Modular light weight structures - Potential off composite structures in commercial vehicles and their production.

Transcription

1 A leading supplier of lightweight systems for road and rail Airex Composite Structures (ACS) a member of 3A Composites Modular light weight structures - Potential off composite structures in commercial vehicles and their production. Bart Radema Key account manager bus Europe PLEASE CONSIDER: ALL INFORMATION SHARED IN THIS PRESENTATION IS INTELLECTUAL PROPERTY OF AIREX COMPOSITE STRUCTURES

2 3A Composites History More than 50 Years of Experience 2

3 One Group Two Leading Divisions SSM Textile Machinery Revenues: 100 MCHF Employees: 230 3A Composites Revenues: MCHF / Employees: 2'200 (of which 700 in Ecuador) 3

4 3A Composites - Global Footprint Assets in North America 4 sites 338 Employees Assets In Europe Headquarters in Cham, CH 6 Sites 806 Employees High Point, NC Glasgow & Benton, KY Statesville, NC Loch Gowna, IE Osnabrück, GER Singen, GER Sins, Altenrhein, Neuhausen, CH Dubai Mumbai/Khopoli Xiamen Changzhou Shanghai Manta Quevedo Guayaquil Cuiabá Singapore Sao Paulo Assets in South America 3 sites Headquarters in Guayaquil Sales office 111 plantations; ha in Ecuador (thereof 5532 ha Balsa plantations) 696 Employees Assets in Asia 5 Sites Headquarters in Singapore Sales office 358 Employees 5

5 Airex Composite Structures (ACS) ACS is located at Altenrhein, CH Competence Center for Engineering, Tooling, Processes & Sales Production co-operations in Eastern Europe and China 6

6 ACS Key Technologies Airex Vacuum Bonding Technology (AVT) Vacuum Assisted Resin Infusion (VAC) Resin Transfer Molding (RTM) Application Area Bus Rail Application Area Primarily Rail Protected Mobility/ Defence Application Area Automotive Low noise fan blades Raw Materials Aluminium, Steel, GFR skins PVC, PS, PMI, and PEI foam cores as well as Balsa cores Integrated aluminium extrusions Advantages Low weight sandwich structures with high stiffness, ready for pre-assembling High potential for the integration of functions High dimensional accuracy Low tooling investment required Raw Materials Glass fiber mats Filled UP resins PVC, and PMI foam cores as well as Balsa cores Advantages High dimensional accuracy Consistent product quality Function integration Closed process, low emission (EHS) Raw Materials Glass-, Carbon-fibers EP, VE, UP-resins PUR, PVC, and PMI-foam cores as well as Balsa cores Advantages ACS is technology leader Consistent product quality Class A surface quality Short-time from design to first part Best for complex shapes w/ hollow parts 04/19/2012 7

7 INNOCAB Free formed surfaces Structural Large size components Impact resistant up to 600 km/h Mechanical interfaces integrated Painted and fully equipped on demand Proven cold repair concepts 9

8 System competency CAD - Design & Engineering From design to finished systems Assembly & Painting FEA / Real Tests Together with external partners Tooling Manufacturing 10

9 COMFLOOR 80% assembly time reduction 750 kg weight reduction per rail car 300 mm more internal width 30 years product lifetime Integrated heating system Maintenance free 11

10 ACS Heated structural floor concept conventional Heated floors T 1 Limited leg space Local hot / and cold area T 2 Practically zero heat differences Low weight + space requirements High customer comfort 12

11 XBODY Structural, lightweight, stiff systems Mechanical interfaces integrated Maximum size 18m x 2.8m Modular construction kit Painted and fully equipped on demand Supports excellent crash behavior Proven cold repair concepts 13

12 ACS current bus development projects Composite bus parts ACS develops OEM s Sandwich roofs Components Structural 2D Parts Structural 3D Parts Middlechassis Composite-Sidewalls Sandwich interdeck with seat fixations Flooring systems Engine tower Sub-System Suppl. Systems Subassemblies Mechanical integration Electrical integration Painting etc. 14

13 ACS Selected references Monorail 10/10/

14 The Modular Sandwich Roof 19

15 Airex Composite Structures Sandwichtechnology for Bus solutions Traditional Bus Roof Modular Sandwich Roof b b a 1 a2 t 2 t 1 a t 1 Cross-beam: 25 mm x 50 mm x 1,2 mm (a 1 x a 2 x t 2 ) Solebar: 50 mm x 50 mm x 2,0 mm (a 1 x a 2 x t 2 ) Cover sheet: Steel (0,6 mm); GRP (2,0 mm) (t 1 ) Adhesive thickness: 3-5 mm (tough-elastic adhesive) Foam core: mm (a) Cover sheet: Aluminium 0,6-0,8 mm (t 1 ) GRP 2,0 mm (t 1 ) Adhesive thickness : 0,2 mm (structural adhesive) Dimensions for a representative City- and Coachbusroof Reference-dimensions: Length: Width: L = m B = 2,2 bis 2.4 m B Dimensions L 20

