With the Aus­trian com­pany Teufel­berger Com­pos­ite GmbH, HIRSCHMANN has the ideal part­ner at its side to re­al­ize their in­no­v­a­tive prod­ucts for aero­space. They have decades of ex­pe­ri­ence in de­vel­op­ment and man­u­fac­tur­ing of fiber ropes. For the HIRSCHMANN in­no­va­tion, Teufel­berger pro­duces the Tie Rods (cou­pling bars) as con­nect­ing el­e­ments be­tween the LW spher­i­cal bear­ings. These ex­tremely re­sis­tant sta­bi­liz­ers are a mesh of high-ten­sile, high per­for­mance com­pos­ite fibers such as car­bon, glass, or aramid. For pro­cess­ing the pre­form, Teufel­berger prefers the Com­pos­ite braid­ing tech­nol­ogy resulting in a de­fined braid­ing of hol­low bod­ies.

The braid­ing process for com­pos­ite fibers is done by ra­dial plait­ing ma­chines. In these ma­chines, the com­pos­ite fibers are de­parted in con­trolled an­gles and in sev­eral lay­ers with the help of spe­cially de­signed bob­bins on a braid­ing core, and are moved through the ma­chine by a robot. Ad­di­tional fibers in lon­gi­tu­di­nal unit di­rec­tion (UD fil­a­ments) are placed over the ma­chine cir­cum­fer­ence along the axis of the braid­ing core. The form­ing hose cov­ers the shape of the braid­ing core ex­actly, and a pre­form is made that al­ready cor­re­sponds to the final con­tour of the com­po­nent being manufactured. The braid­ing tech­nol­ogy is pre­des­tined for au­to­mated man­u­fac­tur­ing of mul­ti­layer, three-axial hol­low meshes made of com­pos­ite fiber ma­te­ri­als and al­lows the pro­duc­tion of var­i­ous com­po­nent geome­tries near to final con­tour. For op­ti­mum strength, a resin is in­jected into the mesh in RTM process (Resin Trans­fer Mold­ing).

Automatisiertes Wickeln der Tie-Rods.
Braider with robot

Hybrid meshes – different types of fibers within one mesh layer – are a special feature of Composite braiding. Because the mesh is closed completely only on the component surface, it is possible to add additional elements as the patented T-IGEL® connecting technology.

Into the joint elements with T-IGEL® connection, made by 3D-printing in titanium, the aluminum-titanium spherical bearings are pressed and rolled in by HIRSCHMANN at a later stage. Further on in production process of the Tie Rods, the core braided with composite fiber materials is solved and washed out in a water quench. The result of this process is ultralight, hollow inside, but extremely resilient Tie Rods.

The stabilizer bars are available in different lengths and diameters. A special program calculates according to the application, where the highest forces should be transmitted – this point is basis for material thickness. Available are units with a diameter from 25 to 300 mm in length up to 15 m. Depending on component diameter, machine size, and type of composite fiber braiding angle in the range of [-25/25°] up to [-85/85°] can be realized.