Airex Composite Structures (ACS) a member of 3A · PDF filePLEASE CONSIDER: ALL INFORMATION...
Transcript of Airex Composite Structures (ACS) a member of 3A · PDF filePLEASE CONSIDER: ALL INFORMATION...
PLEASE CONSIDER: ALL INFORMATION SHARED IN THIS PRESENTATION IS INTELLECTUAL PROPERTY OF AIREX COMPOSITE STRUCTURES
Modular light weight structures - Potential off composite structures in
commercial vehicles and their production.
Bart Radema Key account manager bus Europe
A leading supplier of lightweight
systems for road and rail
Airex Composite Structures (ACS) a member of 3A Composites
3A Composites History –
More than 50 Years of Experience
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One Group – Two Leading Divisions
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Revenues: 100 MCHF Employees: 230
SSM Textile Machinery
3A Composites Revenues: 600-800 MCHF / Employees: 2'200 (of which 700 in Ecuador)
3A Composites - Global Footprint
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Assets in North America
• 4 sites
• 338 Employees
High Point, NC Glasgow & Benton, KY Statesville, NC
Assets in South America
• 3 sites
• Headquarters in Guayaquil
• Sales office
• 111 plantations; 8’651 ha in Ecuador (thereof 5532 ha Balsa plantations)
• 696 Employees
Manta Guayaquil
Quevedo
Assets in Asia
• 5 Sites
• Headquarters in Singapore
• Sales office
• 358 Employees
Changzhou Shanghai
Singapore
Xiamen
Assets In Europe
• Headquarters in Cham, CH
• 6 Sites
• 806 Employees
Osnabrück, GER Singen, GER
Sins, Altenrhein, Neuhausen, CH
Loch Gowna, IE
Sao Paulo
Cuiabá
Dubai
Mumbai/Khopoli
Airex Composite Structures (ACS)
ACS is located at Altenrhein, CH
Competence Center for Engineering,
Tooling, Processes & Sales
Production co-operations in Eastern
Europe and China
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04/19/2012
ACS – Key Technologies Airex Vacuum Bonding
Technology (AVT)
Vacuum Assisted Resin
Infusion (VAC)
Resin Transfer Molding
(RTM)
Application Area
Bus
Rail
Raw Materials
Aluminium, Steel, GFR skins
PVC, PS, PMI, and PEI foam cores as well
as Balsa cores
Integrated aluminium extrusions
Advantages
Low weight sandwich structures with high
stiffness, ready for pre-assembling
High potential for the integration of functions
High dimensional accuracy
Low tooling investment required
Application Area
Primarily Rail
Protected Mobility/ Defence
Raw Materials
Glass fiber mats
Filled UP resins
PVC, and PMI foam cores as well as Balsa
cores
Advantages
High dimensional accuracy
Consistent product quality
Function integration
Closed process, low emission (EHS)
Application Area
Automotive
Low noise fan blades
Raw Materials
Glass-, Carbon-fibers
EP, VE, UP-resins
PUR, PVC, and PMI-foam cores as well as
Balsa cores
Advantages
ACS is technology leader
Consistent product quality
Class A surface quality
Short-time from design to first part
Best for complex shapes w/ hollow parts
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INNOCAB®
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Free formed surfaces
Structural
Large size components
Impact resistant up to 600 km/h
Mechanical interfaces integrated
Painted and fully equipped on demand
Proven “cold” repair concepts
System competency
CAD - Design
& Engineering
Manufacturing
Assembly & Painting From design to
finished systems
Tooling FEA / Real Tests Together with external partners
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COMFLOOR®
80% assembly time reduction
750 kg weight reduction per rail car
300 mm more internal width
30 years product lifetime
Integrated heating system
Maintenance free
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ACS – Heated structural floor concept
conventional Heated floors
Limited leg space
Local hot / and cold area
T
1 T
2
Practically zero heat differences
Low weight + space requirements
High customer comfort
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XBODY®
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Structural, lightweight, stiff systems
Mechanical interfaces integrated
Maximum size 18m x 2.8m
Modular construction kit
Painted and fully equipped on demand
Supports excellent crash behavior
Proven “cold” repair concepts
ACS – current bus development projects
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Components
Structural 2D Parts
Structural 3D Parts
Sandwich
interdeck with
seat fixations
Composite bus parts OEM’s ACS develops
Systems
Subassemblies
Mechanical integration
Electrical integration
Painting
etc.
