʻole, me nā ʻaoʻao curved a me nā mea me nā ʻāpana ʻokoʻa like ʻole, a me ka hoʻopili ʻana i nā ʻāpana kūloko a me nā hāʻule o ka ply," wehewehe ʻo ia."Ke hana nei mākou e hoʻokaʻawale i ke kaʻina hana no ka hoʻohui ʻana i nā pā kūloko a laila hoʻohui pū iā lākou me ka ʻaoʻao composite.ʻO ke kumu, hiki iā ʻoe ke hana me nā laminates palahalaha a me nā pūpū, hiki iā mākou ke hana no nā paipu a me nā profiles.
ʻO ka hana ʻana i kēia mau ʻōlelo hollow TPC kekahi o nā paʻakikī paʻakikī loa, wahi a Garthaus.“ʻAʻole hiki iā ʻoe ke hoʻohana i ka hoʻoheheʻe ʻana a i ʻole ka puhi ʻana me ka ʻōpū silicone;no laila, pono mākou e kūkulu i kahi kaʻina hana hou.Akā hiki i kēia kaʻina hana ke kiʻekiʻe loa a me nā ʻāpana i hoʻopaʻa ʻia i ka shaft.Hiki iā ia ke hoʻohana i ka molding hybrid i hoʻomohala ʻia e Victrex, kahi i hoʻoheheʻe ʻia ai ka wela hoʻoheheʻe haʻahaʻa ʻo PAEK me ka PEEK, e hoʻohui i ka ʻāpana organo a me ka hoʻoheheʻe ʻana i hoʻokahi ʻanuʻu.
ʻO kekahi hiʻohiʻona ʻē aʻe o ka hoʻohana ʻana i ka organoTube braided tape preforms ʻo ia ka hana ʻana i nā ʻōpala liʻiliʻi loa."Me ka ulana ʻana, ʻoi aku ka liʻiliʻi ma mua o 2% o ka ʻōpala, a no ka mea he lipine TPC ia, hiki iā mākou ke hoʻohana i kēia ʻōpala liʻiliʻi i ka overmolding e kiʻi i ka nui o ka hoʻohana ʻana i nā mea a hiki i ka 100%," wahi a Garthaus.
Ua hoʻomaka ʻo Barfuss lāua ʻo Garthaus i kā lāua hana hoʻomohala ma ke ʻano he mea noiʻi ma ka Institute of Lightweight Engineering and Polymer Technology (ILK) ma TU Dresden."ʻO kēia kekahi o nā kula ʻEulopa nui loa no nā composites a me nā hoʻolālā māmā hybrid," wahi a Barfuss.Ua hana ʻo ia a me Garthaus ma laila no kahi kokoke i 10 mau makahiki ma kekahi mau hanana, e komo pū ana me ka pultrusion TPC mau a me nā ʻano like ʻole o ka hui ʻana.Ua hoʻopau ʻia kēlā hana i ka ʻenehana kaʻina TPC herone i kēia manawa.
"A laila ua noi mākou i ka papahana EXIST German, kahi i manaʻo ʻia e hoʻololi i ia ʻenehana i ka ʻoihana a me ke kālā i nā papahana 40-60 i kēlā me kēia makahiki ma kahi ākea o nā kahua noiʻi," wahi a Barfuss."Ua loaʻa iā mākou ke kālā no nā lako waiwai, ʻehā mau limahana a me nā hoʻopukapuka no ka pae aʻe o ka hoʻonui."Ua hana lākou i ka herone ma Mei 2018 ma hope o ka hōʻike ʻana ma JEC World.
