Plastic Innovations: Fiber

Intelligent quality and process control in CFRP manufacturing

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Intelligent quality and process control in CFRP manufacturing</h1>
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At Composite Europe, Pixargus – reputed as a supplier of individual measuring systems – will present itself as a provider of systems for integrated measurement solutions for inline quality control of carbon fiberfabrics, a product increasingly used in applications such as automotive and aviation construction, and wind power plants.</div>
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Starting out from optical measurement and inspection devices for rubber and plastic profiles, Pixargus has continuously expanded its range of products. The Aachen/Germany-based company now also offers integrated inline quality control systems for CFRP production processes. By applying these systems, Pixargus customers ensure that all products leaving their works are 100 percent defect-free.</div>
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With the exception of the weight per area, all measurements and inspections are based on optical methods. A key element of the technology is the Pixargus WebControl CarbonFiber system, which inspects the web surface. With the framework software architecture, which has been specifically developed for the inspection of this type of surfaces, it is possible to map the complex web structure while detecting defects typical of carbon fiber material.</div>
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As a general contractor for total quality control systems, Pixargus supplies several interlinked measuring systems and combines the data measured by the various sensors into a global data map, allowing the customer to analyze the results within a context, not isolated from one another.</div>
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This systems approach is characterized by a wide array of applied technologies, namely surface inspection of the heavily textured fabrics by means of complex image processing and pattern recognition algorithms, optical measurement with an accuracy down to the micrometer, lighting solutions using innovative LED technology and non-contact thickness measurement.</div>
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An example of these systems solutions is the inline inspection of the carbon fiber fabrics used to make car body components for a new generation of electric vehicles made by a leading German premium car producer. The system comprises hybrid quality assurance systems for measurements and inspections during processes as diverse as the application of powder, the detection of missing bundles, the analysis of material flaws and sintering.</div>
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Dirk Broichhausen, Vice President Sales & Marketing at Pixargus, explains which factors were decisive for winning this contract: “Our company was chosen as contract partners for all quality assurance assets used in the final inspection of the products for various reasons. One reason was our technological lead in the field of optical surface inspection. Another important reason was the good experience the car maker – to whom our customer supplies his products – had previously made with other Pixargus measuring systems. And the experience which we have gained during previous projects with important players in the automotive industry was certainly another decisive factor.”</div>
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In their systems, the Pixargus specialists combine many years of experience in sensor technology – mainly in optical measuring systems – with expertise in industrial production processes and innovative materials. According to Björn Lindner, one of the founders and managing directors of Pixargus, his company”s growth strategy has turned out successfully. “This system solution underpins that Pixargus has evolved from a manufacturer of individual sensor systems to a systems provider of comprehensive inline quality assurance solutions for complete production lines. This also becomes obvious in the fact that we combine separate measuring systems into networked solutions and the data from different sources into a global picture.”</div>
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About Pixargus</div>
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Intelligent quality and process control in CFRP manufacturing</div>
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PIXARGUS designs systems for optical inline measurements and inspections of carbon fiber fabrics, which may be used, for example, in electric vehicles. The company is one of the world’s technology leaders in the field of optical inline quality control.</div>
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In the production chain for CFRP, PIXARGUS systems detect weaving and material defects, inspect the distances between bundles, measure and check whether the powder has been properly deposited, measure the degree of sintering, and so on. To allow a comprehensive data analysis, the data measured by the various sensors are interlinked and integrated into a “global data map”. This makes it possible to optimize production processes and guarantees 100 percent flawless products.</div>
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By combining its many years of experience in sensor technology – mainly in optical measuring systems for rubber profiles and tubing – with expertise in industrial production processes and innovative materials, PIXARGUS can serve its customers as a general contractor for total quality control in CFRP production.</div>
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Worldwide almost all major manufacturers of automotive rubber profiles use Pixargus systems for surface inspection and profile measurements. Also in medical engineering Pixargus has set new standards with its inline surface inspection systems for medical tubing. The underlying image processing technology is also the basis for the recent foundation of the company GoalControl GmbH and for the soccer goal-line technology of the same name, which proved itself in practice during the FIFA World Cup 2014 in Brazil.</div>
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Pixargus is based in Würselen near Aachen/Germany. The company is active worldwide through its US branch and various international technical agencies.</div>
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Intelligent quality and process control in CFRP manufacturing

Optical inspection of the degree of sintering in carbon fiber fabric production Intelligent quality and process control in CFRP manufa...

Carbon Fiber Car Components—What’s That Got to Do with Plastics?

