MANUFACTURING with COMPOSITES 2012 Automated Composites Manufacturing Review

At the forefront of technology At the forefront of technology MANUFACTURING with COMPOSITES 2012 “Automated Composites Manufacturing Review” October...
1 downloads 1 Views 4MB Size
At the forefront of technology

At the forefront of technology

MANUFACTURING with COMPOSITES 2012 “Automated Composites Manufacturing Review” October 23, 2012

MTORRES PROPRIETARY INFORMATION

At the forefront of technology

2



THE ENVIRONMENT



THE DRIVERS



M TORRES PATH



CONCLUSION

MTORRES PROPRIETARY INFORMATION

At the forefront of technology  THE ENVIRONMENT

SECTOR MARKET

COMMENT AIRCRAFT BACKLOGS ARE LARGER, BUT COST CHALLENGES ARE LARGER. THE MAJOR PROGRAMS HAVE STARTED AND RATE MACHINES ARE NEXT.

ECONOMY

MATERIAL COST ARE RISING, BUT LEADTIMES ARE JUST AS DAMAGING. CAPITAL FUNDS ARE BASED ON NEW PROGRAMS CHANGING FROM “LOWEST PRICE” TO “TOTAL SYSTEM COST” “YOUR GUESS IS AS GOOD AS MINE”

POLITICS

“YOUR GUESS IS AS GOOD AS MINE” FEDERAL FUNDING WILL BE LOWER AND MORE UNPREDICTABLE

ENVIRONMENT “SMART IS THE NEW GREEN” 3

MTORRES PROPRIETARY INFORMATION

At the forefront of technology  THE DRIVERS

DRIVER FLEXIBILITY INTEGRATION

COMMENT FASTER TRANSISTION TO PRODUCTION, MULTIPLE PART TYPES- RECONFIGERABLE FACTORY MANAGEMENT, ERP/MRP MUST MANAGE THE SYSTEM

PERFORMANCE MACHINE PERFORMANCE TO SPECIFICATION AND CONTRACT

4

LIFE CYCLE COST

STAFFING AND EARLY ENVOLVEMENT ARE REQUIRED TO DETERMINE BEST SWAG.

ASSET UTILIZATION

EVERY SECOND IS TRACKED, ALTHOUGH TRAINING MAY BE OUR ONLY CONTRIBUTION

GLOBAL SUPPORT

THE SUN NEVER SETS ON AEROSPACE, LANGUAGES AND CULTURES ARE CRITICAL

LOCAL SUPPORT

IN THE BEGINNING ITS COLOCATED ENGINEERS AND DESIGNERS, THEN SERVICE MTORRES PROPRIETARY INFORMATION

At the forefront of technology

MTORRES COMPOSITE TECHNOLOGY ROADMAP

MTORRES PROPRIETARY INFORMATION

At the forefront of technology PRODUCTIVITY LAY-UP TIME 100 45 lbs/h

kg/h

75

34

lbs/h

kg/h

 MTORRES COMPOSITE TECHNOLOGY ROADMAP RANGE OF STRINGER AFP

RANGE OF FUSS AFP

NO STEERING FIBERLAYUP 25 – 100 lbs/h Any complex surface

50 lbs/h

23 kg/h

HIGHEST STEERING 24” MULTITAPE 50 – 75 lbs/h Flat type surfaces

DRYFIBER 50 – 100 lbs/h Wing type surfaces

25 lbs/h

RANGE OF SPAR AFP

11 kg/h

TORRESLAYUP

6 6

25 – 50 lbs/h Stabilisers type surfaces

MULTITAPE LAY-UP 25 – 50 lbs/h Wing type surface

ROBOTLAYUP 15 – 40 lbs/h Any type surfaces COMPLEXITY OF THE PIECE

MTORRES PROPRIETARY INFORMATION

At the forefront of technology  MTORRES COMPOSITE TECHNOLOGY ROADMAP: AFP CONFIGURATION  GANTRY TYPE MACHINE MTorres has invested in its own temperature and humidity controlled clean room for R&D purposes and customer demonstrations. Lay-up trials, new material trials, pre-series manufacturing could be done in this R&D machine.

R&D MTorres Gantry type machine

Process development machine for dry fiber and fiber placement.



7

Standard strokes: X35m (115ft) Y5.4-7.8m (18-25ft) Z0.85-1.5m (2.8-5ft) A95º B 40º C 145º but any stroke length can be built MTORRES PROPRIETARY INFORMATION

At the forefront of technology  POSSIBLE PIECES TO MANUFACTURE Machine is a technological demonstrator and a first article manufacture cell Machine will be capable of typical wing lay-ups: Skin type lay-up Spar type lay-up Stringer type lay-up Machine will be capable of typical fuselage lay-ups: OML up to R3m layup IML down to R1m layup Sideways angle is 25º. Attack angle 18º.

