Dr.-Ing.

Janssen, Henning

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  • Publication
    Advanced production of thermoplastic composite pipes
    ( 2019)
    Schäkel, Martin
    ;
    Peters, Tido
    ;
    Janssen, Henning
    ;
    Brecher, Christian
    A novel system for thermoplastic composite tape winding was developed as part of the ambliFibre multinational research project. The system features multiple functionalities for improved quality and reliability in the manufacturing of safety-critical structures such as composite armours for unbonded flexible pipes.
  • Publication
    Individualisierte Fertigung von faserverstärkten Hybridbauteilen
    ( 2019)
    Hopmann, Christian
    ;
    Ophüls, Max
    ;
    Schulz, Martin
    ;
    Janssen, Henning
    Das IKV und das Fraunhofer IPT stellen zusammen mit den Partnern des LightFlex-Projekts ein flexibles Verfahren für die Herstellung individualisierter Prototypen aus tapebasierten Laminaten und additiv gefertigten Funktionsstrukturen vor. Eine Produktionsanlage verarbeitet dabei unidirektionale Tapes mithilfe eines Tapelegeprozess mit In-situ-Konsolidierung zu Laminaten. Die Funktionalisierung erfolgt werkzeuglos und im Stempelumformverfahren.
  • Publication
    Data Collection and Analysis for the Creation of a Digital Shadow During the Production of Thermoplastic Composite Layers in Unbonded Flexible Pipes
    ( 2018)
    Schäkel, Martin
    ;
    McNab, John
    ;
    Dodds, Neville
    ;
    Peters, Tido
    ;
    Janssen, Henning
    ;
    Brecher, Christian
    Unbonded flexible pipes present a mature technology for the efficient recovery and transport of hydrocarbons offshore. The substitution of metallic reinforcement layers in the multilayered structure by thermoplastic fiber-reinforced polymer (FRP) presents a solution for self-weight issues of especially long pipes, as FRP materials display high specific strength and modulus while being resistant to external pressure and corrosion. The production of these layers is automated by the laser assisted tape winding process without the need of additional curing steps. During the manufacturing process, several data like process temperature and consolidation pressure are continuously monitored by non-contact sensors to ensure process stability without interfering in the consolidation process. To gain additional information about the temperature distribution within the multi-layered laminate, contact temperature sensors were introduced in the tape winding process. By this method the temperature of subjacent tapes can be assessed during the continued winding process. Additionally, this paper features a new approach of utilizing winding path data for relating the time-dependent sensor data to the exact position on the produced part. The visualization of path-dependent sensor data opens up possibilities of linking quality monitoring results to manufacturing insufficiencies and potential part defects.
  • Publication
    Quantification of micro-pullwinding process as basis of data mining algorithms for predictive process model
    ( 2017)
    Wasiak, Christian
    ;
    Nettleton, David
    ;
    Janssen, Henning
    ;
    Brecher, Christian
    Cost efficient customization of goods is a very important field of interest in many areas of the manufacturing sector today. New research tries to extend the concept of customized products to the field of medical devices. In particular, the focus is set on the production of minimally invasive disposables. In this context, fiber reinforced plastics (FRP) do not only provide compatibility with all relevant medical imaging technologies but can also be used to realize mechanical customization. Currently, the physician has to choose from the available product range predefined by the manufacturers. However, to maximize the ease of use of the medical devices and, thus, to optimize the outcome of the intervention a customized product would be the perfect solution. The involved devices are disposable items and todays production technology is optimized to produce high amounts of these devices with low variability at low costs. Also an individualized version of these devices would be a disposable. Therefore a still cost efficient and at the same time adaptive production system would be needed to manufacture such individualized disposables. One solution to overcome this challenge would be to link the necessary adaptive production systems in a continuous production line. On the one hand, the product can be produced cost efficiently in an endless process with minimum handling operations, on the other hand the adaptiveness of the involved production systems allows for customized manufacturing. However, the complexity of such combined continuous production system calls for new ways to control and optimize the process using data mining technologies. In this context, this work presents the initial steps to create a model of a micro-pullwinding process. The micro-pullwinding process as part of the linked production system will be used to produce FRP wires with customized mechanical properties. A process analysis reveals the crucial process parameters and their relationships, which are investigated in more detail afterwards. The results of this quantifying investigation can be used to train a process model based on self-learning algorithms.
