P. R. Lewis Consulting, LLC & Zeon Technologies, Inc. From the molecule to the molded part

Transcription

1 P. R. Lewis Consulting, LLC & Zeon Technologies, Inc From the molecule to the molded part

2 Firestone Cotton Mill, Gastonia, NC - 20,000 Employees, 537,000 Sq Ft, 49 square-blocks of company housing. All to make Cotton Tire Cord.

3 Labor is a commodity just like pork bellies and soybean $0.50 per week

4 Labor intensive manufacturing moves to where labor is cheap New England to the South The South to Mexico Mexico to China China to India

5 Competing NC in 1912, China today Presswerk_China.wmv

6 Cheap Labor The Chinese are doing exactly what my father s generations did in the south. The Chinese are not wrong to compete with the best they have. My father was not wrong to compete with the best he had. Is the US Competing with the best it has?

7 Also!!! Raw material price per Lb. is not everything it is the only thing. Vince LamAmerican President Last Surviving American Industry Greenback, WI 20% lower price every year?

8 Cheap raw materials = Rejects & Low Production Facilities More Press Maintenance Mold Wear Freight More Warehouse Space More Operators More Presses More QC More Floor Space And on and on and on Through Put Problems Scheduling Missed Shipments Dissatisfied Customers Lost Sales Mad Boss Cheap Raw Material works with cheap Labor

9 How does the US compete in this New World Order? We have technology We have R&D We have an educated work force We have experience We can t do cheap, but we try It s Ingrained!!!

10 A Novel Solution, Use Your Strength Carver had a problem that had existed for thousands of years Not price per Lb, Solve the problem

11 The Carver Pump of 250 BC by Archimedes

12 The Archimedes Screw of Today

13 Pump Components

14 The Shaft turns The housing is stationary > FRICTION & Wear

15 Sacrifice the Cheap Wear components to Save the shaft Wear the shaft or wear the bushing has been the choice

16 Down Time A pump shaft is $ A Pump wear bushing is $40.00 The True Cost is in Down Time Sea Island

17 Maintaining Tolerances between Stationary & Moving is Pump Efficiency

18 Carver Pump Wish List The component must be: Able to be machined to a smooth surface to hold the exceedingly tight tolerances around the turning pump shaft over a wide and changing temperature range to eliminate vibration Hard and tough enough so that any foreign matter inadvertently carried in the liquid does not damage the bushing Chemically resistant enough so that it is not attacked by what is purposely or inadvertently pumped along with the liquid Soft enough not to wear the shaft Tough enough to withstand press fit assembly Adhesion between resin and fibers sufficient enough so that the adhesion is stronger than the force required to cut the fibers, thus leaving a smooth dimensionally accurate machined surface Low enough water absorption so that it does not absorb the liquids in the pump causing expansion and contraction

19 Pretty Tough Order In other words, the perfect bushing must be molded from a material that is tough, soft, hard, flexible, stiff, thermally stable, easily machined, and that does not absorb liquids.

20 Everything was on the Table Except Hard Fillers Thermoplastics Nylon, UHMW, PTFE THERMOSETS Unsat Poly, Phenolic, Melamine Molding Process - Injection, Compression, Resin Transfer Resin Nothing Available Off the Shelf Works Hard Fillers wear the shaft Glass and Quartz are out

21 New Resin & Kevlar We had a new Zeon resin that stuck to Teflon, so why not Kevlar, Soft and Strong. DuPont s Response: Nothing sticks to Kevlar! You will get a fuzz ball if you machine a Kevlar filled part! Are you an Engineer?

22 I decided to respond to arrogance with arrogance Lewis Law: If the adhesion of the resin to the fiber in the molded part is greater than the force exerted on the fiber when it is cut you do not get fuzzies.

23 DuPont V/S Carver R3 Machined Kevlar A Fuzzy Molded Part

24 It Works so the cost: Carver Pumps Cost between $10,000 and $50,000 New BMC Components went from $10.00 / $20.00 to $30.00 / $40.00 Old V/S New - % of Selling Price Old Components = 00.03% to 00.15% New Components = 00.07% to 00.35%

25 Gain: Tighter Tolerance, Superior Product, Less Wear The new Kevlar filled BMC maintains tighter tolerances than anything before Thus: Pump maintenance and thereby down time has been reduced to virtually ZERO No Bushing Wear and no Shaft Wear No vibration No loss of pumping efficiency

26 Press fit assembly The first was a mistake! circumference reduction Machined too Large for the Hole

27 Tighter Tolerance = Higher Efficiency Less Vibration & Less Wear. Tighter Tolerances No Wear Yet Over 500,000,000 linear feet (107,955 Miles 5 times around the earth) and no loss of pump efficiency 4 shaft turning 3300 rpm. Pump fully instrumented It does not look like it s ever going to wear

28 Chemical Resistance and Water Absorption The base resin sits in 125⁰C phosphoric acid and does not degrade Water absorption of the Kevlar filled material is equal to the bench mark of filled plastics, glass filled epoxy.

29 Randy: Carver Pump has been working with a potential new customer who is an OEM to sell them high pressure pumps (Carver Ring Section RS pump) for inclusion in their product. Each ring section in one of these pumps contains multiple wear rings and bushings made of Zeon ZTX 3033 HT molded and machined by R3 Composites. Carver Pump supplied one typical pump to this customer for their evaluation before placing orders. They ran this test pump through performance, endurance and accelerated usage test and returned it to Carver pump for inspection. The customer reported the pump ran beautifully no matter what they through at it. On inspection it appears they ran everything but the kitchen sink through the pump with out problems or loss of performance. Metal parts and hose fittings were found lodged inside the pump along with other discarded floor debris. All of the rings and bushings appear to be in good shape with minimal dimensional change except for scars on the working surfaces where the foreign materials worked their way through the tight clearances on the pump during operation. In addition we have completed machining of 9 impact test samples and have sent off to Stork Technimet for testing. Aron Rutin R3 Composites arutin@r3composites.com

30 The New Solution is: Tough, soft, hard, flexible, stiff, thermally stable, easily machined, does not absorb liquids.

31 A novel Solution Use your Strength Presswerk_China.wmv