1st year meeting

SMART

Rome, February 27-28th 2013

Mechanical design updates

Topics:• WP1 – Moulding machine specification summary• WP4 – Products and mould design • WP5 – Moulding machine design• WP7 – Moulding machine logistic issues

WP1 – SMART requirements and specifications

Main specification summary from D2.1•Max moulding pressure: 40 bar ( = about 100 T on 500x500 mm product area)•Max moulding temperature: 200° C (maybe 250° C)•Max moulding time: 30 min•Stroke: 200 mm (suitable for 50 mm height products)•Structure with side columns plate guides

WP4 – Product and mould design

Sport & Leisure

Multi-purpouse flooring surfaces for indoor/outdoor covering:

•Children playground areas •Swimming pools•Shooting ranges•Gyms

Industry

•Trolley or container wheels•Precast concrete support•Floor covering for cows indoors

Transport

•Block for railway application •Kerbs for disables

List of selected possible products

WP4 – Product and mould design

Possible approachsNumber of products

Three products at least expected according with DoWMore products could be considered if possible:•unused budget available•person months available... possibly resulting from moulding machine design

Tall shaped productsCurrently excluded because of very high mould cost and moulding machine cost (long stroke)

Could be reconsidered if possible:•unused budget available•long stroke press available

Large shaped productsCurrently excluded in order to limit moulding machine size Possible realization of relevant sections as

demonstration

WP5 – Moulding machine design

Possible mechanical design approachs1) Machine fully designed

Machine completely conceived, designed and built within the project period / project budget.Extremely time consumingComplex and extremely specific design work to be performed: result quality issuesProblems in obtaining heavy machine framework parts by metal castingLimited time available for moulding and testing, so for refining the SMART process

2) Machine functional groups purchased, design for connection and integrationMain machine functional groups (hydraulic press mechanics and thermal plates) procured on the market. Design activity is performed on their integration.

Easy to find pressing machine parts on the market, both new and used: remarkable time savingRemarkable money savingPossible to start very soon with moulding and testing

3) Machine fully purchasedA complete pressing machine could possibly be found on the market with thermal plates and accessories.

Maybe impossible to find a complete machine exactly fulfilling our needsExtreme time saving

WP5 – Moulding machine design

Approach n°2 seems the most beneficial for the project

Clamping force: max 200 T ( = 40 bar on 700x700 area)Work area: 850 x 1000 mmStroke: 1500 mm

Some examples of used press mechanics found on the market:

Clamping force: max 350 T ( = 40 bar on 935x935 area)Work area: 1000 x 1650 mmStroke: 700 mmAverage price level: €

50000

WP5 – Moulding machine designApproach n°2 seems the most beneficial for the

projectDesign work to be performed on purchased functional

groups•Customized mechanical integration of press, thermal plates and accessories•Possible integration of pressed air system for mould extraction•Possible integration of loading table•Control panel customization and machine setting to running order•Control system and user interface complete design

Reviewer’s questions:

D1.1:  Did this deliverable change your plans for WP5 and WP6? Will you try to buy a commercial machine which meets the specification?  Will you try to build your own prototype? Will you try to modify a commercial design?

D1.2:  The concerned WP was expected to specify the type and condition of starting materials and the range of temperatures and pressures to be applied - in order to produce rubber items (from recycled rubber) for particular markets (sports, traffic etc.).  However these results are missing in the conclusions.  No tables are provided to show how the performance of recycled rubber could be improved.  The graphs are impressive but explain very little.Reference is made to reinforcement of the rubber (with fabric, wire, plastic or filler) - but, again, no recipe for when and how to use reinforcement is shown.

D1.1

D1.2

NO

NO

Hopefully NOT YE

S!

WP7 – Products prototyping beta test and result assessment

SMART moulding machine will be used for moulding of selected rubber products

QUESTION and DISCUSSION:

Where can the SMART moulding machine be placed for testing and moulding?

•Available room•Suitable access door (width and height) and proper industrial floor•Location easily accessible to Labor and UTV for integration, testing and moulding•Easy and fast supply of raw material (different rubber granulates and buffing)

Practical requirements

•The machine is property of the SMEs and Associations•The machine is to be considered available at any time for any SME test and/or demonstration need

Conditions

AGREEMENT

Thank you !

Labor s.r.l.Via Giacomo Peroni 386C/O Tecnopolo Tiburtino

00131 Roma

Ilaria Iannaccone: i.iannaccone@labor-roma.it

Cristina Torrisi: c.torrisi@labor-roma.it

Andrea Salvo: a.salvo@labor-roma.it