16 A Proven Concept Anforderungen Requirements Sandwich Anforderungen Requirements Busdach Roof Werkstoff Material Konstruktion Construction Produktion Production Functions Funktion Komfort Comfort Kosten Costs Sonstiges Others VDL Bova Magiq Dach Roof Deckschicht: Aluminium cover Aluminium sheets VDL Phileas Dach Roof & und Floor Boden Deckschicht: Aluminium cover Aluminium sheets VDL Ambassador Dach Roof & und Floor Boden Deckschicht: GRP cover sheets GFK VDL Citea Dach Roof & und Floor Boden Deckschicht: GRP cover sheets GFK Nabi Metro 45C Dach Roof & und Floor Boden Deckschicht: GRP cover sheets GFK Temsa Avenue Dach Roof & und Floor Boden Deckschicht: GRP cover sheets GFK OPTARE/ EAST LANCS Zwischenboden Interdeck Deckschicht: Aluminium cover Aluminium sheets Merceds-Benz Cito Dach Roof & und Floor Boden Deckschicht: Aluminium cover Aluminium sheets Quellen: VDL, Nabi, Alcan, Temsa, ATZ 21

17 Airex Composite Structures Sandwichtechnology for Bus solutions Aluminium and GRP Density E-Modul Long. strength Cover sheets Cantrails Execution of cantrail as extruded aluminiumprofile Cantrail could be connected to Steel- or Aluminium structures of busses. It s possible about a bolted or glued connection. Mechanical properties g/cm³ MPa MPa Thermoconductivity W/mK Aluminium 2,6-2, Sandwich properties GFK 1, ,1-0,2 adhesive connection profile skeleton Connection to the cantrail adhesive cantrail Connection to the bus structure cantrail sandwich sandwich 23

18 Airex Composite Structures Sandwichtechnology for Bus solutions Sandwich properties Core materials XPS- and PU-foams Absorption of dynamic loads Low Thermoconductivity High temperature resistance Use of XPS-foams in case of higher mechanical requirements, higher durability, is a future trend Use of PU, higher temperature resistance, lower mechanical properties, embrittling possible Mechanical properties PU Foam density E-Modul Tensile strength Modulus of shear kg/m³ kpa kpa kpa Thermoconductivity W/mK 0,024 Compressive strength kpa 400 Shearing resistance kpa 240 XPS ,

19 Airex Composite Structures Sandwichtechnology for Bus solutions Stiffness- and weight comparision 250% +125% Steifigkeit Stiffness Gewicht Weight 200% +68% 150% +45% +44% +8% 100% 50% -53% -49% -61% -57% -7% -37% -34% 0% Steel Stahl AL 08 - XPS 40 AL 08 - XPS 50 AL 06 - XPS 40 AL 06 - XPS 50 GF 2 - XPS 40 GF 2 - XPS 50 25

20 Airex Composite Structures Sandwichtechnology for Bus solutions Requirements/ Funcitions Connections Aluminium/ framing ACS glued cone connection adhesive Aluminium cantrail for High loads Aluminium Sandwich roof Mechanical properties 1K-PU 1K-PU (SMP) 2K-PU Long. strength MPa 1 3, glued Cone connection Long.- shear strength MPa connection Steel sidewall Skeleton with steel connection-profile Ultimate elongation Max. temperature % C

21 Airex Composite Structures Sandwichtechnology for Bus solutions FE Analysis with glued cone connection in the complete vehicle model 12 m complete citybus model with high load gas tanks an airconditioner Tensions in Sandwich cover sheets and cantrail Distensions in cone connection 27

22 Improved Stiffness Compared to the steel roof, the sandwich roof is stiffer under longitudinal, vertical and torsional loading (5% to 22% smaller displacements), Sandwich Compared to the a welded joint bounded joint is 50 % stronger Bending Test (push/pull testing) of sandwich roof element with integrated cant-rail and welded steel side-wall underbody structure joined by bonded V-notch joining 28

23 Airex Composite Structures Sandwichtechnology for Bus solutions Doubledecker series development E400 for Alexander Dennis SOP 2014 FE calculation: 3 g vertical hit Displacement Tension distribution incl. passanger loads and seats 29

