Machine solutions for the production of automotive composites. Composites without borders October 14-16, 2014 / Moscow

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Solomon Lester
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1 Machine solutions for the production of automotive composites Composites without borders October 14-16, 2014 / Moscow

2 Content Information about Stäubli Group Introduction Comparison of fabrics and application 3D fabrics and pattern possibilities Double-rapier weaving system 2

3 Stäubli Group Originated in 1892 in Switzerland 4000 employees Family owned Textile Connectors Robotics 3

4 Stäubli Group: Global Presence Present across 5 continents with units in 25 countries and agents in 50 countries Stäubli Units Agents 4

5 Stäubli Germany Start up 1969 from the former company Trumpelt All 3 divisons are located in Bayreuth About 450 employees Source: 5

6 Stäubli Textile Frame Weaving Jacquard Weaving Weaving Preperation Weaving machines Carpets Technical Textiles 6

7 Stäubli Connectors Mould loading tables and carts Mould Clamping systems Quick release couplings Tool change systems 7

8 Stäubli Robotics 4- and 6-axis robot arms Low (0.5 to 10 kg) to heavy (over 80 kg) payload Compact size, high speed and precision Resistance to all types of environments 8

9 Content Information about Stäubli Group Introduction Comparison of fabrics and application 3D fabrics and pattern possibilities Double-rapier weaving system 9

Introduction Market situation Increasing demand for composites (reinforcement textiles) Composites are at the threshold to mass production (still niche market) Carbon fiber reinforced composits [Tsd.

10 Introduction Market situation Increasing demand for composites (reinforcement textiles) Composites are at the threshold to mass production (still niche market) Carbon fiber reinforced composits [Tsd. T] Glas fiber reinforced composits [Tsd. T] 14,8-76,8 Tsd. t. p.a. 1 5% p.a. 5,1-6,6 Tsd. t. p.a. 13 bis 17% p.a. Source: AVK, Composites Forcast and Consulting LLC, Industry Experts Publications, SGL Carbon, Roland Berger Marktmodell, Mc Kinsey, light weight design 10

11 Production costs Introduction Initial situation Composites are to expensive Material properties are not fully utilized Niche markets (high number of product changes) High potential for automatization 100 % Material -50 % 70-75% Process -90 % ~30 % Paint -70 % Material Process Paint 2010 Vision Aluminum Steel Source: Audi (Timm) 11

fiber density Integral design Requirement production High reproducibility

12 Introduction Requirement composite (reinforcement textile) High stiffness (non-undulated yarns) High delamination resistance Net-shape fabrics High fiber density Integral design Requirement production High reproducibility High productivity High flexibility Low set-up effort Low fiber damage 12

13 Content Information about Stäubli Group Introduction Comparison of fabrics and application 3D fabrics and pattern possibilities Double-rapier weaving system 13

14 Comparison of fabrics Fabric types 2D fabric 2,5D fabric 3D fabric Spacer fabric Warp/Weft Yes Yes Yes Yes Pile/Binding No No Yes Yes Application Shell like Car roof Bonnet Complex Joints Nodals Solid Integral Stringer Spacer Tanks Sandwich Source: conrad, sigmatex, Stäubli 14

15 Comparison of fabrics Process steps: composite production 2D fabric 2,5D fabric 3D fabric Spacer fabric Cutting Stacking Draping Joining In-plane Out off plane Expertise R&D effort Better than average (not necessary/easy) Average Lower than average (necessary/challenging) 15

Yarn delivery Reed motion Dobby Jacquard Jacquard Warp beam Creel Creel

16 Comparison of fabrics Production requirements 2D fabric 2,5D fabric 3D fabric Spacer fabric Rapier Single Single/Double Double/Single Double Shedding Motion Yarn delivery Reed motion Dobby Jacquard Jacquard Warp beam Creel Creel Rotation Rotation / Parallel Parallel Dobby / Jacquard Warp beam / creel Parallel 16

17 Content Information about Stäubli Group Introduction Comparison of fabrics and application 3D fabrics and pattern possibilities Double-rapier weaving system 17

18 Basic structures of 3D fabrics: Basic structures of multilayer fabrics Orthogonal-Interlock Angle-Interlock Layer-to-layer Through-the-thickness Source: Yi, H. L.; Ding, X.: 18

19 Characteristics of 3D fabrics: Advantages and Challenges Advantages Challenges Single-step process High reproducibility High productivity High delamination resistance High fiber density Low in-homogeneities Low fiber damager Low application experience High expertise required More complex fiber impregnation with thermoset matrix Fiber orientation 0 and 90 Source: Hufenbach et. all. 19

20 Pattern possibilities Two fabrics above each other Connected by pile yarns Different pattern 20

21 Pattern possibilities Weft yarns separated by warp yarns Connected by pile yarns Different yarns 21

22 Pattern possibilities Weft yarns separated by warp yarns Connected by pile yarns Different thickness / apertures 22

23 Pattern possibilities Pattern possibilities Different yarns Different pattern Different thickness / apertures Combination of spacer and multilayer fabric 23

24 Content Information about Stäubli Group Introduction Comparison of fabrics and application 3D fabrics and pattern possibilities Double-rapier weaving system 24

25 A machine woven carpet: Production Two fabrics above each other Connected by pile yarns Cut in the middle Characteristics High thread densities Complex patterns Large pile height (thickness) Very coarse yarns 25

26 Double-rapier weaving system Products 26

27 Double-rapier weaving system 27

28 ALPHA 500 TECH Loom for heavy fabrics with single or double rigid rapiers Technical yarns like Carbon, Glass, Aramid, PES, etc. Weaving-width: 0,7 5,3 m 28

29 Thank you for your attention! 31

Weaving machines for 3D hybrid fabrics

Weaving machines for 3D hybrid fabrics Stäubli Group Technological solutions for a vast range of industries textile machinery, industrial connectors and robotics A family owned industrial company which