Smart production technology for complex fiber composites*

Transcription

1 Smart production technology for complex fiber composites* SAMBA & ARTIST STUDIO The advanced production solution for complex fiber preforms Thorsten Groene, CEO & Co-Founder September 2017 milestones in composites 1

2 Complex composites still manufactured by hand! Long production cycles No effective quality control High scrap rate High cost Need for automation solutions? 2

3 Fiber Patch Placement Additive 3D preforming technology for complex fiber composites SAMBA Automated production systems Benefits ARTIST STUDIO CAD-CAM software End-to-end automated process Self-correcting quality inspection 150% higher strength & stiffness 25% less material & weight 3

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5 The Cevotec solution Fiber Patch Placement (FPP) additive 3D preforming for complex fiber composites 6

6 The Cevotec patch gripper Adapting to complexity Available in tailored sizes Key for automated fiber placement on complex surfaces 7

7 Main application areas Broad range of applications across industries Complex geometries Tailored reinforcements Surface design 8

8 Automated handling of SAMBA fiber preforms End-to-end automation for complex preforms in series production Automated removal from mold Innovative tooling concept for first ply release Standard gripper equipment for lifting and transport Increase output and maximize productivity of the SAMBA systems 9

9 Integration of SAMBA in industrial composites lines Patch technology: decrease cost and improve product performance 10

10 SAMBA Series Additive 3D preforming systems for complex fiber composites. Tailored to your product and process requirements. Tailored to your requirements SAMBA Pro flexible (batch) series production Modular, scalable components Patch feeding & cutting e.g. laser, ultrasonic, mechanical Quality control cameras incl. image processing computers Robot with patch gripper e.g. 4-axis pick & place, 6-axis robot SAMBA Scale high-throughput mass production SAMBA Step low-investment entry to patch technology Tool manipulator e.g. 6-axis robot, tilting rotator, linear table Dust and gas suction with appropriate filter SAMBA Prepreg currently in development. Please contact us and share your requirements. 11

11 ARTIST STUDIO CAD-CAM software for patch technology Incl. export of patch laminate for FEM simulation 12

12 The Cevotec portfolio Your one-stop partner for patch-based production equipment & software Production systems SAMBA Series CAD-CAM software ARTIST STUDIO Patch technology services & products Development, production, spread tow, gripper Direct 3D preforming systems Tailored configurations Full automation incl. preform handling CAD-CAM for patch technology Export of laminate for FEM Perfectly matches SAMBA systems Product development, prototyping & series production CAE analysis & FEM-based optimization Customized fiber spread tow and patch grippers Automation solutions for complex fiber composites 13

13 milestones in composites Your one-stop-shop partner for patch technology Production systems CAD-CAM software Product development (incl. CAE) Prototyping & series production Carbon fiber spread tow tape Adaptive, customizable fiber patch grippers Headquartered on the Ludwig Bölkow Innovation Campus near Munich, Germany High-tech production facility & development lab Get in touch to discuss your project! Thorsten Groene (CEO & Co-Founder) We enable manufacturers to produce complex composites in high volume and superior quality. For a lighter, more sustainable future. Strategic partners 14

14 From the press (selection) Complete press review: Cevotec presenta l imbuto di finestra al progetto Fiber Patch Placement del Paris Aviation Show July 05, 2017 Cevotec Samba: software en robotcel voor 3D composietdelen March 13, 2017 Industry 4.0 for carbon composites October 4, 2016 Fiber Patch Placement machine, software April 19, 2017 Exclusive preview of SAMBA preforming demo March 6, 2017 Durchbruch in der Composite-Produktion September 23, 2016 Cevotec celebrates successful market launch at JEC World 2017 March 28, 2017 A crowded house of composites March 6, 2017 Cevotec, Baumann announce partnership to industrialize FPP September 16, 2016 Automated production of complex carbon composites March 23, 2017 Automatisierungsgrad stark erhöht Fertigungsautomation December 16, 2016 Fiber patch placement at JEC 2016 March 9, 2016 Industrial Fibre Patch Placement machine and software Cevotec brings virtual reality to Composites Europe Fiber patch preforms help tailor kiteboard performance March September 16, November 22, 2016 milestones in composites January 28,