24 Airex Composite Structures Sandwichtechnology for Bus solutions Verification of the structure rollover test ECE-R66 rollover requirements today will fulfilled with the amount of potential of the sandwichstructure Survival space remains preserved Fulfillment of requirements will tested in FE- Simulations and attempts Verification of the cantrail connection Bending charge of the sandwichpanels against connection profile Failure of component at the steel connection on the termation bar (section window pillar) Sufficent strenghtness of sandwich panels Survivalspace Sources: Temsa 30

25 Crash & Roll Over 31

26 Airex Composite Structures Sandwichtechnology for Bus solutions 32

27 Fertigungszeit [min] Airex Composite Structures Sandwichtechnology for Bus solutions Various advantages through the modular assemblage of the roof Ergonomical assemblage (no overhead assembling) Optimized work flow Reduced floor space in BiW Lower warehousing costs Simplier handling in the factory Pooling of all glue processes to one sector (Front- and Side windows) Summarized and optimized quality inspection Reduction of the assembly time (concept 1) in BiW and assembling (- 50 %) % - 50 % % Rohbaufertigung Montage Summe 33

28 Airex Composite Structures Sandwichtechnology for Bus solutions kg Weight balance Roof module weighs ca kg* (6 % amount of total weight) Weight reduction through sandwichroof ca. 160 kg (= 20%) Gewichtsanteile Sonstiges Beplankung Stahlgerippe Gewichtsanteile Gewichtsanteile Sonstiges Anschlussprofile Sandwichprofil Weight saving variies and depending on the execution of the sandwich technology For example omission of interior cladding (24 kg), optimization of the aluminiumprofile (ca. 30 kg), design of cut-outs, integration of HLK-channels etc. * Declaration for a full assembled and isolated roof 34

29 Fertigungskosten Busdach [ ] Fertigungskosten [ ] Airex Composite Structures Sandwichtechnology for Bus solutions Manufacturing costs Higher material costs of the roof framing (purchased part versus raw steel) Saving of material costs in the buildout throught component integration Significant reduction of manufacturing costs through lower personel expenses** (50 %) Savings of manufacturing costs (10 %) Manufacturing costs bus roof - 21 % + 24 % - 10 % Manufacturing costs bus roof - 10 % + 7 % - 50 % Stahl Sandwich 0 Stahl Sandwich Stahl Sandwich Stahl Sandwich Rohbau Montage Summe Arbeitskosten Materialkosten Materialkosten Arbeitskosten Gesamt ** labor costs are based on a westeurope production 35

30 Higher flexibility and reduction of variants Variants induced through: Vehicle length Quantity of doors and bus specific positions Engineconcept/ doors Escape hatch Air conditioning Left/ Right drivervariants Art of propulsion technology 36

31 Airex Composite Structures Sandwichtechnology for Bus solutions As example the brand new Alexander Dennis Enviro 400 MMC 400 kg weight saving in the new model design MMC only through the composite-components it was achieved arround 80 % of the total weight savings at the sametime the stiffness was significantly improved Due to the weight savings it was possible to win up to 7 seating capacities, as result the bus could be authorized to 86 seats The new production method, the modular construction, allows to improve essentially the production time, quality and consistency in production over the different plants Due to excellent thermic isolation of the Composite-roof it was possible to prevent condensation 37

32 Weightsaving potential as example Weight reduction: Sandwich-roof primary: kg Sandwich-roof, floor and optimised chassis: kg Total including down-sized engine: kg No structural reinforcements in the sandwich roof are necessary, indipendent for the drive concepts. 40 % weight reduction in comparision to the convetional solution Lower overall weight results with significant fuel savings up to 16%. VDL Citea: overall weight reduction of 2000 kg results in a only 12 tons weighty bus 38

33 Proved repair methods Repair methods Proved and authorized repair methods ACS After-Sales provides on request a qualified repair team Repairing of small damages could be done locally (provider or ACS) Repairing of structural damages could be executed from service centers or qualified staffs (MAN or ACS)

34 Airex Composite Structures Sandwichtechnology for Bus solutions Bus product development Airex Composite Structures Sandwichpanels fulfill all the requirements for a bus roof Stiffness, strength Durability Repair Comfort Advantages: Weightsavings in the roof section Reduced manufacturing costs Higher manufacturing flexibility, lower diversity of variants Lower vulnerability in operation Alternative provisions for lightweight construction are less effective and associated with higher costs, but realisable without impact on the existing prodution.

35 Thank you for your attention ACS Mission We offer customers high value mobility and industrial composite solutions for a sustainable future Airex Composite Structures Airex AG Park Altenrhein CH-9423 Altenrhein, Switzerland Phone Fax info@3acomposites.com CHINA Jeffrey.zhang@3AComposites.com 41