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Polymer Days 2010 Fredrikstad November 24 - 25, 2010 Robotics and Composites

Polymer Days 2010 Fredrikstad November 24 - 25, 2010 Robotics and Composites. What trends and perspectives for the automation of the composite market ? What are the advantages of the automation of processes in the composites industry ?.

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Polymer Days 2010 Fredrikstad November 24 - 25, 2010 Robotics and Composites

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  1. PolymerDays 2010 Fredrikstad November 24 - 25, 2010Robotics and Composites What trends and perspectives for the automation of the composite market ? What are the advantages of the automation of processes in the composites industry ?

  2. MATRASUR Composites Making composites easier Norican Group Shaping Industry • A Company of • Supplying the composites market since 1972 • + 400 machines configurations • + 5 500 installed units • + 1 100 customers worldwide

  3. Automation in the Composites industry: Facts & perspectives Facts: Composite products suffer from excessive labor costs Perspectives: Automation potentials remain high and under investigated

  4. Robotics : A new tool for the industrialization of composites (source “World robotics 2007”) (source “World robotics 2007”) Some figures: • Number of robots installed per year • Robot population per 10,000 workers in the manufacturing industry

  5. Composites & Industrialization Potentials for automation today: Potentials offered by the industrialization of composites are high as they still remain poorly investigated to this date This potential represents with no doubt the best source of improvement for competitiveness Automation contributes to a sustainable development approach

  6. Industrialize, yes, but How? • By rethinkingthe production methodology • By modernizing it • By considering current and future environmental requirements towards asustainable development

  7. Main steps of the industrialization process • Exhaustive audit of methods, technical resources and skills • Analysis of production goals (quantity, quality, economical, ergonomics, ecological aspects…) • Review of all technical solutions • Technical and economical choices> financing • Comprehensive engineering study and implementation planning • Implementation

  8. Multi-competent engineering resources: mechanics, automatism, robotics Software: 2D and 3D Cad software, robotic dedicated software, Visual Basic Feasibility studies and development Complete integration & turn-key approaches Programming capacities Process Engineering Key elements • Internal • or • External • resources

  9. Developing competencies:

  10. Industrializing Composites through Robotics Handling systems Release agent spray-up Gelcoat spray-up (single or multi color) Barrier-Coat spray-up Resin spray-up Chopped lamination Paint spray-up Robotic solutions now available for : • Roll-out • Insert positioning • Adhesive lay down • PU foam spray-up • Resin cast on press • Trimming, machining, surface grinding • Fiber placement All workshop sectors are concerned!

  11. Industrializing Composites through Robotics Traditional Mode versus Robotic Mode

  12. Robotics for composites industries • Industry fields already using Robotic solutions for composites: • Automotive industry: Spray-up, trimming, adhesives… • Aerospace industry: Fiber placement, part trimming and finishing... • Industrial parts: Spray-up, trimming,.. • Boat industry: Gelcoat, barrier-coat and release agent spray-up • Sanitary ware: Handling systems, spray-up, part trimming, insert positioning… • Rail Industry: Trimming of parts for High Speed Trains (TGV) • Water treatment: Spray-up of reservoirs and filters • Swimming pools and Spas: Spray-up of pool shells, trimming • Energy: Wind blades coating

  13. Case studies • Turn Key robotic system for a GRP Pool manufacturing Plant • Industrializing production in a Small Size Company

  14. Industrial production line for GRP pools : • Encountered problems: • Creation of a new production site • Unexperienced staff with respect to the product • Limited workshop surface • Desire to have a highly automated solution • Desire to have a total control over production costs

  15. Industrial production of GRPpools • Industrialized process: • Robotic spray-up of release agent • Robotic multicolor gelcoat spray-up • Robotic barrier-coat spray-up • Robotic chopped laminate spray-up • Production flow management on carousel • BEFORE/AFTER • 40h Labor/ Pool brought down to: 13h/Pool (-70%) • Yearly raw material cost savings : 320,000 € (-12%) • Significant increase in: Product, quality, working conditions…

  16. Spray-up robot for release agent, gelcoat barrier-coat Resin&fiberglass spray-up robot Part demoulding Transfer Automatic conveyor Curing zone

  17. Case study 2 • Industrialization & (Very) Small Size Companies

  18. Small Size Companies on the path of industrialization Problems faced: • Large variety of parts • Small series • Limited personnel • Company oriented towards “hand made” work • No 3D drawings available • Undefined company strategy • Short term vision

  19. Robotic becomes accessible:Low Cost Robot now available Part Identification SensorcontrolledExhaust Linear 8th Axis Rovingfeeding Bridge Crane Robot Material Mix Filtration Rotating 7th Axis Safe Enclosure Material T° control Part positionning Multiclolorgelcoat Unit PC Controls Anticollision safetydevice Part Loading Automaticpumpfeeding Chopper unit

  20. Robotic becomes accessible: Programming now simplified Step1 Programming Step2 Producing

  21. Phase 1:Robot for acrylic reinforcement with system based on teach-through robot Small size companies on the path of industrialization: Technological evolution step by step Phase 2:Robot for part trimming and drilling with offline programming system

  22. How robotics brings Sustainable Development Benefitsto composites shops

  23. Robotics : transforming composite workshops

  24. Reducing production surface for significant energy costs reductions • VOC’s exposure at lowest (no personnel in lamination areas) • No more dangerous nor painful work stations • No more dust nor chemical residues in the workshop

  25. Concentrated VOCs are easier to treat Effluent treatment now affordable (less air volume for a higher VOC concentration) • Photo-catalytic treatment • Charcoal filtration • Incineration • Etc..

  26. Minimized extraction volumes in smokestacks • Extraction directly from VOC source for a minimized extracted volume • Air exhaust from VOC source for ventilation control through sensor • Better control of VOC effluents preserves workshop surrounding environment

  27. Robotics : transforming composite workshops • ECONOMICAL ASPECTS • Productivity, cost effectiveness, Raw material Savings Competiveness • Production Management • Increased quality • Reduced production surface Energy Cost reduction • ENVIRONMENTAL ASPECTS • Working Conditions significantly improved • Reduced Air exhaust Volumes & VOCs in Stacks • Affordable VOCs treatment • Lower Energy requirement • Affordable Regulation compliance

  28. Robotics applied to composites: An unexpected opportunity for combining quality, productivity and sustainable development while satisfying the highest standards requirements

  29. Thankyou for your attention www.matrasurcomposites.com

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