Na JEC World 2019, ua hana ʻo herone i nā ʻāpana hōʻike, me kahi māmā māmā, kiʻekiʻe-torque, integrated gear driveshaft, a i ʻole gearshaft."Hoʻohana mākou i kahi ʻāpana kalapona/PAEK tape organoTube i wili ʻia ma nā kihi i makemake ʻia e ka ʻāpana a hoʻohui i ia mea i loko o kahi paipu," wehewehe ʻo Barfuss."A laila hoʻomaʻamaʻa mākou i ka paipu ma 200 ° C a hoʻoheheʻe ʻia me kahi mea hana i hana ʻia e ka hoʻokomo ʻana i ka PEEK pōkole i hoʻoikaika ʻia i ka fiber carbon ma 380 ° C."Ua hoʻohālike ʻia ka overmolding me ka hoʻohana ʻana iā Moldflow Insight mai Autodesk (San Rafael, Calif., US).Ua hoʻonui ʻia ka manawa hoʻopiha piha i ka 40.5 kekona a loaʻa me ka Arburg (Lossburg, Kelemānia) ALLROUNDER injection molding machine.
ʻAʻole hōʻemi wale kēia overmolding i nā kumukūʻai hui, nā hana hana a me nā logistic, akā hoʻonui pū i ka hana.ʻO ka ʻokoʻa o 40°C ma waena o ka wela hoʻoheheʻe ʻana o ka pahu PAEK a me ka mea o ka PEEK i overmolded e hiki ai i ka hoʻoheheʻe hoʻoheheʻe ʻana ma waena o nā mea ʻelua ma ka pae molekala.Loaʻa ʻia kahi ʻano lua o ka hui ʻana, form-locking, me ka hoʻohana ʻana i ke kaomi injection i ka manawa like e thermoform i ke kumu i ka wā overmolding e hana i kahi contour paʻa puka.Hiki ke ʻike ʻia kēia ma ka Fig. 1 ma lalo nei he "injection-forming".Hoʻokumu ia i kahi ʻāpana corrugated a i ʻole sinusoidal kahi i hui ʻia ai ke kāʻei me kahi ʻāpana poʻe poʻe maʻemaʻe, kahi e loaʻa ai kahi ʻano paʻa geometrically.Hoʻonui kēia i ka ikaika o ka gearshaft i hoʻohui ʻia, e like me ka mea i hōʻike ʻia ma ka hoʻāʻo ʻana (e nānā i ka pakuhi ma lalo ʻākau).1. Hoʻomohala ʻia me ka hui pū ʻana me Victrex a me ILK, hoʻohana ʻo herone i ke kaomi injection i ka wā o ka overmolding e hana i kahi ʻano paʻa paʻa i loko o ka gearshaft i hoʻohui ʻia (luna). e hoʻomau i ka torque kiʻekiʻe aʻe me kahi pahu-driveshaft overmolded me ka hoʻopaʻa ʻole ʻana (ka ʻeleʻele ʻeleʻele ma ka pakuhi).
"Ke hoʻokō nei ka nui o ka poʻe i ka hoʻoheheʻe ʻana i ka hoʻoheheʻe ʻana i ka wā overmolding," wahi a Garthaus, "a ʻo nā mea ʻē aʻe e hoʻohana ana i ka paʻa paʻa i loko o nā composites, akā ʻo ke kī ʻo ka hoʻohui ʻana i nā mea ʻelua i hoʻokahi kaʻina hana automated."Ua wehewehe ʻo ia no nā hopena hoʻāʻo ma Fig. 1, ua hoʻopaʻa kaʻawale ʻia ke kumu a me ka puni piha o ka mea hana, a laila hoʻohuli ʻia e hoʻoulu i ka hoʻouka ʻana.ʻO ka hāʻule mua ma ka pakuhi i kaha ʻia e kahi pōʻai e hōʻike ai no kahi mea PEEK i overmolded me ka laka ʻole.ʻO ka lua o ka hāʻule ʻana ua hōʻailona ʻia e kahi pōʻai crimped e like me ka hōkū, e hōʻike ana i ka hoʻāʻo ʻana i kahi mea hana overmolded me ka paʻa puka."I kēia hihia, loaʻa iā ʻoe kahi hui paʻa a paʻa ʻia," wahi a Garthaus, "a loaʻa iā ʻoe kahi kokoke i 44% ka piʻi ʻana o ka ukana torque."ʻO ka paʻakikī i kēia manawa, ʻōlelo ʻo ia, ʻo ka loaʻa ʻana o ka paʻa puka e lawe i ka ukana ma kahi pae mua e hoʻonui hou i ka torque e mālama ai kēia gearshaft ma mua o ka pau ʻole.
