In cooperation with. ipul pultrusion systems More speed in pultrusion. Engineering Passion

Transcription

1 In cooperation with ipul pultrusion systems Engineering Passion

2 Fascinating insight A tour round the ipul system Material handling Manual filling, filling via barrel pumps or IBC containers Stations with individual programming of mixing times. Metering machine with mixing head for polyurethane, epoxy resin or polyamide for different discharge areas with tailored temperature concept. Injection box for optimum wetting of fibers with highly reactive matrix systems Fiber rack and fiber guides for glass and carbon fibers Mold with different temperature zones for hardening and final shaping

3 3 Central control regulates and stores all process parameters, e.g. discharge output and haul-off speed. Support table or winder Saw for precise cutting and prefabrication Haul-off Synchronized puller with spindle drive available with different clamping forces for complex profile geometries. Alternatively a crawler or belt haul-off can be used for simpler geometries.

4 4 ipul Productivity and cost-efficiency for straight and curved profiles With ipul, KraussMaffei is revolutionizing pultrusion, the procedure for the continuous production of highly filled fiber-reinforced plastic components. Pultruded profiles are thus opening up new areas of application. The new economical system solution allows production speeds of up to 3 m/min and works with a closed injection box. Besides simple and complex linear profile geometries, curved profiles can also be produced. In the ipul pultrusion process, glass or carbon fibers are pulled off and fed through the injection box by fiber guides. The metering machine heat-balances and mixes the matrix material (polyurethane, epoxy or polyamide systems) in a mixing head in optimal process technology conditions and conveys the mixture into the injection box. Here, the fibers are saturated to an optimum level with highly reactive matrix materials at an inner pressure of 5 to 100 bar. Then, the final shaping and curing of the profile takes place in various heating zones within the mold (e.g. 100 to 250 C). The extruded profile can be removed using either an electro-pneumatic extractor device or a belt/crawler haul-off. The profiles are then cut to the desired length or can be wound or prefabricated. The central system control regulates the process technology parameters and the haul-off speed. 1. Material handling Optimized material mixing process and automatic filling of material into the day tank from barrels or IBC containers. Individually programmed mixing times Material recirculation Special stirrers Dry-run protection Ventilation to prevent bubble formation 2. RimStar Nano metering machine Innovative metering system with accurate temperature sensing, suitable for matrix systems such as polyurethane, epoxy resin or polyamide. Low-pressure mixing head with dynamic mixing element and optional addition of separating agent Tailored temperature concept Compact design with frame on rollers Continuous recirculation of components Well-designed self-explanatory operating software with online remote service 3. ipul pultrusion line Different system concepts for straight and curved profiled and for simple and complex geometries. Fiber rack and fiber guides for glass or carbon fibers Electro-pneumatic extractor device with different haul-off forces for complex profile geometries or crawler/belt haul-off for simple geometries Defined length cut with saw and use of winders and other prefabrication units Reliable increase of haul-off speed and thus productivity up to 3 m/min Central control regulation of discharge output according to haul-off speed and central storage of process parameters

5 5 (Photo: Thomas Technik) (Photo: Covestro / Internorm) (Photo: Evonik) Pressure jacket for a deep sea pipeline. Radius pultrusion allows longer risers and flowlines. Fiber-reinforced window profiles allow narrow frames with high insulation capability, even for large window areas. Concrete reinforcement rods (rebars) made of fiber composite materials are stable and corrosionresistant. RimStar Nano metering machine for epoxy resin, polyurethane or polyamide. Low-pressure mixing head with dynamic static mixer and recirculation. Central user interface: process parameters are adjusted to the haul-off speed, production data stored. 4. Mold technology From component analysis to the configuration of the right mold design in accordance with the required haul-off speed. Injection box for optimal fiber wetting and use of highly reactive 2K PU, epoxy and PA systems Molds with individual heating zones for final shaping Increased productivity with multiple cavities Concepts for fast opening and locking of molds 5. Technological support Consultation, layout recommendations, process optimization and training as well as production support and customerorientated service. Capacity for developing new ideas Prototype manufacture Good network of material suppliers and institutes Many years of experience with highly reactive matrix systems Quick interface clarification Detection and resolution of problems via Teleservice Global sales and service structure Spare parts stocks Application areas: Automotive Infrastructure Construction industry (windows, rebars) Energy sector (wind energy) Your advantages: Machine, mold and process innovations from a single source Highly efficient, high-quality turnkey systems Fully automated processes Process optimization, consultation and training

6 6 ipul Technological leadership through cooperation KraussMaffei works closely with Thomas Technik to develop innovative ideas and provide turnkey series production plants. For an optimum production chain for the ipul process, we are pooling our competence together with our cooperation partner Thomas Technik + Innovation. Our objective is to advance the marketing of turnkey systems for the production of profiles for the construction industry, the automotive industry, the energy industry and the aerospace industry together. Our pooled expertise allows us to give our customers qualified consultation. Your advantages: Pooled expertise throughout the entire production chain Development, prototype manufacture and testing of new components Optimized interface between the individual system components Process-oriented component design, development and production Component analysis Mold prototype Feasibility study Simulation of fiber infiltration Consultation in the choice of materials Support in the calculation Mold design Prototype manufacture Definition of production parameters

7 7 Radius pultrusion Thomas Technik und Innovation KG The cooperation with Thomas Technik, the inventor of radius pultrusion, makes it easier for our customers to access this innovative process and opens up new areas of application. We create tailor-made solutions for the production of curved profiles. Production markets develop constantly and new visions are created almost on a daily basis. In order to profit from these visions, we must develop the right concept for you and provide you with a unique precision mold that satisfies your specific needs. We transform inspiration into products that impress. Radius pultrusion allows the production of curved profiles on an industrial scale The gripper closes and holds the end of the profile tight. The mold moves on the profile. The gripper opens. The mold moves to its initial position. No relative movement between the mold and the profile. Key Fiber rack Metering machine Heated mold Puller Saw Series production Production consultation Preparation of fibers and matrix Pultrusion line startup and adjustment Production of multiple cavities with high speeds Automated prefabrication and storage of profiles Support for new developments Layout and optimization of production procedure Maintenance plan Spare parts package Online support

8 ipul pultrusion systems KraussMaffei is working with a network of partners to refine pultrusion technology. Here, the haul-off speed is decisively increased without negative impact on the high quality standards demanded. System, process and mold technology all under one roof. Together with partner Thomas Technik, KraussMaffei is able to implement the entire process chain from the design of components to the tailored ipul system. We provide turnkey solutions with a high degree of system expertise from many years of process experience. Pooled competences allow the holistic further development of plants and process technology together with the customer. This cooperative approach will consolidate and further extend our position as technology and market leaders in the long term WE 1st edition 06/17 RPM 601 FL 06/2017 EN Subject to technical changes Printed in the Federal Republic of Germany.