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Carbon Fiber Car Components—What’s That Got to Do with Plastics?</h1>
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Plastic has two words for you: carbon fiber.</div>
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When planning and building our new cars, automakers are increasingly turning to carbon fiber—the same type of material used in Boeing’s high-tech 787 Dreamliner airplanes. It’s said to be up to 10 times stronger than steel yet four times lighter.</div>
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Beyond autos and aerospace, carbon fiber is used in sporting goods, wind energy turbines, military applications and more. And its use is expected to double or even triple by 2020.</div>
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So … just what is carbon fiber? And why does Professor Plastic care? I mean, it’s not a plastic, right?</div>
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It’s true that carbon fiber is not itself a plastic. It’s an incredibly small diameter fiber (or filament) made mostly of carbon atoms. And I do mean small—usually between 5 and 10 microns in diameter (a micron is a millionth of a meter or about 0.000039 inches). These fibers usually are bundled to form thread (or tow) that often is woven into a fabric.</div>
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You might remember from chemistry class that diamonds—one of the hardest natural substances—are composed of carbon atoms arranged in a particular lattice. So it’s not surprising that carbon fiber is stiff, strong and light, plus resistant to chemicals and tolerant of high temperatures. Sounds ideal for making stuff.</div>
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Well, on its own, carbon fiber often is <i style="background: transparent; border: 0px; margin: 0px; outline: 0px; padding: 0px; vertical-align: baseline;">not</i> ideal. It typically is combined with other materials to provide the properties needed for a racecar chassis or airplane fuselage or prosthetic limb or tennis racket or fishing rod or bicycle frame.</div>
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Typically combined with <i style="background: transparent; border: 0px; margin: 0px; outline: 0px; padding: 0px; vertical-align: baseline;">what</i> other materials, you ask?</div>
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Plastics.</div>
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The term “carbon fiber” when used in layman terms (such as in news stories) most often refers to “carbon-fiber-reinforced plastics”—that is, a composite made up of carbon fibers PLUS some type of plastic. Or some combination of plastics. And perhaps some other materials. Since “carbon-fiber-reinforced plastics” is a mouthful, many people simply shorten it to: “carbon fiber” or “carbon-fiber composite.” And the “plastics” get forgotten. (So sad.)</div>
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Combining carbon fiber with plastics is sort of like adding rebar (“reinforcing bar”) to concrete, which creates “reinforced concrete.” The combination of carbon fiber and plastics results in materials with superman qualities, including greater strength and durability.</div>
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As mentioned above, our new cars likely will see rapid growth in the use of carbon-fiber-reinforced plastics. (OK, let’s just call it CFRP.) To date, CFRP auto components—chassis, spoilers, roofs, hoods and many internal and external parts—largely but not exclusively have been employed in higher-end luxury or performance cars due to high manufacturing costs. Today many automakers (e.g., Ford, Mercedes, General Motors, BMW) are investing heavily in CFRP applications, now that costs are coming down and new technologies allow these components to be produced more quickly.</div>
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Why should we drivers (or passengers) care? Because increased use of CFRP can reduce vehicle weight, improve fuel economy and contribute to safety.</div>
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<li style="background: transparent; border: 0px; margin: 0px 0px 4px; outline: 0px; padding: 0px; vertical-align: baseline;">Weight/fuel economy: As noted above, CFRP is much stronger than steel yet lighter, so car components can be made lighter. That’s one reason Ford has partnered with Dow Chemical Company to expand CFRP use, with the goal of reducing auto weight 750 pounds by 2020. Just a 10 percent reduction in vehicle weight can increase fuel efficiency 6 to 8 percent over the life of today’s cars. That’s a lot of gas.</li>
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<li style="background: transparent; border: 0px; margin: 0px 0px 4px; outline: 0px; padding: 0px; vertical-align: baseline;">Safety: CFRP auto components can have a higher energy-absorption rate than steel, which can contribute to improved safety in a collision. As an example, race cars today are made largely with CFRP, which has led to reduced weight, improved performance—and enhanced safety. Like other safety advances developed for the racetrack, CFRP components now are headed toward mainstream use in the family car.</li>
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The growth in CFRP auto components will expand the already extensive and growing use of plastics in our cars. Today’s new cars already are made up of approximately 10 percent plastics <i style="background: transparent; border: 0px; margin: 0px; outline: 0px; padding: 0px; vertical-align: baseline;">by weight </i>but 50 percent plastics <i style="background: transparent; border: 0px; margin: 0px; outline: 0px; padding: 0px; vertical-align: baseline;">by volume</i>.</div>
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The combination of carbon fiber and plastics is poised to expand that ratio even further—while contributing to fuel efficiency and our safety.</div>
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Carbon fiber. Sounds like an ideal material.</div>
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Just don’t forget the plastics …</div>
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Carbon Fiber Car Components—What’s That Got to Do with Plastics?

Carbon Fiber Car Components—What’s That Got to Do with Plastics? Plastic has two words for you: carbon fiber. When planning and bui...

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Intelligent quality and process control in CFRP manufacturing

Carbon Fiber Car Components—What’s That Got to Do with Plastics?

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