Sub-System Suppl.
Composite-Sidewalls
Flooring systems
Sandwich roofs
Middle-
chassis
Engine tower
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ACS – Selected references – Monorail
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The Modular Sandwich Roof
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Reference-dimensions:
Length: L = 9.8- 13.3 m
Width: B = 2,2 bis 2.4 m
t1 a1
a2
b
t2
Cross-beam: 25 mm x 50 mm x 1,2 mm (a1 x a2 x t2)
Solebar: 50 mm x 50 mm x 2,0 mm (a1 x a2 x t2)
Cover sheet: Steel (0,6 mm); GRP (2,0 mm) (t1)
Adhesive thickness: 3 - 5 mm (tough-elastic adhesive)
b
Foam core: 35 – 50 mm (a)
Cover sheet: Aluminium 0,6 - 0,8 mm (t1)
GRP 2,0 mm (t1)
Adhesive thickness : 0,2 mm (structural adhesive)
t1 a
Dimensions
Dimensions for a representative
City- and Coachbusroof L
B
Modular Sandwich Roof Traditional Bus Roof
Airex Composite Structures Sandwichtechnology for Bus solutions
A Proven Concept
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Funktion
Komfort
Sonstiges
Anforderungen Sandwich
Anforderungen Busdach
Kosten
Werkstoff Konstruktion Produktion
Temsa Avenue
Nabi Metro 45C
• Dach und Boden
• Deckschicht: GFK
Quellen: VDL, Nabi, Alcan, Temsa, ATZ
VDL Citea
VDL AmbassadorVDL Bova Magiq
OPTARE/ EAST LANCS
VDL Phileas
Merceds-Benz Cito
• Dach und Boden
• Deckschicht: GFK
• Dach und Boden
• Deckschicht: Aluminium
• Dach und Boden
• Deckschicht: GFK
• Dach und Boden
• Deckschicht: Aluminium
• Dach
• Deckschicht: Aluminium
• Zwischenboden
• Deckschicht: Aluminium
• Dach und Boden
• Deckschicht: GFK
Requirements Roof
Functions
Comfort
Costs
Others
Material Construction Production
Requirements Sandwich
Roof
Aluminium cover sheets
Roof & Floor
Aluminium cover sheets
Roof & Floor
GRP cover sheets
Roof & Floor
GRP cover sheets
Roof & Floor
GRP cover sheets
Roof & Floor
GRP cover sheets
Interdeck
Aluminium cover sheets
Roof & Floor
Aluminium cover sheets
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• Aluminium and GRP
Density
E-Modul
Long. strength
Thermoconductivity
Aluminium
2,6 - 2,8
70.000
300
80-220
GFK
1,6
17.600
267
0,1-0,2
g/cm³
MPa
MPa
W/mK
Mechanical properties
Cover sheets
Cantrails
• Execution of cantrail as extruded aluminium-
profile
• Cantrail could be connected to Steel- or
Aluminium structures of busses. It‘s possible
about a bolted or glued connection.
