Cevotec GmbH Munich, Germany milestones in composites

Transcription

1 Cevotec GmbH Munich, Germany milestones in composites

2 Cevotec offers production solutions based on Fiber Patch Placement technology from CAE to automated fiber lay-up Fiber Patch Placement Fiber Patch Placement is the additive manufacturing technology for the automated production of geometrically complex fiber composites and curvilinear reinforcements. It enables a new degree of freedom in automated fiber deposition for complex shapes. Defined patches are automatically cut from a tape and precisely placed by two robots and a flexible patch gripper. Your component is built up additively, flexibly and in a completely automated manner. Handle complexity with ease SAMBA is the Fiber Patch Placement system for manufacturing your demanding 3D geometries and complex fiber structures fully automated, quality-controlled and material-efficient. The associated CAD-CAM software ARTIST STUDIO with an additional plug-in for FE-programs shortens your development time and improves the mechanical properties of your products. Additive manufacturing Patch technology is additive manufacturing in sensible increments, called patches. It provides automation and the speed for mass-market applications while featuring benefits unique to additive manufacturing: 3D net-shape lay-up with minimal scrap Flexible orientation of every fiber patch Variable laminate thickness Very high material efficiency Your benefits Integrated automation from CAE to final fiber lay-up High-resolution camera control & continuous part quality protocol 150% higher strength & stiffness through optimal fiber orientation 25% less material & weight through additive manufacturing 1 Feed carbon fiber tape 2 Cut carbon fiber tape into patches 3 Inspect fiber patch quality 4 Pick up patch, check patch position 5 Position patch on 3D form tool

3 Composites 4.0 the Cevotec portfolio Cevotec s SAMBA fiber lay-up systems set new standards for the automated production of complex composites. Based on Fiber Patch Placement technology, SAMBA uses industrial robots to place fiber patches on complex 3D geometries. SAMBA allows for a discrete orientation of each patch and eliminates scrap as well as additional forming processes through 3D net-shape fiber lay-up. ARTIST STUDIO is Cevotec s associated CAD-CAM software, tailored for integrated and fast product development. Powerful algorithms create an optimized patch laminate from CAD files and generate machine data for SAMBA, allowing for easy robot programming as well as rapid prototyping cycles. Production systems - SAMBA Series Direct 3D fiber lay-up systems Tailored robot and machine configurations Suitable for processing dry fiber and prepreg tape Full automation incl. laminate handling CAE software - ARTIST STUDIO CAD-CAM software for patch technology Perfectly supporting SAMBA systems Additional plug-in for commercial FE-software New: Customized software development for your individual processes available Patch technology services & products Development, production, carbon fiber tape, gripper Product development & prototyping Series production FE-simulation and optimization Customized carbon fiber tape Form-flexible patch gripper tailored to your applications

4 SAMBA Series customizable Fiber Patch Placement systems SAMBA - automated 3D fiber lay-up system The Fiber Patch Placement system SAMBA manufactures your fiber laminates with challenging 3D geometries and complex fiber architectures. General features Processing of carbon / glass / aramid fiber tape, adhesive films, etc. Prepreg and dry fiber capable Direct, integral 3D / 2D fiber lay-up of complex shapes Flexible, curvilinear fiber orientation High accuracy of fiber deposition Seamless quality protocol Perfectly aligned CAD-CAM software ARTIST STUDIO Prediction of mechanical properties with plug-in for commercial FE-software Advantages 24/7 fully automated series production of complex 3D geometries Higher stiffness and strength of parts through load-adjusted fiber orientation Less material, weight and cost through additive manufacturing Seamless quality protocol through industrial camera inspection system Main application areas across industries Parts with complex geometries and shapes Tailored, curvilinear reinforcement structures Unique surface design Customizable system modules Cooled material storage Patch feeding & cutting unit, e.g. laser, ultrasonic, mechanical Quality control cameras incl. image processing computer Material-specific, energy-efficient heating of patches, e.g. electric, photonic Robot with patch gripper, e.g. 4-axis pick & place, 6-axis robot Tool manipulator, e.g. 6-axis robot, tilting rotator, linear table Dust and gas suction with appropriate filter End-to-end automation After fiber lay-up, an additional robot detaches the inherently stable laminates automatically from the tool and moves them to the next processing step.

5 Automated 3D fiber lay-up tailored to your needs SAMBA Scale Scaled Patch Placement system for high fiber throughput Individual robot configuration tailored to a range of parts Integration into industrial composite lines possible Fiber throughput ~ 15 kg/h per feeding unit Application areas Mass series production of large to medium parts Optimized for continuous, high-throughput production SAMBA Scale Line Patch Placement line for high fiber throughput Hybrid fiber laminates (e.g. carbon and glass) possible Handles high geometrical complexity Individually configured to match your product Throughput of 100 kg/h or more feasible Application areas Mass series production of large to medium parts Optimized for continuous, high-throughput production SAMBA Pro Up to 12 robot axes for highest degree of geometrical complexity Individual configuration upon request Integration into industrial composite lines possible Fiber throughput ~ 2-3 kg/h Fast and easy tool change system Application areas Mass series production of medium to small parts Flexible batch series production SAMBA Step Low-investment entry to Patch Placement technology Flexible degree of automation Individual robot configuration, up to 12 axes Fiber throughput ~ 500 g/h Fast and easy tool change system Application areas Flexible, low-volume series production Prototyping and product development Research and development Individual system configuration Different size? Individual process? Other materials? We like to hear from you! Our process specialists are looking forward to solving your individual production challenge. Together with our partner Baumann Automation, we provide turnkey production lines in any dimension you require.

6 Comprehensive software solutions from CAD to machine data ARTIST STUDIO ARTIST STUDIO is the perfect tool for your digital product development and robot programming. The software creates an optimized patch laminate and generates the corresponding machine data for SAMBA. ARTIST STUDIO combines multiple, perfectly aligned modules for your product development on a single platform. Advantages for virtual product development Stand-alone CAD-CAM software with plug-in for commercial FE-software Fast and continuous process from CAD to machine data on a single platform Easy operation of the software through simple and intuitive interface Import of all common CAD-file formats MOTION ARTIST enables you to simulate and program the SAMBA robots offline and in a fully automated way. The preparation time for production is significantly shortened, as modifications in the patch-book are automatically transferred to MOTION ARTIST. The built-in collision detection and visual process simulation also increase the safety on your shop floor. Advantages for robot programming and production preparation Fast creation of machine data through offline robot programming Efficient manufacturing process through optimized movement of robot axes Reduction of preparation time through integrated process simulation Increase of production safety with integrated collision detection Advantages for fast laminate generation PATCH ARTIST is the fiber laminate design module. Its user interface is designed to easily define patch zones on imported CAD surfaces, as well as layer size, layer orientations, layer thickness, tape width, patch length, etc. The layer orientation based on already calculated load paths can be constructed as splines within a CAD-system. The splines can be imported directly in PATCH ARTIST or alternatively load paths can be generated as so called guide curves. High performance laminates & reinforcements with direction-variable fiber orientation Excellent mechanical properties through an integrated algorithm for optimizing patch overlaps Optional, simple manual laminate modification by intuitive user interface logic Cevotec plug-in for FE-software. In addition to the standalone software ARTIST STUDIO, Cevotec offers a patchbased plug-in for commercial FE-software HyperMesh, one of the leading FEA preprocessors on the market. This plug-in allows users to generate a patch-based laminate inside HyperMesh in a fully automated way, based on geometry, position and orientation of individual patches exactly as defined in Artist Studio. The features of the plug-in enable the modelling of the precise fiber orientation of each patch and even the thickness distribution due to gaps and overlaps. This is possible on a sublayeror even on patch-level for a more detailed analysis. Advantages for automated modelling Different analysis types through automated modelling approaches Improvement of the out-of-plane deformation behavior using thick shell elements Better prediction of patch delamination through cohesive zone modelling

7 cevogripper flexible and form-adaptive fiber placement cevogripper - adapting to complexity Your key to an automated process for complex shapes is our form-flexible patch gripper. The gripper is available in tailored sizes to perfectly match your product. The gripper adapts to the most complex surfaces. Even across 90 angles and biaxially curved surfaces, patches are placed precisely and without draping effects. In the SAMBA Series systems, the robot axes ensure that the gripper reaches every position. Upon request, Cevotec also develops gripper solutions suited to your individual requirements in fiber placement. Configuration Key for automation of Fiber Patch Placement on complex shapes Available in sizes from 30x60 mm 2 up to 300x1000 mm 2 Automated quick-mount device for fast and easy gripper changing on-the-fly Anodized, precisely machined aluminum baseplates High mass-flow vacuum stream, powered by pressured air Customized body to meet specific compaction requirements Customized heating field suitable for heat-activated binder Optional: Active deformation capabilities for concave surfaces

8 cevotape tailored to your automated fiber placement processes The right fiber is crucial for the performance of your composite part. Automated fiber placement processes require superior tape quality to minimize downtime and ensure high precision and repeatability. Thus, Cevotec exclusively processes unidirectional dry carbon fiber tape (spread tow), tailored for the requirements of AFP, ATL and FPP processes to create high quality laminates. In a protected and quality-controlled process, we manufacture these spread tow tapes in-house and guarantee highest quality for all processes as well as compatibility to our SAMBA Series lay-up systems. You can use cevotape in a variety of different applications. It features binder material on one side of the tape, so that it can be easily fixed during processing. cevotape has a customized width within minimal tolerances and features a homogeneous filament distribution without gaps or wavy edges. cevotape - unidirectional carbon fiber tape Tight width tolerance Single-sided, uniformly distributed PA-Binder Binder activation from 90 to 160 C Produced with integrated quality monitoring on width & gaps Storing at room temperature Individual configuration Approach us with your roving material and have us manufacture your individual tape, or choose from our stock. Fiber material Areal weight Tape width Binder material Storage Any high quality fiber gsm mm Spunfab: PA1541, PA1300 further materials on request 250 m on Häfner spools separated with non-adhesive paper film Available tapes currently on stock (03/2018) Tape Fiber Binder width Material Areal weight Filaments Material Areal weight CEVOTAPE HTS K-S mm Tenax-E HTS45 80 gsm 24K PA gsm CEVOTAPE HTS K-S mm Tenax-E HTS45 80 gsm 36K PA gsm CEVOTAPE HTS K-S mm Tenax-E HTS gsm 48K PA gsm

9 cevoservices efficiently supporting your processes Cevotec development services We offer patch technology also as a service. Our composite experts assist you in conception, design, FEMbased simulation and optimization as well as in production preparation. Together, we achieve efficiency for your individual lightweight and product strategies. 1. Planning & conceptualization 2. Construction 3. FEM-simulation 4. Optimization 5. Offline programming Performance optimization Patches perfectly align to curvilinear load paths. Therefore, patch technology maximizes the performance of your parts, no matter if the basis is glass fiber or carbon fiber. Stiffness and strength increase up to 150% compared to conventional lay-ups Fiber lay-up services No matter whether if s finished components or carbon fiber laminates that require further treatment in your existing processes, Cevotec is a reliable and competent partner at your side. We combine various processing methods to fulfill your individual product requirements. Automated series production of your individual fiber laminates Our series manufacturing services focus on automated laminate production. Use the trimmed laminates in your existing processes or, alternatively, have us and our partners finish the components to your requirements. The Cevotec laminates can be easily combined with products of other dry-fiber or prepreg processes. Application areas Geometrically complex products Reinforcements with complex fiber architecture Individual design and ornamental surfaces Industry expertise Aerospace Automotive Medical devices Sports & leisure Industrial products

10 Enabling manufacturers to produce complex composites in high volume and superior quality Cevotec Cevotec enables manufacturers to build complex fiber composites in high volume and quality by smart process automation based on Fiber Patch Placement technology. With SAMBA Series, Cevotec offers tailored, automated fiber layup systems for challenging 3D geometries and laminates with complex fiber orientation. ARTIST STUDIO is the associated CAE software for generating patchbased fiber laminates and automated robot programming. Along with development services that include FE-based modeling and simulation, Cevotec offers the entire process chain from digital design to final fiber product. Passion for innovation and efficiency Patch technology is the key technology to advance industrialization in the production of complex fiber products. Our interdisciplinary team follows one goal: to provide the best production solution for your complex fiber products. We innovate at the intersection of software engineering, fiber technology and process automation to establish Fiber Patch Placement as the leading technology for automated fiber lay-up. Your one-stop-shop partner for patch technology Production systems CAE software Product development Prototyping Series laminate production Carbon fiber tape Customized fiber patch grippers Headquartered on the Ludwig Bölkow Innovation Campus near Munich, Germany, with high-tech development lab & production facility. Strategic partners Strong partners share our vision, support us and work jointly with us towards a better future! The Cevotec founders: Felix Michl, Thorsten Groene, Dr. Neven Majic