Presentation of Presentation of Axson Axson Shanghai activities - - PowerPoint PPT Presentation

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Matwind/ 2011 - Axson/ BUE JNGentili

Presentation of Presentation of Axson Axson Shanghai activities Shanghai activities

MATWI ND 2011 MEETI NG - AGENDA

INTRODUCTION to AXSON

CONSTRUCTION of LARGE MASTER MODEL (PLUGS) FOR WINDBLADES

General concept / Main Spécification. ( Chassis / backup /surface coating / preparation ) Surface coating alternative techniques : hand or machine application

• Manual paste / Machininable boards/ Extrudable Paste
• Equipment overview : CNC / extrusion
• Equipment overview : CNC / extrusion.

Trouble shooting / Repairing / Preparing /finishing…. Question / answer

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Matwind/ 2011 - Axson/ BUE JNGentili

MATWI ND 2011 MEETI NG - AGENDA

PART 2 : LARGE DIMENSION MOULD MAKING General concept ion / Main Spécification / Expected Productivity / Limitations. Alternatives materials : Liquid epoxies/ Prepregs/others Alternatives materials : Liquid epoxies/ Prepregs/others. Alternatives techniques : Wet Lay up / Infusion. Fabrics / Core fillers / Vacuum accessories Preparation / repairing QUESTION / ANSWER + CONCLUSION QUESTION / ANSWER + CONCLUSION.

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Matwind/ 2011 - Axson/ BUE JNGentili

I NTRODUCTI ON to AXSON

Head quarter : Cergy France 6 production site 12 subsidiaries. 32 distributors. 350 employees 60 M€ T° 4

Matwind/ 2011 - Axson/ BUE JNGentili

I NTRODUCTI ON to AXSON

Expertise = Formulation and production of thermosetting epoxy and polyurethane resins for thermosetting epoxy and polyurethane resins for multi-industrial applications

4 DIVISIONS DESIGN / PROTOTYPING / MODELING / TOOLING DESIGN / PROTOTYPING / MODELING / TOOLING DIELECTRICS ADHESIVES COMPOSITES

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Matwind/ 2011 - Axson/ BUE JNGentili

I NTRODUCTI ON to AXSON DESIGN / MODELING / PROTOTYPING / TOOLING DESIGN / MODELING / PROTOTYPING / TOOLING

Automotive design Automotive design Ceramic wares Tooling FRP molds Glass and cristal wares Toys

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Matwind/ 2011 - Axson/ BUE JNGentili

Metal sheet Stamping molds

I NTRODUCTI ON to AXSON DIELECTRICS

Automotive Sensors : for engine management systems, automotive technology, safety systems or

DIELECTRICS

Railway transformer encapsulation gy, y y product enhancements

Coils

Airbag sensor encapsulation

Coils encapsulation for transportation

Encapsulation of capacitors

Electronic lighting sensors

p p

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Matwind/ 2011 - Axson/ BUE JNGentili

Electrical and electronic resins

I NTRODUCTI ON to AXSON STRUCTURAL ADHESIVES

Adhesives for body parts and windows for transportation vehicles and for limited series

STRUCTURAL ADHESIVES

and for limited series Structural Adhesives for chassis of vehicles Structural Adhesives for chassis of vehicles

structural bonding

• f lift doors

Solar panel bonding Railways interior parts bonding Load-bearing mastic for insulation of LNG vessels

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Matwind/ 2011 - Axson/ BUE JNGentili

I NTRODUCTI ON to AXSON COMPOSITES COMPOSITES

MARINE

Aerospace Sports and leisure

MARINE

AXSON OFFERS A 360 ◦ SOLUTION : DESIGN TOOLING PARTS ASSEMBLY

LIGHTNESS STRENGTH DURATION

Automobile

WIND ENERGY

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Matwind/ 2011 - Axson/ BUE JNGentili

ASSEMBLY

I NTRODUCTI ON to AXSON WINDMILL SOLUTIONS WINDMILL SOLUTIONS

CAD design

AXSON = A to Z solution provider to wind blade makers

MODEL MOULD

BONDING

PARTS

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Matwind/ 2011 - Axson/ BUE JNGentili

CONSTRUCTION of LARGE MASTER MODEL (PLUGS) FOR WINDBLADES CONSTRUCTION STEPS > >>>>>>>>>>>>>>>>>> 11

Matwind/ 2011 - Axson/ BUE JNGentili

CONSTRUCTION of LARGE MASTER MODEL GENERAL CONCEPT / DEFINITIONS

MODEL

GENERAL CONCEPT / DEFINITIONS

CROSS SECTION

COATING optionnal CONTACT SURFACE Monobloc with backup BACKUP STRUCTURE CONTACT SURFACE - Monobloc with backup

• r added to backup ( slab /paste/…)

CHASSIS

A cohesive construction !!

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Matwind/ 2011 - Axson/ BUE JNGentili

CONSTRUCTION of LARGE MASTER MODEL CHASSIS > CONSTRUCTION ALTERNATIVE

MODEL

CHASSIS > CONSTRUCTION ALTERNATIVE MDF sections Sandwich pannels assembly assembly Metallic welded.

