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A process and a production installation for producing shell-shaped, fiber-reinforced plastic parts are provided. The plastic parts can be produced efficiently, in an automated manner which is flexible with respect to the process and workpiece and is operationally reliable. A blank of the endless fi

A process and a production installation for producing shell-shaped, fiber-reinforced plastic parts are provided. The plastic parts can be produced efficiently, in an automated manner which is flexible with respect to the process and workpiece and is operationally reliable. A blank of the endless fiber mat corresponding to a workpiece is placed in an automated manner by industrial robots onto a clamping frame surrounding the female mold and is taken over by the clamping frame in a clamping manner and in such a way that it can slide after itself against a defined resistance. Wide-ranging accessibility required for this is created by a horizontally movable unit, comprising a female mold and a clamping frame, being temporarily moved completely out from the forming press and moved back again into the forming press after completion of loading.

대표청구항 ▼

The invention claimed is: 1. Process for producing shell-shaped plastic parts from fiber-reinforced, thermosetting plastic in a forming press with a forming tool having a female mold, a female mold-clamping unit, and a male mold, comprising: moving the female mold out of the forming press, placing

The invention claimed is: 1. Process for producing shell-shaped plastic parts from fiber-reinforced, thermosetting plastic in a forming press with a forming tool having a female mold, a female mold-clamping unit, and a male mold, comprising: moving the female mold out of the forming press, placing a blank cut off from an endless fiber mat and corresponding to a workpiece in an automated manner by an industrial robot onto the female mold, which has been moved out of the forming press, and is firmly held there, in such a way that the blank is fed after itself, by a surrounding clamping frame, spraying the blank placed in the clamping frame over an entire surface area with a specifically set amount of reactive matrix resin in the region covering the female mold by a spraying nozzle guided movably at a distance from the blank, after moving the female mold-clamping frame unit back into the forming press and closing the forming tool, while maintaining a specifically set tensile stress in the blank, draping the blank into the female mold without any folds or incipient tears, the blank is thereby formed into a desired shell form, at the same time the matrix resin is pressed into spaces between fibers and entrapped air is forced out, keeping the resin-impregnated fiber mat in a formed and pressed state for a specifically set time period and, at the same time, curing the matrix resin within the forming tool, and after opening of the forming tool, removing the plastic part and cutting off an edge of the blank lying outside the desired shell form of the workpiece, serving for stretching out the blank during the forming phase, from the workpiece. 2. Process according to claim 1, wherein, on account of a multiple arrangement of horizontally movable units each comprising a female mold and a clamping frame, the horizontally movable units is loaded outside the forming press and handled within the forming press in an alternating cycle. 3. Process according to claim 1, wherein a free end of a fiber mat web wound up on a storage roll, which said end is held ready in a positionally defined manner by a fixed holding bar, which is controlled in a holding function, is taken up by a robot-guided gripping bar over the entire width of the web, a portion of the fiber mat web corresponding to the workpiece is drawn off from the storage roll, the other end of the portion is taken up by a second robot-guided gripping bar, likewise over the entire width of the web, the fiber mat web is cut through in a region lying between the fixed holding bar and the second gripping bar and the cut-off portion is placed onto the clamping frame. 4. Process according to claim 1, wherein a portion of a fiber mat drawn off from a storage roll and corresponding to the workpiece is cut off from the wound-up fiber mat web by a high-speed rotating narrow grinding wheel, which is moved parallel to a plane of rotation and along a line between two closely neighboring holding or gripping bars, firmly holding the fiber mat web, with a specifically set advancing rate through the fiber mat. 5. Process according to claim 1, wherein the blank cut off from a stored fiber mat web and corresponding to the workpiece is taken over on two opposite sides by robot-guided gripping bars and placed onto the clamping frame and the female mold. 6. Process according to claim 1, wherein, before placement of the blank of a number of blanks onto the clamping frame, firstly insert parts or locally delimited preforms are placed into the female mold. 7. Process according to claim 6, wherein all the preforms to be placed in advance before placement of the blank onto the clamping frame are sprayed over an entire surface area with a specifically set amount of matrix resin. 8. Process according to claim 1, wherein the placing and firm holding of said blank corresponding to the workpiece on the clamping frame and subsequent spraying of the placed blank with reactive matrix resin is repeated in a way corresponding to a desired number of plies and the forming and pressing of the placed and sprayed blanks is only carried out subsequently for all of them together. 9. Process according to claim 1, wherein epoxy resin, which is set in viscosity to be sprayable and highly fluid, is used as the matrix resin, the spraying nozzle being selected or set with respect to a form of jet in such a way that, taking into consideration the distance of the spraying nozzle from the fiber mat blank to be sprayed, a width of from 5 to 15 cm, is sprayed with epoxy resin during movement of the spraying nozzle. 