8

MTORRES PROPRIETARY INFORMATION

At the forefront of technology  MTORRES COMPOSITE TECHNOLOGY ROADMAP  INFRARED HEATING & HEAD CLEARANCE For very complex shapes, MTorres has developed a “high clearance” AFP head to be able to lay-up most complicate shapes. Head will be installed in the R&D Gantry for qualification.

MTorres has developed a double unit IR heater to improve resin activation in hard resins like Hexcel M21E or Toray 3900.

System is being qualified at the moment at KHI facilities in Nagoya. 9

MTORRES PROPRIETARY INFORMATION

At the forefront of technology  MTORRES COMPOSITE TECHNOLOGY ROADMAP: AFP CONFIGURATION  CANTILEVER TYPE MACHINE •

Simplest AFP machine

Cut/Add maximum speed capability: 60 m/min (2400 ipm)



A350XWB Wing stringer 2D •

10

Standard strokes: X35m (115ft) Y1.8m (6ft) Z0.25-1m (1-3ft) A0º-45º B 0º-30º C 145º but any stroke length can be built. 2D or 3D.

7axis 3D Cantilever type machine

MTORRES PROPRIETARY INFORMATION

At the forefront of technology  MTORRES COMPOSITE TECHNOLOGY ROADMAP: AFP SPAR CASE STUDY First goal was to substitute the Hot Drape forming to final shape lamination. R&D project brought TRL to 5-7 It is possible to design for manufacture much more complicate Spars  Save Aircraft weight Scrap is reduced from 20% to 0.5% Furthermore, back-to-back lay-up increased layup rate and reduced tooling requirements.

To serial production machine 2010 11

From R&D test 2008

GKN&SPIRIT Spar AFP column type machine MTORRES PROPRIETARY INFORMATION

At the forefront of technology  Case Study: Wing A350XWB SKIN COVERS Biggest Commercial CFRP structure, 35m x 7m Upper cover is done in Airbus Stade Lower cover is done in Airbus Illescas

Optimization of deposition rate. Always lay-up to the equivalent of 12” band width, even if 3” or 6” tape is used  multitape. Every single sequence of the laminate is done automatically: GLASS-COPPER-CFRP 12

MTORRES PROPRIETARY INFORMATION

At the forefront of technology MTORRES COMPOSITE TECHNOLOGY ROADMAP Autosplicer - Saves time (4h every 60h of lay-up) - No operator intervention). - Scrap reduced to 0. (Tow usage is never 100% in AFP machines) - Splice done in 2-3s.(10s chip to chip). - Double amount of material is loaded. - Empty reels changed during inspection

1st step

Reel utilization 100,00% Material Consumption (ft)

90,00% 80,00% 70,00% 60,00% 50,00% 40,00% 30,00% 20,00%

2

1

2

1

2

1

2nd step

10,00% 0,00% 1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

Nº of reel

Automatic Splice is done by means of compaction force (blue line), temperature (red). Finally, cutters (yellow) are needed to cut the previous spool line. 13

3rd step

MTORRES PROPRIETARY INFORMATION

13

At the forefront of technology  MTORRES COMPOSITE TECHNOLOGY ROADMAP  100% AUTOMATIC WIND BLADE MANUFACTURING •

Customer: GAMESA

Installation in MTorres Murcia 14

MTORRES PROPRIETARY INFORMATION

At the forefront of technology  MTORRES COMPOSITE TECHNOLOGY ROADMAP  100% AUTOMATIC WIND BLADE MANUFACTURING •

15

Customer: GAMESA

MTORRES PROPRIETARY INFORMATION

At the forefront of technology  MTORRES COMPOSITE TECHNOLOGY ROADMAP  DRY CARBON FIBERLAYUP + TP BINDER •

Layup of dry UD carbon fiber (low lateral stiffness and no tacking)



A thin resin veil provides: o o

some degree of stiffness/stability to the material Binder activation (LASER)

tacking when activating the resin veil at high temperature (120- 180ºC)  Diode laser needed to reach such temperature.



The thermoset resin is added to the final dry preform through an infusion process (possibility of integrating elements (stringers…) at this stage  one shot process



The curing of the part succeed in an oven (no autoclave required) Temperature distribution

MTorres technology developed for automatic wind blade production AFP is implemented into Dry Fiber AFP for aerospace applications. First Dry Fiber AFP machine for MS_21 wing manufacturing contract! Dry Fiber AFP demonstrator 1x50mm

Wind Blade Production AFP Gamesa 16

MTORRES PROPRIETARY INFORMATION

At the forefront of technology  MTORRES COMPOSITE TECHNOLOGY ROADMAP  OUT OF AUTOCLAVE PREPEG + LASER HEATING

Based on laser heating know how, it is also possible to increase consolidation level in-situ of “out of autoclave” OOA materials, to reduce porosity levels.