  • Publication
    Efficient production of tailored structural thermoplastic composite parts by combining tape placement and 3d printing
    ( 2017)
    Janssen, Henning
    ;
    Peters, Tido
    ;
    Brecher, Christian
    Thermoplastic composites, such as organosheets and unidirectional tapes, have become more and more popular in recent years. In certain high volume applications, they are often combined with non-reinforced plastics in overmolding processes. However, for product development or customized parts, more flexible process chains for the production of continuous fiber-reinforced thermoplastic parts are required. The automated placement of continuous fiber-reinforced thermoplastic tapes is an additive manufacturing technology which can be used to produce load-optimized tailored blanks. These blanks can be formed and joined with 3d printed structures to complex, function integrated, customized hybrid thermoplastic structures without the need of expensive molds.
  • Publication
    Continuous assessment of geometrical properties from unidirectional fiber reinforced tapes
    ( 2017)
    Buschhoff, Clemens
    ;
    Schäkel, Martin
    ;
    Janssen, Henning
    ;
    Brecher, Christian
    Fully impregnated thermoplastic tapes are one of the most promising materials. However, no standards for tape material and its properties are available. Thereby tape quality varies between manufacturers and can even vary within one tape spool. Changing properties can result in poor and inhomogeneous laminate quality. To overcome these obstacles, a module is developed to scan continuously the tape geometry. The module can be implemented within a manufacturing environment and provides key parameters for intimate contact modeling directly.
  • Publication
    Laminate aus duroplastischen Prepregs mit aktivierbarer Adhäsion
    ( 2016)
    Werner, Daniel
    ;
    Janssen, Henning
    ;
    Brecher, Christian
    Neben der Reduktion des manuellen Fertigungsaufwands ist die Senkung der Materialkosten ein wesentlicher Aspekt zur wirtschaftlichen Herstellung faserverstärkter Kunststoffbauteile. Beide Ziele werden durch die Entwicklung neuartiger Matrixsysteme und durch die Entwicklung hierfür anwendbarer automatisierter Verarbeitungsprozesse fokussiert. Die neuartigen Matrixsysteme kombinieren die Vorteile konventioneller duroplastischer und thermoplastischer Matrixsysteme (kostengünstige Harze, einfache Imprägnierung durch niedrige Viskosität bzw. trocken und adhäsionsfrei bei Raumtemperatur, niedrige Taktzeiten, Lagerung bei Raumtemperatur). Die Verarbeitung im automatisierten Tapelegeprozess ermöglicht die Herstellung belastungsoptimierter Strukturbauteile, bei denen Faseranordnung und -orientierung an die erwartete Belastungssituation des Bauteils anpasst sind. Die hieraus resultierenden Möglichkeiten zur Verarbeitung werden am Fraunhofer IPT hergeleitet und untersucht.
  • Publication
    Individuell und automatisiert. Vernetzte Produktionstechnik für die additive Fertigung individualisierter Faserverbundbauteile
    ( 2016)
    Brecher, Christian
    ;
    Werner, Daniel
    ;
    Janssen, Henning
    ;
    Hildebrandt, Markus
    ;
    Beste, Christian
    Die Fertigung von Produkten in großen Stückzahlen weicht zunehmend dem Bedarf nach Produktionslösungen für kostengünstige und individualisierte Produkte. Das bringt neue Herausforderungen für die Produktentwicklung, Prozessflexibilität, Kosteneffizienz und Produktionstechnik. Der Artikel beschreibt einen umfassenden Lösungsansatz für die individualisierte Fertigung geometrisch komplexer faserverstärkter Bauteile.