ʻO kahi mea koʻikoʻi e pili ana i ka hoʻopaʻa ʻana i ka contour form-locking i loaʻa i ka herone me kāna hana injection, ʻo ia ka mea i hoʻopili piha ʻia i kēlā me kēia ʻāpana a me ka hoʻouka ʻana o kēlā ʻāpana e kū pono.No ka laʻana, ma ka gearshaft, he circumferential ka puka-locking, akā i nā struts tension-compression ma lalo, he axial."ʻO kēia ke kumu o ka mea a mākou i kūkulu ai he ala ākea," wahi a Garthaus."Pehea mākou e hoʻohui ai i nā hana a me nā ʻāpana e pili ana i ka noi pilikino, akā ʻoi aku ka nui o ka hiki iā mākou ke hana i kēia, ʻoi aku ka nui o ke kaumaha a me ke kumukūʻai hiki iā mākou ke mālama."
Eia kekahi, ʻo ka ketone i hoʻoikaika ʻia i ka fiber pōkole i hoʻohana ʻia i nā mea hana overmolded e like me nā gears e hāʻawi i nā papa lole maikaʻi loa.Ua hōʻoia ʻo Victrex i kēia a ʻoiaʻiʻo, kūʻai aku i kēia ʻoiaʻiʻo no kāna mau mea PEEK a me PAEK.
Hōʻike ʻo Barfuss ʻo ka gearshaft i hoʻohui ʻia, i ʻike ʻia me ka 2019 JEC World Innovation Award i ka ʻāpana aerospace, he "hōʻike o kā mākou ala, ʻaʻole wale ke kaʻina hana i kau ʻia ma kahi noi hoʻokahi.Makemake mākou e ʻimi i ka nui o kā mākou hiki ke hoʻololi i ka hana ʻana a me ka hoʻohana ʻana i nā waiwai o nā TPC e hana i nā hana i hoʻohui ʻia.Ke ʻimi nei ka ʻoihana i nā koʻokoʻo hoʻopaʻapaʻa tension, i hoʻohana ʻia i nā noi e like me struts.
Fig. 3 Tension-compression strutsInjection-forming ua hoʻonui ʻia i nā struts, kahi e hoʻoheheʻe ai ka herone i kahi mea hoʻoili hoʻoili metala i loko o ka hale ʻāpana me ka hoʻohana ʻana i ka axial form-locking e hoʻonui i ka ikaika hui.
ʻO ka mea hana no nā struts tension-compression struts he ʻāpana hoʻokaʻawale metala e hoʻoili i nā ukana i a mai ka lāʻau metala a i ka paipu hui (e nānā i ke kiʻi ma lalo).Hoʻohana ʻia ka hana injection no ka hoʻohui ʻana i ka mea hoʻokomo i ka ukana metala i loko o ke kino strut composite.
"ʻO ka pōmaikaʻi nui a mākou e hāʻawi ai ʻo ka hoʻemi ʻana i ka helu o nā ʻāpana," wahi āna."Hoʻomaʻamaʻa kēia i ka luhi, kahi paʻakikī nui no nā noi strut mokulele.Ua hoʻohana mua ʻia ka paʻa ʻana i ka thermoset composites me ka plastic a i ʻole ka mea hoʻokomo metala, akā ʻaʻohe paʻa paʻa, no laila hiki iā ʻoe ke loaʻa kahi neʻe iki ma waena o nā ʻāpana.ʻO kā mākou ala, e hāʻawi ana i kahi ʻano hui pū me ka ʻole o ia neʻe. "
Ua ʻōlelo ʻo Garthaus i ka hoʻomanawanui ʻino ʻana ma ke ʻano he pilikia ʻē aʻe no kēia mau ʻāpana."Pono ʻoe e hoʻopili i nā struts a laila hana i ka hoʻāʻo luhi," wehewehe ʻo ia."No ka mea ke hoʻohana nei mākou i nā mea hana thermoplastic matrix kiʻekiʻe, hiki iā mākou ke hoʻokō i ka nui o ka 40% kiʻekiʻe o ka hoʻomanawanui pōʻino me nā thermosets, a me nā microcracks mai ka hopena e emi iho me ka luhi luhi."