Infrared camera

Lens 52mm wide

MTorres is the suitable partner for process development (heating Tª, cfrp thickness, …) even before machine installation (MTorres R&D machine)

pirometer

17

MTORRES PROPRIETARY INFORMATION

At the forefront of technology  MTORRES COMPOSITE TECHNOLOGY ROADMAP  OUT OF AUTOCLAVE PREPEG + LASER HEATING

Laser wavelength only visible in camera Nd-Yag 500W laser 18

Refrigeration unit

MTORRES PROPRIETARY INFORMATION

Fibre and fixed lens

At the forefront of technology  MTORRES COMPOSITE TECHNOLOGY ROADMAP  THERMOPLASTIC AFP MTorres has worked during the last 12 months (under a contract with Spanish Composite R&D center FIDAMC) in the design and develop of a novel Thermoplastic AFP machine for final consolidation process. OBJETIVES:  Final consolidation of TP material.  No autoclave needed. MAIN CHARACTERISTICS:  Main Laser heating for TNP400ºC  High compaction in tooltip  Gantry  Control of Cool down Tc300ºC  Higher compaction in cold pressure

TNIP ≈ 400ºC

Tm = 340ºC

Tc = 310 ºC Tg = 145 ºC

 MTorres Patented Rotary cut&add of our thermoset AFPs used, Thermoplastic materials (PEEK typically, but other types to be tested at a later stage)

19

MTORRES PROPRIETARY INFORMATION

Cold presure Hot presure

At the forefront of technology  MTORRES COMPOSITE TECHNOLOGY ROADMAP  THERMOPLASTIC AFP

TNIP ≈ 400ºC

Tm = 340ºC

Tc = 310 ºC Tg = 145 ºC Cold presure Hot presure

20



Diode Laser used for heating purposes, installed with a scanner (rather than a fixed lens used in dry AFP) to apply the heat at different locations.



Infrared camera installed in AFP to verify laser temperature.



High compaction by means of deformable compaction roller (patent pending)

MTORRES PROPRIETARY INFORMATION

At the forefront of technology  MTORRES COMPOSITE TECHNOLOGY ROADMAP

 THERMOPLASTIC AFP

Gantry installed in FIDAMC facilities (Madrid) It has been maintained the AFP head in MTorres Pamplona for process development and panel qualification. To be installed in Madrid in March 2012.

Demo AFP head installed in MTorres facilities (Pamplona) 21

MTORRES PROPRIETARY INFORMATION

At the forefront of technology  MTORRES ROBOTIC TAPE LAYER For Fan cases type components, where tape width is limited to 75mm, it is possible to increase productivity by very dynamics Robots and multiple stations.

Small Cylindrical components. Tape width: 1x75mm or 1x150mm X3m Y2m Z1. 5m 22

MTORRES PROPRIETARY INFORMATION

At the forefront of technology  MTORRES STRINGER 2D ATL with 3D ultrasonic cutting machine

787 stringers & fillers. C Axis travel: 190º 1x12” or 1x6” or 1x3” X8m Y1.25m Z0.25m

For legacy programs, where it is not possible to change tow width and lay stringers with 12.7mm tow width (most optimum solution), it is possible to lay-up small components with a dedicated 2D ATL. In order to have 2 working areas, it is possible to “cross” both ATL cantilever and Ultrasonic Cutting gantry. This way, 100% availability of both working zones is obtained. 23

MTORRES PROPRIETARY INFORMATION

At the forefront of technology  MTORRES COMPOSITE TECHNOLOGY ROADMAP  MTORRES INTERCHANGEABLE ATL-AFP

MTorres AFP machine

MTorres ATL machine

Drivers for rotary cutter

C_axis

A_axis

C2_axis

Ultrasonic Cutting machine

It will be an Ultrasonic cutting machine, Automatic Tape Laying machine, Advanced Fiber Placement machine in ONE CELL! 24

16 Spools of 6lbs

Standard MTorres AFP head. 16x½” or 16x¼” Patented servo rotary cutter

MTORRES PROPRIETARY INFORMATION

At the forefront of technology  CONCLUSION •

Strong focus on Composite Manufacturing Equipment, not only in Aerospace but other sectors like Wind Blade Manufacturing, Automotive and Transport Industries. Cross Pollinate



The “World Market” is unforgiving and leads development through funding and timing.



Continue relationship with material suppliers and innovative OEMs that are developing complementary technology.



25

Stronger permanent presence in Key Geographical Areas.

MTORRES PROPRIETARY INFORMATION

At the forefront of technology

THANKS FOR YOUR ATTENTION

MTORRES PROPRIETARY INFORMATION