RTM/INFUSION processes TRY AUTOMATION (Carbon Fiber Reinforced Thermoset liquid way injection )

Transcription

1 RTM/INFUSION processes TRY AUTOMATION (Carbon Fiber Reinforced Thermoset liquid way injection )

2 Summary of presentation ISOJET equipements AUTOMATION / OPTIMISATION step by step CONCLUSIONS

3 Founded persons 3.5 million TO 65% abroad 60 MACHINES PER YEAR More 300 units sold in universities, industrial groups in aerospace/ automotive field Representative agents in europe and in far east References in Europe = Airbus group (more than 50 units ), Dassault, Facc, Daher, Lamborghini, Dlr, Fraunhoffer, GKN, Safran, Volvo, Sonaca, Terma, OAK, COMAC, EMBRAER,GE aerospace, Teknologya, Aerocomposit, Duqueine, Valeo, Bosch, Volvo aerospace, Swerea

4 Isojet representatives Composite alliance DISSOL s. Korea Isojet gmbh Umesh INDIA

5 WHY Automation? Performances Quality Production rate Different way to increase production Costs automation Increase added value on part more complex design (3D ) reduction of finishing reduction of cycle time

6 Full automated production line Now automation and optimisation are possible on each steps of the production of a part

7 STEP 1 material and Fabrics forming One of the most complex step in a part production.

8 Before: Manual - Automation of woven fabric lay-up - Traditionnaly hand lay-up process - Special focus on Automation for Out of Autoclave Process Now: Robotic

9 KEY step prepare the fabrics This step is a key step to improve productivity Patches positionning 3D forming Carbon Material 2D cutting Storage Consolidation - knitting 2D - Powder /heating Direct postionning In tool Storage - robot - compression (preforming tool ) - Netshape cutting - knitting 3D Position preform in tool

10 - Existing automation processes - AFP (Automated Fiber Placement) - ATL (Automated Tape Laying) - Filament winding - They use NON woven materials Filament winding Automated tape laying (ATL) and automated fiber placement (AFP)

11 VIDEO of an automation for beam preform Copyright = Technimodul engineering

12 Step 2 = design and automation with mould It is a key point to think about productivity and optimisation in the phase of a mould design. Heating rate Clamping of mould Automation IN/OUT of resin Net shape design Sensing in mould

13 Step 2 the mould Mould design and technology can give high improvement on automation Reducing operation (moulding / demoulding ) Sensing in mould to have mould with process interaction (for eaample pressure sensor to see end polymerisation phase ) Optimise the heating Think about heating rate and technologies this can reduce cycle time Heating source Ramping Température Maxi Convection by water circulation 5 to 8 C/mn 200 C Convection by oil circulation 2 to 5 C/mn 350 C Conduction electrical 5 to 10 C/sec. >300 C Induction 10 to 20 C/sec. >400 C

14 MOULD Automatic Connection (Patented COMPOSE /ISOJET) automatic connection inlet resin Automatic connection inlet vacuum Reduction of losses (tubes, resin ) No operator manpower Patented worlwide COMPOSE tools / ISOJET equipements Can be operated for RTM technologies but also other connection operations Injection system Mould RTM Venting system Automatic connnection

15 STEP 3 injection of liquid resin Possibility injection of resin 1 component or 2 components Machine can manage synchronization between cycle Machine can be connected to mould informations and/ or press / oven

16 Injection= push limits and automatise Injection RTM = automation is now frequent operation, machine interacts with other elements like press, tools.. Cycle automation and synchronization is important to reduce cycle time. High pressure injection = it is optimising the cycle for high production rates (automotive ) Injection RTM thermoplastics = starts on market and some experimentation = injecting plastics monomers or polymers in dry fibers

17 Injection= push limits and automatise and synchronise cycles Inject Monocomponent resin Inject thermoplastics resin Inject 2 components resin

18 Injection= push limites / interact/ regulate Interaction between injection machine and other tools Vacuum cycle Vents Mould heating steps injection Resin in / out Multiple moulds Sensing in mould

19 Video of an animation automatic connection IN/OUT mould RTLM With greetings COMPOSE TOOLS / DLR Stade

20 Step 4 Integration of all processes in a global line Management of global line is important to optimise Storage and management of multiple tools Step by step process integration Manipulation robots

21 production lines / integration of technologies Inject Store prehension Data record Heating Fiber placement Press Pdf 3d cellule RTML25262 Cleaning cooling Transfer Connect

22 Example DASSAULT AVIATION Biarritz (2014) Composites parts FALCON jet Oil heaters Tool manipulation Press Tool storage Press Tool preparation Moulds COMPOSE, integration and press PEI

23 DLR Stade EVO line (2013) Heated platens Robot preform Mould RTM Oven Préparation Station Transfer cart injection RTM Press

24 Conclusions For each step the automation and the optimisation can be realised Textile reinforcements Manipulation Transfer tool / fabrics Injection Heating/ cooling Maximum operation can be realised as hidden operations Resin suppliers also work hard to reduce cycle times Final taget Reduce cost part Optimise capital investment Increase quality and repetability of process

25 Special thanks Technimodul engineering (France ) Compose tools (France ) CT1 (France ) Pinette Emidecau (France ) DLR stade (Germany ) Dassault aviation (France ) Globalrtm (France) Sise (France )

26 Thanks for attention