STAXX COMPACT 1700 - cfk-convention.com · STAXX COMPACT 1700 Low Scrap for high volume part production ... First IPAC First Turnkey & Ring Riveter First Wing Riveter M-Technologie,

STAXX COMPACT 1700

Low Scrap for high volume part production

1© Broetje-Automation GmbH

CFK Convention

Dr. Matthias Meyer

BA USA

History

Broetje-

Automation

Hydro-

Control

Relocation to

Wiefelstede


1974 - 1980

First FAL

First IPACFirst Turnkey

& Ring Riveter

First Wing

Riveter

M-Technologie,

France

BA RUSSIA &

BA CHINA

MBO with

DBAG

First FSW

System

BA Services,

BA Changhzou

& BA UK

First

MPAC

BA Composites

Compose 2

Compete

BA ATS

Relocation of

Broetje-

Automation

& BA Services

BA Japan K.K.

1990 - 2000

Start

external

activities in

tool making

2000 - 2010 2010 - 2016

BA Score &

BA Scale

STAXX

Compact 1700

Sealing

Broetje-Automation – Production Facilities


France, Toulouse

Germany, Rastede

Facts

Countries

7

Sales & Service

Locations

23

Total Sales

120 - 150 Mio €

TotalIEmployees

800

Germany, Grenzach-Wyhlen

Installed Volume – Geographical Distribution


Asia

Europe

Installation value more

than 3 Billion €uro

45%

30%

25%

America

Customized Solutions



Placement Systems / STAXX Automated Solutions

Preforming Systems

BA Composites

GmbH

Started in 2014

Located in Grenzach-Wyhlen, Germany

Based upon previous developments of

Broetje Automation and MAG IAS

Composites Germany

BA Composites

Products

STAXX Compact Fiber Placement machining

Center

Customized Fiber Placement and Tape

Laying machines

Composites Handling and Automation


High volume production: Cost Challenges

8

Material

Challenge

raw material costs

intrinsic scrap

waste in production

Chance

tow preg

netshape layup

use of prepreg

Production

Challenge

cycle time

reliability

handling

quality

Chance

automated layup

machineoperations

automation

processcontrol

Process Chains

9

Cutting/Stacking Shaping/StampingRTM

T E X T I L E T E C H N O L O G Y

Preforming Curing

Manufacture

Compression

Moulding

Direct Layup of Prepreg (automatic)

D I R E C T L A Y U P

Fabric

UD

Material

STAXX Compact 1700: addressing cost challenges

Direct layup of prepreg material

Netshape or near netshape layup

Preforms ready to mould and cure

No limitations in fibre orientation

Local reinforcements

Clear interface to automation and handling


STAXX Compact 1700: addressing cost challenges

16 lane Fiber Placement

¼’, ½’, 24K, 50K wide material

Thermoset and thermoplastic matrices

4-axis (x, y, z, c)

Siemens 840 D-SL Control

Rotary table with vertical lay up

Air conditioned enclosure

Double sided loading

Table size: max. diagonal 1850

Z-Travel: 500

Feed rate 45 m/min

Cut on the fly with 35 m/min

Usage of standard raw material

Pallet handling system

Length/Width/Height: 6500/3000/3000

Electrical Installation: 30 kW


STAXX Compact


http://youtu.be/-FqG0-sZKzc

http://youtu.be/-FqG0-sZKzc

Requirements for high productivity & profitability

13

PROCESS

Standards in process steps

Reduction of manual labor

Extensive automation

Simplified tools

Reduced forces for molding press

MATERIAL

Standard tow widths

Direct impregnation

UD Material

Cycle-time-optimized resins

Reduction of Shrinkage and Curing time for

Prepregs

Towpreg

Fiber Placement

Prepreg

Reduced production costs by standards

Risk management

increase the reliability by automation

obey risk when adding value

Raw materials

UD-Fibres

Automation

2D Handling

Manufacturing Technology


S T A N D A R D S

Reduce your risk when adding value!

STAXX Process from 2D Stack to 3D demo part

15

Moulding

Demo part(untrimmed)

Demo part

3D-Design

Stack

© Benteler SGL, Broetje-Automation GmbH

CAD CAM Software

CAM-Software for offline programming of AFP-

processes

Robust NC-encoding due to specific parametring of the

machine and material

Embedded function for scrap analyses, processing

time and process optimisation

Simulation of demoulding behaviour of the preform


CAM modification

TWL tailored wave layup improves the moulding

performance of a 2 D Stack

TWL enables 2D layup for complex shapes


Tow Preg moulding

2 D Layup near net shape, depending on the mould

Single tows can shear during moulding; the shear allows the part to

stretch during preform

Shown part could not be done in traditional prepreg due to fatal

wrinkles.


Fatal wrinkling

with traditional

prepregs

Pictures © Mitsubishi Rayon Carbon Fibre

Direct Towpreg Technology

19

Reduction of scrap (from up to 50 % for RTM to less than 5 %

for FP!)

Raw material: standard tow preg

Increased freedom of design

Significant reduction of tooling cost and processing risks

Improvement of process reliability and quality

Low operating costs due to high automation

Flexibility and work space

Shown part: automotive body part in direct towpreg technology

Tow Preg for Fiber Placement

Advantages

Ease of processing (low tack)

Fast curing cycles (100s)

Health and safety

Excellent mechanical performance

Types

50K, 24K

Epoxy, thermoset

Thermoplastic

Width: 5 to 15 mm

STAXX has highest cost efficiency

21

0,00 €

10,00 €

20,00 €

30,00 €

40,00 €

50,00 €

60,00 €

€10 €15 €20 €25 €30 €35

Pro

du

cti

on

co

sts

fo

r 1

kg

pa

rt

Raw material cost (50% fiber volume content)

Comparison: STAXX vs. RTM-Process

STAXX RTM

Cost savings today:

Equipment-34%

Material -31%

Cost saving potential:

Equipment -40%

Material -54%

Cost performance today

STAXX saves 15 €/kg part

Cost potential

Production szenario

Datum

Cleaning

Trimming

Moulding

Handling

STAXX Compact

1700

Stacking

Conclusion

Automation is not a bottleneck for high volume production

The supply for low cost CFRP production is available today

Cost breakdown has proofed the feasibility of the process

Freedom of design is improved

Mechanical performance is very high

Process chain is fully digital

Technology sets standards

23

Thank you

Special thanks to our partners from SGL, MRCF, SWMS

For further questions:

[email protected]

Or call +49 7624 3112


mailto:[email protected]

Documents

STAXX COMPACT 1700 - cfk-convention.com · STAXX COMPACT 1700 Low Scrap for high volume part production ... First IPAC First Turnkey & Ring Riveter First Wing Riveter M-Technologie,