STAXX COMPACT Low Scrap for high volume part production. CFK Convention Dr. Matthias Meyer. Broetje-Automation GmbH

Transcription

1 STAXX COMPACT 1700 Low Scrap for high volume part production CFK Convention Dr. Matthias Meyer 1

2 History BA Score & BA Scale STAXX Compact 1700 Sealing First Turnkey & Ring Riveter First Wing Riveter First IPAC First FSW System First MPAC BA Services, BA Changhzou & BA UK Relocation of Broetje- Automation & BA Services BA Japan K.K. Start external activities in tool making Broetje- Automation First FAL Relocation to Wiefelstede BA USA Hydro- Control M-Technologie, France BA RUSSIA & BA CHINA MBO with DBAG BA Composites Compose 2 Compete BA ATS

3 Broetje-Automation Production Facilities Facts Countries 7 Sales & Service Locations Germany, Rastede 23 Total Sales Mio TotalIEmployees 800 Germany, Grenzach-Wyhlen France, Toulouse 3

4 Installed Volume Geographical Distribution Europe 30% America 45% Asia 25% Installation value more than 3 Billion uro 4

5 Customized Solutions 5

6 Placement Systems / STAXX Automated Solutions Preforming Systems 6

7 BA Composites GmbH BA Composites Products Started in 2014 STAXX Compact Fiber Placement machining Center Located in Grenzach- Wyhlen, Germany Customized Fiber Placement and Tape Laying machines Based upon previous developments of Broetje Automation and MAG IAS Composites Germany Composites Handling and Automation 7

8 High volume production: Cost Challenges Material Production Challenge Chance Challenge Chance raw material costs tow preg cycle time automated layup intrinsic scrap netshape layup reliability machine operations waste in production use of prepreg handling automation quality process control 8

9 Process Chains Material Preforming Curing Fabric Cutting/Stacking Shaping/Stamping Manufacture RTM T E X T I L E T E C H N O L O G Y UD Direct Layup of Prepreg (automatic) D I R E C T L A Y U P Compression Moulding 9

10 STAXX Compact 1700: addressing cost challenges Direct layup of prepreg material Netshape or near netshape layup Preforms ready to mould and cure No limitations in fibre orientation Local reinforcements Clear interface to automation and handling 10

11 STAXX Compact 1700: addressing cost challenges 16 lane Fiber Placement ¼, ½, 24K, 50K wide material Thermoset and thermoplastic matrices 4-axis (x, y, z, c) Siemens 840 D-SL Control Rotary table with vertical lay up Air conditioned enclosure Double sided loading Table size: max. diagonal 1850 Z-Travel: 500 Feed rate 45 m/min Cut on the fly with 35 m/min Usage of standard raw material Pallet handling system Length/Width/Height: 6500/3000/3000 Electrical Installation: 30 kw 11

12 STAXX Compact 12

13 Requirements for high productivity & profitability PROCESS Standards in process steps Reduction of manual labor Extensive automation Simplified tools Reduced forces for molding press MATERIAL Standard tow widths Direct impregnation UD Material Cycle-time-optimized resins Reduction of Shrinkage and Curing time for Prepregs 13

14 Reduced production costs by standards Risk management S T A N D A R D S increase the reliability by automation obey risk when adding value Raw materials UD-Fibres Prepreg Towpreg Automation 2D Handling Manufacturing Technology Fiber Placement Reduce your risk when adding value! 14

15 STAXX Process from 2D Stack to 3D demo part Demo part 3D-Design Stack Moulding Demo part (untrimmed) Benteler SGL, Broetje-Automation GmbH 15

16 CAD CAM Software CAM-Software for offline programming of AFPprocesses Robust NC-encoding due to specific parametring of the machine and material Embedded function for scrap analyses, processing time and process optimisation Simulation of demoulding behaviour of the preform 16

17 CAM modification TWL tailored wave layup improves the moulding performance of a 2 D Stack TWL enables 2D layup for complex shapes 17

18 Tow Preg moulding 2 D Layup near net shape, depending on the mould Single tows can shear during moulding; the shear allows the part to stretch during preform Shown part could not be done in traditional prepreg due to fatal wrinkles. Fatal wrinkling with traditional prepregs Pictures Mitsubishi Rayon Carbon Fibre 18

19 Direct Towpreg Technology Reduction of scrap (from up to 50 % for RTM to less than 5 % for FP!) Raw material: standard tow preg Increased freedom of design Significant reduction of tooling cost and processing risks Improvement of process reliability and quality Low operating costs due to high automation Flexibility and work space Shown part: automotive body part in direct towpreg technology 19

20 Tow Preg for Fiber Placement Advantages Ease of processing (low tack) Fast curing cycles (100s) Health and safety Excellent mechanical performance Types 50K, 24K Epoxy, thermoset Thermoplastic Width: 5 to 15 mm

21 Production costs for 1 kg part STAXX has highest cost efficiency 60,00 50,00 Comparison: STAXX vs. RTM-Process Cost performance today STAXX saves 15 /kg part 40,00 30,00 Cost savings today: 20,00 Equipment-34% Material -31% 10,00 Cost potential Cost saving potential: Equipment -40% 0,00 Material -54% Raw material cost (50% fiber volume content) STAXX RTM 21

22 Production szenario Trimming Handling Moulding Cleaning STAXX Compact 1700 Stacking Datum

23 Conclusion Automation is not a bottleneck for high volume production The supply for low cost CFRP production is available today Cost breakdown has proofed the feasibility of the process Freedom of design is improved Mechanical performance is very high Process chain is fully digital Technology sets standards 23

24 Thank you Special thanks to our partners from SGL, MRCF, SWMS For further questions: Or call