In-Line Integration of Sensors in Thermoplastic Composite Structures Using Novel Continuous Orbital Winding Technology

Abstract:

Currently there is a great demand for energy and resource efficient and also function integrating manufacturing processes. Therefore, suitable technologies and corresponding foundational researches are being pursued in the federal cluster of excellence “MERGE Technologies for Multifunctional Lightweight Structures” at the Technische Universität Chemnitz. A part of this project is the development of the continuous orbital winding (COW) technology including the goal of a large-scale process used for special fiber-reinforced thermoplastic semi-finished products. This method is an inverted winding process. The winding core needs to perform only the feed motion. Furthermore, this allows synchronization to upstream and downstream process chains.Due to the modular structure of the machine concept, it is possible to integrate a sensor system during production without interrupting the process. For this purpose, a textile carrier tape with integrated electrically conductive fibers and applied sensors is embedded. Various silicon sensors, e.g. acceleration, pressure or stress sensors are applied by micro-injection molding. A so-called “interposer” is used as an electrically adapter between the microstructures of the sensor system and the mesostructures of the textile.In this article, basic investigations for the continuous processing of semi-finished thermoplastic structures and the integration of sensors are presented. It is intended to determine the bonding properties, possible structural thickening by the sensors and the resistance of the sensor systems and its electronic components to the process conditions.In summary, investigations are carried out to determine the parameters of the machine system as well as to determine the optimum processing conditions for the application of additional elements.

• Periodical: Key Engineering Materials (Volume 742)
• Pages: 490-497
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.742.490
• Online since: July 2017
• Authors: Ricardo Decker, Benjamin Arnold, Rainer Wallasch*, Angelika Bauer, Ramon Tirschmann, Jan Mehner, Wolfgang Nendel, Lothar Kroll
• Keywords: Continuous Orbital Winding, In-Line Sensor Integration, Large Scale Manufacturing, Lightweight Structures, MEMS, Processing Fiber-Reinforced Thermoplastics, Silicon Sensors, Smart Textile

References

[1] R. Schulze, P. Streit, T. Fischer, A. Tsapkolenko, M. Heinrich, M. Sborikas, L. Kroll, T. Gessner, M. Wegener, Fiber-reinforced Composite Structures with Embedded Piezoelectric Sensors, IEEE SENSORS 2014, Valencia, Spain, 2014, DOI: 10. 1109/ICSENS. 2014. 6985315.

DOI: 10.1109/icsens.2014.6985315

[2] L. Kroll, W. Nendel, M. Heinrich, R. Stelzer, J. Tröltzsch, M. Walther, Valuation of process-induced initial stresses of micro injection moulded piezo-active hybrid modules, Journal of Plastics Technology 7 (1), pp.17-43, (2011).

DOI: 10.1007/978-3-642-17384-4_10

[3] R. Schulze, M. Heinrich, P. Nossol, R. Forke, M. Sborikas, A. Tsapkolenko, D. Billep, M. Wegener, L. Kroll, T. Gessner, Piezoelectric P(VDF-TrFE) transducers assembled with micro injection molded polymers, Sensors and Actuators A: Physical 208, pp.159-165.

DOI: 10.1016/j.sna.2013.12.032

[4] A. Sorger, C. Auerswald, A. Shaporin, M. Freitag, M. Dienel, J. Mehner: Design, Modeling, Fabrication and Characterization of a MEMS Acceleration Sensor for Acoustic Emission Testing, 17th International Conference on Solid-State Sensors, Acturators and Microsystems (TRANSDUCERS 2013), Barcelona, Spain, 2013, DOI: 10. 1109/Transducers. 2013. 6626869.

DOI: 10.1109/transducers.2013.6626869

[5] Wallasch, R.; Tirschmann, R.; Spieler, M.; Nendel, W.; Kroll, L.: Continuous Winding Technology for Specific Closed Structural Components. 20th Symposium on Composites, Wien, 2015, S. 687-694, ISBN: 978-3-03835-515-1.

DOI: 10.4028/www.scientific.net/msf.825-826.687

[6] R. Wallasch, R. Tirschmann, M. Spieler, W. Nendel, L. Kroll, DE102015009250A1: Verfahren und Anlage zum kontinuierlichen Herstellen endlosfaserverstärkter rotationssymmetrischer und/oder nicht rotations-symmetrischer Bauteile mit unterschiedlichen Querschnittsverläufen mittels Orbitalwickeltechnik, German Patent and Trademark Office, 21. 07. (2015).

[7] R. Wallasch; R. Tirschmann; M. Spieler; W. Nendel; L. Kroll: Mehrkörpersimulation zur Realisierung ei-ner Demonstratoranlage für die Orbitalwickeltech-nologie. SAXSIM - Saxon Simulation Meeting, Chemnitz, Germany, 2015; ISBN: 978-3-944640-47-1.

[8] R. Wallasch, R. Tirschmann, M. Spieler, W. Nendel, L. Kroll, Pilotanlage der Orbitalwickeltechnologie für die kontinuierliche Fertigung endlosfaserverstärkter Strukturbauteile, 15. Chemnitzer Textiltechniktagung, Chemnitz, Germany, 2016, pp.247-255.

[9] F. Rost, B. Arnold, R. Decker, A. Bauer, A. Tsapkolenko, L. Kroll, J. Mehner, S. Rzepka, Development of sensor integration concept for mass production processes, Smart Systems Integration 2017, Cork, Ireland, (2017).

DOI: 10.21935/tls.v1i2.82

[10] M. Heinrich, R. Decker, J. Schaufuß, J. Tröltzsch, J. Mehner, L. Kroll, Electrical contact properties of micro-injection molded Polypropylene/CNT/CB-composites on metallic electrodes, Advanced Materials Research 1103, pp.77-83.

DOI: 10.4028/www.scientific.net/amr.1103.77