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Matwind/ 2011 - Axson/ BUE JNGentili

CONSTRUCTION of LARGE MASTER MODEL BACKUP CORE > MATERIAL ALTERNATIVES

MODEL

BACKUP CORE > MATERIAL ALTERNATIVES PU /EPO Machinable Boards Medium sdensity PU /EPO Machinable Boards Medium sdensity MONOBLOC

++ Dimensionnal stability ++ surface aspect Cost

• Cost
• - Time

PU FOAM + COMPOSITES LAMINATING.

++ Cost efficient ++ dimensionnal stability given by composites Foaming equipment

• - Foaming equipment
• - Time

OTHERS: non detailed Wood /PS / Composites sandwichs...

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Matwind/ 2011 - Axson/ BUE JNGentili

CONSTRUCTION of LARGE MASTER MODEL BACKUP CORE alternatives

MODEL

BACKUP CORE alternatives....

• 1 ) Metallic Chassis
• 2 ) OSB Wood Sheets (Screwed/Bonded)
• 3) Sealing layer : Epoxy resin EPOLAM

2015 on quadriaxial .

• 4) BALSA Wood + Infusion Epoxy
• 1 ) Metallic Chassis
• 2 ) horizontal grids
• 3) Pu foamed + machined
• 4) composites coupling layer : 6 plies UD

300gr/M2 + EPOLAM 2020 epoxy hand lay g p y y up

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Matwind/ 2011 - Axson/ BUE JNGentili

MODEL

MASTER MODEL or PLUG CONSTRUCTION BACKUP CORE CONCLUSION

MODEL

BACKUP CORE CONCLUSION

Several options and combinations possible : Metallic frame PU foam or PS foam base Epoxy/glass hand laminate Sandwich MDF core with epoxy/glass laminate skins Sandwich MDF core with epoxy/glass laminate skins Quality is determined by :

• 1. Dimensional accuracy and stability
• 2. Ability to support static weight

3 Surface adhesion and compatibility with

• 3. Surface adhesion and compatibility with

surfacing material 16

Matwind/ 2011 - Axson/ BUE JNGentili

CONSTRUCTION of LARGE MASTER MODEL CONTACT SURFACE ALTERNATIVE

MODEL

1 Manual application Polyester Putty surfacing material?

CONTACT SURFACE ALTERNATIVE

Advantages Low material cost Disadvantages Too fast curing limiting area and thickness Easily available in the market with many suppliers g g applied at once High exothermy and shrinkage Many manual repairs Several layers to reach total thickness N di i l t bilit No dimensional accuracy nor stability High density E il d d f ki ld Easily damaged surface upon making mold High toxicology

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Matwind/ 2011 - Axson/ BUE JNGentili

CONSTRUCTION of LARGE MASTER MODEL CONTACT SURFACE ALTERNATIVE

MODEL

CONTACT SURFACE ALTERNATIVE

2 Manual application EPOXY Putty surfacing material?

Advantages Applicable in a single layer Disadvantages Tedious work to apply on large f Dimensional accuracy and stability Low density surface Some repairs and showing lines due to overlaps Well proven products in other industrial design applications including chinese automotive market p

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Matwind/ 2011 - Axson/ BUE JNGentili

MODEL

CONSTRUCTION of LARGE MASTER MODEL Surface coating alternatives EXTRUDABLE PASTE

MODEL

Surface coating - alternatives EXTRUDABLE PASTE

3 Machine application SEAMLESS EPOXY PASTE (extrudable)

Advantages Applicable in a single layer Disadvantages Requires investment in a g y Dimensional accuracy and stability Low density specific metering machine Seamless surface with even and smooth aspect M hi bl ithi 24h Machinable within 24hrs Well proven products in other industrial design applications including g pp g lowest toxicology in handling

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Matwind/ 2011 - Axson/ BUE JNGentili

MODEL

CONSTRUCTION of LARGE MASTER MODEL EXTRUDABLE PASTE GENERAL PRINCIPLES

MODEL

EXTRUDABLE PASTE GENERAL PRINCIPLES

See pics

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Matwind/ 2011 - Axson/ BUE JNGentili

MODEL

CONSTRUCTION of LARGE MASTER MODEL EXTRUDABLE PASTE WINDMILL PICS

MODEL

EXTRUDABLE PASTE WINDMILL PICS

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Matwind/ 2011 - Axson/ BUE JNGentili

MODEL

CONSTRUCTION of LARGE MASTER MODEL AXSON Paste offer SC 175 modelling paste SC 390 tooling paste

• MODEL

AXSON Paste offer

Low density type Plug making standard

High density type aluminium filled High surface hardness . High surface quality to minimize

Easy set up and process

surface treatment Tg of 90° after post curing Elevated dimensionnal stability

SC 380 tooling paste

Intermediate density Good mechanical features Cost efficient

Run on TDS Run on TDS

Cost efficient. Easy and effective to apply.

Run on TDS R TDS 22

Matwind/ 2011 - Axson/ BUE JNGentili

Run on TDS

MODEL

CONSTRUCTION of LARGE MASTER MODEL EXTRUDABLE PASTE ISSUES

MODEL

EXTRUDABLE PASTE ISSUES

LOOKS SIMPLE !!!!! LOOKS SIMPLE !!!!!

• NO. !

COHERENCE OF WHOLE PLUG SYSTEM ( Chassis + Backup structure) ENVIRONMENTAL ISSUES ( Space, ventilation, