Advanced tape placement technology as an efficient process for local reinforcement

Transcription

1 Brussels, 21/02/2018 Advanced tape placement technology as an efficient process for local reinforcement AFPT GmbH 1

2 Advanced tape placement technology as an efficient process for local reinforcement Roel Baas AFPT GmbH 2

3 Pioneers in Tape Placement AFPT GmbH was founded 2007 by Coert Kok and Patrick Kölzer has 25 well motivated employees is located in Dörth, Germany AFPT offers: automated solutions to produce thermoplastic composite structures with laser assisted placement technology support in planning & designing industrial manufacturing plants small scale manufacturing AFPT GmbH 3

4 Our business Process Machines Equipment Thermoplastic prepreg materials Company Applications Applications/Prototypes Tape AFPT GmbH 4

5 Markets & Applications vessel winding pressure vessels, CNG and H 2 tube winding seals, bearings, piping systems, structural elements Quelle: MT-Aerospace Quelle: IFA ROTORION local reinforcement plastic components, tailored blanks inlays for injection molding Rings, beams, other structures Quelle: Tencate Quelle: EMS-Chemie AFPT GmbH 5

6 Markets & Applications vessel winding pressure vessels, CNG and H 2 tube winding seals, bearings, piping systems, structural elements Quelle: MT-Aerospace Quelle: IFA ROTORION AFPT s mission: Make Tape Placement Process ready for industrial use local reinforcement plastic components, tailored blanks inlays for injection molding Rings, beams, other structures Quelle: Tencate Quelle: EMS-Chemie AFPT GmbH 6

7 Tape Placement Equipment 1 Single tape head 1 Prepreg spool 2 Counter roller flap 3 Head mounting flange 3 4 Rocker arm 2 5 Pressure roller 6 Pneumatic cylinder unit Pyrometer/thermal sensor array 8 Laser optics AFPT GmbH 7

8 projects: R & D cell Project: R & D cell DLR (Germany) AFPT GmbH 8

9 Markets & Applications vessel winding pressure vessels, CNG and H 2 tube winding seals, bearings, piping systems, structural elements Quelle: MT-Aerospace Quelle: IFA ROTORION local reinforcement plastic components, tailored blanks inlays for injection molding Rings, beams, other structures Quelle: Tencate Quelle: EMS-Chemie AFPT GmbH 9

10 Local reinforcement video AFPT GmbH 10

11 Local reinforcement video AFPT GmbH 11

12 Local reinforcement actual AFPT s actual process Tapelaying Thermoplastic Surface The thermoplastic prepreg material is heated by a diode-laser to the processing temperature A placement head positions the prepreg tapes, on a thermoplastic surface A fast control system maintains the desired parameters like process temperature, consolidation pressure and tape tension. The AFPT process results in a composite component which is ready to use All process parameters get logged and can be used for quality assurance AFPT GmbH 12

13 Local reinforcement new ComMUnion challenges Tapelaying Metal Surface The thermoplastic prepreg material is heated by a VCSEL s to the processing temperature A placement head positions the prepreg tapes, on a hybrid surface A fast control system maintains the desired parameters like process temperature, consolidation pressure and tape tension. A toolkit will be developed for process simulation and evaluation. The AFPT process results in a hybrid component which is ready to use All process parameters get logged and can be used for quality assurance. A toolkit will be developed for process evaluation AFPT GmbH 13

14 Local reinforcement new ComMUnion challenges Tapelaying Metal Surface The thermoplastic prepreg material is heated by a VCSEL s to the processing temperature A placement head positions the prepreg tapes, on a hybrid surface A fast control system maintains the desired parameters like process temperature, consolidation pressure and tape tension. A toolkit will be developed for process simulation and evaluation. To be covered in next presentations The AFPT process results in a hybrid component which is ready to use All process parameters get logged and can be used for quality assurance. A toolkit will be developed for process evaluation AFPT GmbH 14

15 Laser vs. VCSEL Challenge: to get homogeneous intensity at nip-point VCSEL Laser Optics Intensity distibutionj of VCSEL as a function of working distance from VCSEL chips (source: Philips) 15

16 Laser vs. VCSEL Diode Laser response time is in the range of milliseconds Laser-radiation by glass-fibre and optics to create a homogeneous rectangular heating spot One width / optics unlimited heating power Serious investment VCSEL s response time is in the range of milliseconds In Situ radiation Width adaptable by control of individual VCSEL-rows Power restricted; additional units requested More cost effective AFPT GmbH 16

17 New tape-head Setup for up to 2 VCSEL-units 20/02/

18 Expected results for AFPT vessel winding pressure vessels, CNG and H 2 tube winding seals, bearings, piping systems, structural elements Quelle: MT-Aerospace Quelle: IFA ROTORION local reinforcement plastic components, tailored blanks, hybrid structures inlays for injection molding Rings, beams, other structures Quelle: Tencate Quelle: EMS-Chemie AFPT GmbH 18

19 Expected results for AFPT Local reinforcement of hybrid materials with proven quality will give entrance to new markets in aerospace and automotive: - Instead of redesign of metallic-parts in thermoplastics, an existing design can be improved vessel winding pressure vessels, CNG and H 2 - Serious weight savings are possible with little effort Overall tape placement process is optimised by - State-of-the-art technologies Quelle: MT-Aerospace Quelle: IFA ROTORION - Extensive toolkits for simulation and evaluation tube winding seals, bearings, piping systems, structural elements local reinforcement plastic components, tailored blanks, hybrid structures Quelle: Tencate AFPT GmbH 19

20 Thank you for your attention Roel Baas Bremen Kiel Hamburg Schwerin Berlin AFPT GmbH Trinkbornstraße 10 Düsseldorf Hannover Potsdam Halle Dörth Bonn Wiesbaden Erfurt Dresden Mainz Saarbrücken Stuttgart München AFPT GmbH 20

21 Consortium Asociación de Investigación Metalúrgica del Noroeste (AIMEN) AUTOTECH ENGINEERING, AIE (AUTOTECH) Thanks for your attention AFPT GMBH (AFPT) New Infrared Technologies SL (NIT) TECNATOM S.A. (TECNATOM) Motofil Robotics, S.A. (MOTOFIL) Philips GmbH (PHILIPS) FRAUNHOFER GESELLSCHAFT ZUR FORDERUNG DER ANGEWANDTEN FORSCHUNG EV (FHG) UNIVERSITY OF PATRAS (LMS) UNIVERSIDADE DE COIMBRA (COIMBRA) Missler Software (MISSLER) ACITURRI ENGINEERING SL (ACIENG) SYM VOULOI KAI PROIONTA LOGISMIKOU AE (CASP) LUNOVU GMBH (LUNOVU) ESI GROUP (ESI) Name and Surname Occupation Phone This Project has received funding from the European Union s Horizon 2020 research and innovation programme under grant agreement Nº The dissemination of the project herein reflects only the author s view and the Commission is not responsible for any use that may be made of the information it contains.