cantrail sandwich
adhesive
Connection to the cantrail
connection profile
skeleton
Connection to the bus structure
adhesive
sandwich
cantrail
Airex Composite Structures Sandwichtechnology for Bus solutions
Sandwich properties
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• XPS- and PU-foams
• Absorption of dynamic loads
• Low Thermoconductivity
• High temperature resistance
• Use of XPS-foams in case of higher
mechanical requirements, higher durability,
is a future trend
• Use of PU, higher temperature resistance,
lower mechanical properties, embrittling
possible
Mechanical properties
Foam density
E-Modul
Tensile strength
Modulus of shear
Thermoconductivity
Compressive strength
Shearing resistance
PU
50
10.000
430
4.000
0,024
400
240
XPS
45
25.000
1.000
14.000
0,025
700
500
kg/m³
kPa
kPa
kPa
W/mK
kPa
kPa
Core materials
Airex Composite Structures Sandwichtechnology for Bus solutions
Sandwich properties
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0%
50%
100%
150%
200%
250%
Stahl AL 08 - XPS 40 AL 08 - XPS 50 AL 06 - XPS 40 AL 06 - XPS 50 GF 2 - XPS 40 GF 2 - XPS 50
Steifigkeit Gewicht
-53%
+45%
+125%
-49%
+8%
-61%
+68%
-57%
-7%
-37%
+44%
-34%
Stiffness- and weight comparision
Airex Composite Structures Sandwichtechnology for Bus solutions
Steel
Stiffness Weight
Airex Composite Structures Sandwichtechnology for Bus solutions
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Requirements/ Funcitions Connections Aluminium/ framing
Mechanical properties
Long. strength
Long.- shear strength
Ultimate elongation
Max. temperature
1K-PU
1
2
400
80
2K-PU
5 - 10
5 - 8
25 - 350
120
MPa
MPa
%
°C
1K-PU (SMP)
3,5
3
200
120
adhesive
glued Cone connection
Steel sidewall Skeleton with steel connection-profile
Aluminium cantrail for High loads
Aluminium
Sandwich roof
connection
ACS glued cone connection
Airex Composite Structures Sandwichtechnology for Bus solutions
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FE Analysis with glued cone connection in the complete vehicle model
Tensions in
Sandwich cover sheets and
cantrail
Distensions
in cone connection
12 m complete citybus
model with high load gas
tanks an airconditioner
Improved Stiffness
Compared to the steel roof, the sandwich roof is stiffer under longitudinal,
vertical and torsional loading (5% to 22% smaller displacements),
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Compared to the a welded joint bounded joint is 50 % stronger
Bending Test (push/pull testing) of sandwich roof element with
integrated cant-rail and welded steel side-wall underbody structure
joined by bonded V-notch joining
Sandwich
Airex Composite Structures Sandwichtechnology for Bus solutions
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Doubledecker series development E400 for Alexander Dennis SOP 2014
FE calculation:
3 g vertical hit
incl. passanger loads and seats Tension distribution
Displacement
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• ECE-R66 rollover requirements today will fulfilled
with the amount of potential of the sandwichstructure
• Survival space remains preserved
• Fulfillment of requirements will tested in
FE- Simulations and attempts
Survival-
space
Sources: Temsa
Verification of the structure – rollover test
Verification of the cantrail connection
• Bending charge of the
sandwichpanels against
connection profile
• Failure of component
at the steel connection
on the termation bar
(section window pillar)
• Sufficent strenghtness of
sandwich panels
Airex Composite Structures Sandwichtechnology for Bus solutions
Crash & Roll Over
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Airex Composite Structures Sandwichtechnology for Bus solutions
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Various advantages through the modular assemblage of the roof
• Ergonomical assemblage (no overhead assembling)
• Optimized work flow
• Reduced floor space in BiW
• Lower warehousing costs
• Simplier handling in the factory
• Pooling of all glue processes to one sector
(Front- and Side windows)
• Summarized and optimized quality inspection
• Reduction of the assembly time (concept 1)
in BiW and assembling (- 50 %)
Airex Composite Structures Sandwichtechnology for Bus solutions
0
500
1000
1500
2000
2500
3000
3500
Rohbaufertigung Montage Summe
Fert
igu
ngs
zeit
[min
]
- 73 %
- 39 %
- 50 %
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0
100
200
300
400
500
600
700
800
Gewichtsanteile Gewichtsanteile
Sonstiges
Beplankung
Stahlgerippe
- 160 kg
0
100
200
300
400
500
600
700
800
Gewichtsanteile
Sonstiges
Anschlussprofile
Sandwichprofil
Roof module weighs ca. 700 - 750 kg* (6 % amount of total weight)
Weight reduction through sandwichroof ca. 160 kg (= 20%)
Weight saving variies and depending on the execution of the sandwich technology
For example omission of interior cladding (24 kg), optimization of the
aluminiumprofile (ca. 30 kg), design of cut-outs, integration of HLK-channels etc.