10. Process according to claim 1, wherein, for maintaining a specific tensile stress in the blank during the draping into the shell form predetermined by the female mold and during the sliding of the edge of the blank after itself out of the edge clamping restraint on the side of the clamping frame surrounding the female mold, the edge of the blank is superficially covered over a specific width and a covering, including the edge of the blank, is sucked with a defined force against an air-permeable upper side of the evacuated clamping frame. 11. Process according to claim 10, wherein, during the draping, the covering along with the edge of the blank can be sucked sectorally with different force against the clamping frame, which is sectorally subdivided into different chambers and is correspondingly evacuated to different degrees. 12. Process according to claim 10, wherein, during the draping, the covering along with the edge of the blank is sucked against the clamping frame with a force changing over time, in that a vacuum evacuating the clamping frame or sectors of the same is changed over time. 13. Process according to claim 10, wherein, in addition to the vacuum pressing, during the draping, the edge of the blank is mechanically pressed by the covering, with a force which can be preset, against the upper side of the clamping frame, which said covering is of an intrinsically rigid form and elastically prestressed. 14. Process according to claim 1, wherein the trimming of the shell form of the workpiece, serving for stretching out the blank during the forming, from the workpiece, takes place by a high-speed rotating narrow grinding wheel. 15. Production installation for producing shell-shaped, fiber-reinforced plastic parts, which said plastic parts comprise an at least single-ply endless fiber mat, following a form of a shell, and a thermosetting polymer matrix or matrix resin, embedding fibers of the fiber mat on all sides and without any pores, which said endless fiber mat in an initial state is formed by the fibers or fiber bundles extending rectilinearly and without interruption over a blank corresponding to a workpiece, comprising: a forming press which can be opened and closed, with a forming tool comprising a female mold and a male mold, the female mold, arranged at a bottom in the forming press, being surrounded on all sides by a clamping frame for the fiber mat blank placed thereon, which said clamping frame is held in a spatially immovable position in relation to the female mold, a securing plane of the fiber mat blank being received in the clamping frame coinciding at least approximately with a form parting plane of the female mold, the clamping frame being designed in such a way that an edge of the blank placed on the clamping frame can be firmly clamped therewith in such a way that, when tension acts on the blank, the edge can slide out against an adjustable resistance, the female mold and the clamping frame being mounted and guided in a horizontally movable manner as a unit, which is moved back and forth between a working position, lying in the forming press under the male mold, and a preparatory position, lying completely outside the forming press, alongside the forming press, at least one industrial robot being arranged in such a way that the preparatory position of the female mold-clamping frame unit lies within a working range of the industrial robot, arranged within the working range of the at least one industrial robot, provision containers for ready-to-hand provision of insert parts or of locally delimited preforms of fiber mats, the at least one industrial robot being provided with a hard-part gripper, which is adapted to the insert parts to be placed in, or with a textile-part gripper, which is adapted to the preforms to be placed in, arranged alongside the forming press, an unwinding station for at least one fiber mat web, which said station has a holding bar, for holding a free end of the web ready, and a cutting-off device, for cutting through a drawn-off portion of the fiber mat alongside the holding bar, the holding bar likewise lying within the working range of the industrial robot, the at least one industrial robot being provided with a gripper for drawing off a portion from the stored fiber mat web and for handling a cut-off blank, the at least one industrial robot being provided with a controllable application nozzle for spraying a reactive matrix resin onto a partial preform placed in the female mold, which is located in the preparatory position, or onto the fiber mat blank placed there, the robot-guided application nozzle being assigned a storing and mixing station for individual components of the matrix resin. 16. Production installation according to claim 15, wherein a number of separate units, respectively comprising a female mold and a clamping frame, are arranged in and on the forming press in a horizontally movable manner, which said units can be alternately displaced back and forth between the working position and preparatory positions. 17. Production installation according to claim 15, wherein two separate female mold-clamping frame units are arranged on opposite sides of the forming press. 18. Production installation according to claim 17, wherein the two separate units, arranged on opposite sides of the forming press, are rigidly coupled to each other and are guided displaceably together in a rectilinear horizontal manner. 