Quality-assured mass production of NCF through an intelligent production machine

Transcription

1 Quality-assured mass production of NCF through an intelligent production machine M. Haeske 1, B. Abbas 2, T. Fuertjes 3, T. Gries 1 1 Institute of Textile Technology (ITA) of RWTH Aachen University 2 Assoc. Institute for Management Cybernetics e.v. (IfU) 3 Chair of Production Metrology and Quality Management (WZL) of RWTH Aachen University

2 Product Increasing use of non-crimp fabric (NCF) Large series production of components No-standardized quality requirements from different companies / industries [1] [2] [3] Reference: [1]: [2]: [3]: 2

3 Outline 1 Introduction and Motivation 2 Approach for a quality control system 3 Machine modifications 4 Investigation on the pressure roll 5 Conclusion and Summary 3

4 Outline 1 Introduction and Motivation 2 Approach for a quality control system 3 Machine modifications 4 Investigation on the pressure roll 5 Conclusion and Summary 4

5 Introduction NCF Production High productivity Manual adjustment of production parameters Tension of stitching yarn Tension of reinforcement fibers Preload of pressure roll 0 -fibers Angle of fiber lay-up Reinforcement fibers Warp knitting unit Warp knitting unit Take-up Non-woven Weft insertion sytems Pressure roll Typical set-up of NCF fabric LIBA Copcentra Max 3 machine Reference: Karl Mayer LIBA GmbH 5

6 Introduction NCF Production Pressure roll is used to homogenize the fabric and to reduce gaps Manually adjusted pre-load on springs pressure Upper pressure roll Production direction Pressure roll Homogenous fabric Takeup Gap (2 ) Fiber layers Lower roll Warp knitting unit Production 6

7 Motivation Errors within the production process thread tension prone to error possible inhomogeneous texture outcome angular deviation erros within intermediate layers foreign object Deficits of the production process non-existing quality monitoring of the production process no detection of errors within intermediate layers no continuous record keeping of texture quality mainly manual on sight quality inspection 7

8 Motivation Research Project: AiF Auto-NCF Goals: Higher quality of the product Less quality cost Quick adjustement of optimum machine settings Lower reject rate Detailed error map for every roll of produced textile Implementing an in-line quality control system into the production of NCF 8

9 Outline 1 Introduction and Motivation 2 Approach for a quality control system 3 Machine modifications 4 Investigation on the pressure roll 5 Conclusion and Summary 9

10 Approach for a quality control system Development of actuators Development of sensors Model-based control 10

11 Approach for a quality control system Visualisation Closed loop control Combination of all sensor data Feedback loop to adjust pressure roll Documentation of all data Creation of error map Data acquisition Creation of error map Pressure measurement Thread tension measurement Visual monitoring Area density measurement Sensor system 11

12 Outline 1 Introduction and Motivation 2 Approach for a quality control system 3 Machine modifications 4 Investigation on the pressure roll 5 Conclusion and Summary 12

13 Machine modifications Light Barriers Breakage of reinforcing fibers Breakage of warp knitting fibers Laser-light barrier Air blow unit Laser-light barrier 13

14 Machine modifications Detection systems Areal weight detection Fiber misalignement detection X-Ray Sensor Camera 1 DSP-Box Camera 2 14

15 Machine modifications Pressure Roll System Camera 1 Pressure Roll Pressure Valve 15

16 Machine modifications Overall System Control Cabinet Mobile Panel LabView PC 16

17 Outline 1 Introduction and Motivation 2 Approach for a quality control system 3 Machine modifications 4 Investigation on the pressure roll 5 Conclusion and Summary 17

18 Investigation on the pressure roll Load cells Load cells are installed A pressure measurement film is used to investigate the influence of the pressure roll and the homogenizing effect 18

19 Pressure Druck [kpa] Investigation on the pressure roll Pressure measurement film Curved irregular characteristic Conclusions about height and width of thick spots can be drawn But: gaps need to be detected without influence on the textile 40,00 Erzwungene Forced Erzwungene gaps Gassen Gassen (Belastung (pre-load durch on pressure je 30 N roll: Federkraft) 30 N) bei Belastung durch je 30 N Federkraft 30,00 20,00 10,00 mittig 0, Messpunkt 19

20 With pressure roll Without pressure roll Investigation on the pressure roll Results 300 g/m² low speed Pressure roll: low tension 600 g/m² low speed Pressure roll: high tension 20

21 Outline 1 Introduction and Motivation 2 Approach for a quality control system 3 Machine modifications 4 Investigation on the pressure roll 5 Conclusion and Summary 21

22 Conclusion and Summary High economical use of quality control system for NCF-production Homogenizing effect of the pressure roll Compression too low ideal too high Not enogh driving force No lateral movement of fibres possible 22

23 Thank you for your attention! Contact: Dipl.-Ing. Dipl.-Wirt. Ing. Marcel Haeske Phone: +49 (0) Fax: +49 (0) Partner: This IGF-project Auto-NCF 494 ZN of the Forschungsvereinigung Forschungskuratorium Textil e.v., Reinhardtstraße 12-14, Berlin is funded via the AiF by the Federal Ministry for Economic Affairs and Energy (BMWi) according to a decision of the German Federal Parliament. 23