15 Product details: SAMBA Series & ARTIST STUDIO

16 SAMBA Pro High-volume, flexible (batch) series production Specs 10 robot axes for highest degree of product complexity Laser cutting for individual patch geometry High-res cameras for maximum placing precision Fiber throughput ~ 2-3 kg/h Fast and easy tool change system Application areas Volume series production of medium to small parts Flexible batch series production 17

17 SAMBA Scale High volume, high throughput series production Specs Scaled patch placement system for high fiber throughput Robust, durable components for 24/7 production settings Integration into industrial composites lines possible Fiber throughput ~ 15 kg/h per patch unit Fiber throughput > 100 kg/h through combination of units Application areas Volume series production of large to medium-sized parts Optimized for continuous, high-throughput production 18

18 SAMBA Step 3D Low-volume, direct 3D production & product development Specs Low-investment entry to patch placement technology Flexible degree of automation, here: 9 robot axes High precision fiber placement Fiber throughput ~ 500 g/h Fast and easy tool change system Application areas Flexible, low-volume series production of 3D components Prototyping and product development Research and development 19

19 SAMBA Step 2.5D Low-volume, 2.5D production & product development Specs Low-investment entry to patch placement technology Flexible degree of automation, here: automated layup table High precision fiber placement Fiber throughput ~ 500 g/h Fast and easy tool change system Application areas Flexible, low-volume series production of 2D reinforcements Prototyping and product development Research and development 20

20 ARTIST STUDIO CAD-CAM software for patch technology Standalone software platform for a continuous process from CAD to machine data. Adjusted to match every SAMBA system. Patch Artist Generates high-performance laminates Enables complex and curvilinear fiber orientations Optimizes patch overlaps and positions Works with all standard CAD file formats Export of patch laminate for FEM simulation Motion Artist Generates machine data for SAMBA Optimizes robot movements Simulates the production process, incl. collision detection Performs offline programming of SAMBA robots 21

21 Beyond application: The theory, principles and scientific results of patch placement technology

22 Bionic lightweight design Motivation for Fiber Patch Placement technology Natural Fibrous Structures Technical Structures Leaf Tree trunk Human bone Hall construction airport Stuttgart Curvilinear carbon fiber orientation Topology optimized chassis Fibers follow curved paths Transferring the principle to lightweight construction New curvilinear textile technologies Fiber Patch Placement Direct patch placement on 3D geometry or along 3D load paths 23

23 Massive drop in strength of classical laminates Average fiber-to-load deviation is significantly reduced with Fiber Patch Placement Fact Multiaxial non-crimp fabrics such as quasi-isotropic lay-ups cannot exploit the full potential of the material. Example Only 15 deviation to a tensionbased load path leads to an extremely reduced strength (>80%) Patch layup supports optimal lightweight design 24

24 210 mm milestones in composites 2.5x stiffness increase with load-optimized patch laminate High performance lightweight design with Fiber Patch Placement Mass-specific stiffness [kn/(mm g)] F F ,3 12,35 13, % ,23 5,31 5, F 150 mm F 1 0 simulation specimen 1 specimen 2 simulation specimen 1 specimen 2 quasi Quasi-isotropic isotropic lay-up FPP lay-up Optimized patch lay-up Source: Cevotec and Technische Universität München 25

25 2.2x strength increase through curvilinear fiber orientation Demonstration at an open hole specimen Biaxial non-crimp fabrics Load path oriented fibers (patch basis) F Mass-specific maximum strength +120% F F F Source: O. Meyer, Short fibre preform technology for load path aligned manufacturing of fibre reinforced plastic components, Doctoral thesis, University of Stuttgart,

26 20% weight decrease with patch reinforcements Load-path-oriented reinforcements reduce material, weight and cost Quasi-isotropic lay-up Lay-up with patch layers M T M T unidirectional layers FPP FPP 4 unidirectional layers with 2 patch layers M T M T 8 unidirectional layers 4 unidirectional layers + 2 patch layers 20% weight reduction 27

27 Cevotec GmbH Willy-Messerschmitt-Str Taufkirchen b. München Phone Fax info@cevotec.com