* Declaration for a full assembled and isolated roof
Weight balance
Airex Composite Structures Sandwichtechnology for Bus solutions
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** labor costs are based on a westeurope production
Manufacturing costs
0
2000
4000
6000
8000
10000
12000
Materialkosten Arbeitskosten Gesamt
Fert
igu
ngs
kost
en [€
]
Stahl
Sandwich
+ 7 %
- 50 %
- 10 %
• Higher material costs of the roof framing (purchased part versus raw steel)
• Saving of material costs in the buildout throught component integration
• Significant reduction of manufacturing costs through lower personel expenses** (50 %)
• Savings of manufacturing costs (10 %)
0
2000
4000
6000
8000
10000
12000
Stahl Sandwich Stahl Sandwich Stahl Sandwich
Rohbau Montage Summe
Fert
igu
ngs
kost
en B
usd
ach
[€]
Arbeitskosten Materialkosten
- 10 %
- 21 %
+ 24 %
Manufacturing costs bus roof Manufacturing costs bus roof
Airex Composite Structures Sandwichtechnology for Bus solutions
Higher flexibility and reduction of variants
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Escape hatch
Air conditioning
Left/ Right drivervariants
Art of propulsion technology
Variants induced through:
Vehicle length
Quantity of doors and bus specific
positions
Engineconcept/ doors
Airex Composite Structures Sandwichtechnology for Bus solutions
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As example the brand new Alexander Dennis Enviro 400 MMC
400 kg weight saving in the new model design MMC
Due to the weight savings it was possible to win up to 7 seating capacities,
as result the bus could be authorized to 86 seats
only through the composite-components it was achieved arround 80 %
of the total weight savings
Due to excellent thermic isolation of the
Composite-roof it was possible to prevent condensation
The new production method, the modular construction, allows to improve
essentially the production time, quality and consistency in production
over the different plants
at the sametime the stiffness was significantly improved
Weightsaving potential – as example
Weight reduction:
Sandwich-roof primary:
160 – 250 kg
Sandwich-roof, floor and optimised chassis:
1.000-1.250 kg
Total including „down-sized“ engine:
2.000 kg
No structural reinforcements in the sandwich roof
are necessary, indipendent for the drive concepts.
40 % weight reduction in comparision to the
convetional solution
Lower overall weight results with significant fuel
savings up to 16%.
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VDL Citea:
overall weight reduction of
2000 kg results in a only 12
tons weighty bus
Repair methods
Proved and authorized repair methods
ACS After-Sales provides on request a
qualified repair team
Repairing of small damages could be done
locally (provider or ACS)
Repairing of structural damages could be
executed from service centers or qualified
staffs (MAN or ACS)
© 3A Composites Holding AG
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Proved repair methods
Airex Composite Structures Sandwichtechnology for Bus solutions
Bus product development Airex Composite Structures
• Sandwichpanels fulfill all the requirements for a bus roof
• Stiffness, strength
• Durability
• Repair
• Comfort
• Advantages:
• Weightsavings in the roof section
• Reduced manufacturing costs
• Higher manufacturing flexibility, lower diversity of variants
• Lower vulnerability in operation
• Alternative provisions for lightweight construction are less effective and associated with
higher costs, but realisable without impact on the existing prodution.
Thank you for your attention
ACS Mission
We offer customers high value mobility and industrial composite solutions for a
sustainable future
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Airex Composite Structures
Airex AG
Park Altenrhein
CH-9423 Altenrhein, Switzerland
Phone +41 71 858 48 48
Fax +41 71 858 48 58
www.airexcompositestructures.com
CHINA
www.airexcompositestructures.com