ʻOiai ke hōʻike nei nā struts hōʻikeʻike i kahi mea hoʻokomo metala, ke hoʻomohala nei ʻo herone i kahi solution thermoplastic a pau, e hiki ai i ka hoʻopaʻa paʻa ʻana ma waena o ke kino strut composite a me ka mea hoʻokomo ukana."Inā hiki iā mākou, makemake mākou e noho i nā mea a pau a hoʻoponopono i nā waiwai ma ka hoʻololi ʻana i ke ʻano o ka fiber reinforcement, me ke kalapona, ke aniani, ka hoʻomau a me ka pōkole pōkole," wahi a Garthaus."Ma kēia ala, hoʻemi mākou i ka paʻakikī a me nā pilikia pili.No ka laʻana, ʻoi aku ka liʻiliʻi o nā pilikia i hoʻohālikelike ʻia i ka hoʻohui ʻana i nā thermosets a me nā thermoplastics.Eia hou, ua ho'āʻoʻia ka pilina ma waena o PAEK a me PEEK e Tri-Mack me nā hualoaʻa e hōʻike ana iā ia he 85% o ka ikaika o ka base unidirectional CF / PAEK laminate a he pālua ka ikaika e like me nā paʻa paʻa me ka hoʻohanaʻana i ka epoxy film adhesive maʻamau.
Ua ʻōlelo ʻo Barfuss he ʻeiwa mau limahana ʻo herone a ke neʻe nei mai kahi mea hoʻolako o ka hoʻomohala ʻenehana i kahi mea hoʻolako ʻāpana mokulele.ʻO kāna hana nui e hiki mai ana ke kūkulu ʻana i kahi hale hana hou ma Dresden."Ma ka hopena o 2020 e loaʻa iā mākou kahi mea kanu pilote e hana ana i nā ʻāpana mua," wahi āna."Ke hana nei mākou me nā OEM mokulele a me nā mea hoʻolako kī Tier 1, e hōʻike ana i nā hoʻolālā no nā ʻano noi like ʻole."
Ke hana pū nei ka hui me nā mea hoʻolako eVTOL a me nā ʻano like ʻole o ka US I ka wā i hoʻomaʻamaʻa ai ka herone i nā noi mokulele, ke loaʻa pū nei ka ʻike hana hana me nā noi mea haʻuki me nā ʻōpeʻapeʻa a me nā ʻāpana uila."Hiki i kā mākou ʻenehana ke hana i kahi ākea o nā ʻāpana paʻakikī me ka hana, ka manawa pōʻai a me nā pono kumukūʻai," wahi a Garthaus."ʻO kā mākou manawa pōkole e hoʻohana ana i ka PEEK he 20 mau minuke, ma mua o 240 mau minuke me ka hoʻohana ʻana i ka prepreg-cured autoclave.ʻIke mākou i kahi ākea ākea o nā manawa, akā i kēia manawa, ʻo kā mākou manaʻo nui i ka lawe ʻana i kā mākou noi mua i ka hana a hōʻike i ka waiwai o ia mau ʻāpana i ka mākeke.
E hōʻike pū ana ʻo Herone ma Carbon Fiber 2019. E aʻo hou e pili ana i ka hanana ma carbonfiberevent.com.
Hoʻopaʻa ʻia i ka hoʻopaʻa lima kuʻuna, nacelle a me thrust reverser mea hana ke nānā aku i ka hoʻohana ʻana o ka automation a me ka hoʻopili pani ʻia.
Loaʻa ka ʻōnaehana mea kaua i ka hana kiʻekiʻe o carbon/epoxy me ka maikaʻi o ka hoʻoheheʻe ʻana.
ʻO nā ʻano hana no ka helu ʻana i ka hopena o nā composites i ke kaiapuni e hiki ai ke hoʻohālikelike i ka ʻikepili i hoʻohālikelike ʻia i nā mea kuʻuna ma ke kahua pāʻani pae.
Ka manawa hoʻouna: ʻAukake-19-2019