19. Production installation according to claim 15, wherein the cutting-off device for the fiber mat web is formed by a high-speed rotating narrow grinding wheel, which is displaceable parallel to a plane of rotation of the grinding wheel and parallel to the holding bar which is firmly holding the free end of the fiber mat web, with an adjustable advancing rate transversely over the fiber mat web. 20. Production installation according to claim 19, wherein the grinding wheel is encapsulated on a side emerging from the fiber mat web and the encapsulation is connected to a dust extraction. 21. Production installation according to claim 20, wherein an opening which can be closed by a flap or a slide and is intended for introducing a dressing tool for the grinding wheel is provided on an outer periphery of the encapsulation. 22. Production installation according to claim 19, wherein a device for advancing the cutting-off device through the fiber mat web is provided with a device for measuring an advancing force and also with a signalling device, which is designed in such a way that exceeding of the advancing force over a threshold value which can be preset can be signalled outwardly. 23. Production installation according to claim 19, wherein the grinding wheel is provided with a dressing tool which is mechanically guided in an axial direction with respect thereto, can be fed in radially and is provided with an axial servo-motor advancing drive and with a radial servo-motor infeed drive, with said tool the grinding wheel can, in response to a dressing command, be automatically dressed in accordance with a program which can be input in advance. 24. Production installation according to claim 15, wherein frame legs of the clamping frame which firmly hold the edge of a blank placed on the clamping frame are respectively designed as suction bars which can be covered and are formed in cross section as a closed hollow profile, with a flat side taking up the edge of the blank and provided with a surface-covering pattern of drilled holes, the interior of the hollow profile optionally being connected to a negative-pressure source or subjected to ambient air pressure by way of a controllable valve. 25. Production installation according to claim 24, wherein at least one of the clamping-frame suction bars is subdivided into chambers, which are divided off from one another and can be activated separately. 26. Production installation according to claim 24, wherein a surface of the flat side of the clamping-frame suction bars which takes up the edge of the blank is of an at least partially smooth form and goes over into the drilled holes of the surface-covering pattern of drilled holes in a rounded manner. 27. Production installation according to claim 15, wherein the covering of frame legs of the clamping frame formed as suction bars is arranged on the male mold, which can be raised and lowered in the forming press, and, with the male mold going down, can be lowered onto the edge of the blank received in the clamping frame and can be pressed elastically against the edge. 28. Production installation according to claim 15, wherein gripping bars for handling the blank are designed as suction bars which can be covered and are formed in cross section as a closed hollow profile, with a flat side which can be brought to bear against the edge of the blank and is provided with a surface-covering pattern of drilled holes, the interior of the hollow profile optionally being connected to a negative-pressure source or subjected to ambient air pressure by way of a controllable valve. 29. Production installation according to claim 28, wherein a surface of the flat side of the suction bars which can be brought to bear against the edge of the blank for handling the blank is roughened or grooved. 30. Production installation according to claim 15, wherein two separate gripping bars are provided for handling of the blank, each of which is arranged on an operating arm of a respective separate industrial robot. 31. Production installation according to claim 15, wherein the textile-part gripper for handling the partial preforms is designed as a needle gripper. 32. Production installation according to claim 15, wherein all infrastructural devices of the production installation, or the industrial robot, unwinding station, cutting-off device, provision containers and placing stations are duplicated and are arranged symmetrically with respect to a center of the forming press. 33. Production installation according to claim 15, wherein logistical devices of the production installation, or the unwinding station, the provision containers and the placing stations, are arranged on a periphery of the production installation. 34. A method of making a contoured plastic part from fiber-reinforced, thermosetting plastic in a forming press with a forming tool having a female mold and a male mold, comprising: moving the female mold out of the forming press, forming a blank by cutting off a portion of a fiber mat, placing the blank corresponding to a workpiece in an automated manner by an industrial robot onto the female mold, firmly holding the blank on the female mold by a clamping frame surrounding the blank in such a way that the blank can be fed after itself, spraying the blank over a surface area with a specifically set amount of reactive matrix resin in a region covering the female mold by a spraying nozzle guided movably at a distance from the blank, moving the female mold and clamping frame as a unit into the forming press, closing the forming tool, while maintaining a specifically set tensile stress in the blank, draping the blank into the female mold without any folds, forming the blank into a desired contoured form and pressing the matrix resin into spaces between fibers, keeping the resin-impregnated blank in a formed and pressed state for a specifically set time period and curing the matrix resin within the forming tool, opening the forming tool, removing the plastic part, and cutting off an edge of the blank lying outside the desired contoured form of the workpiece, said edge serving for stretching out the blank during forming, from the workpiece.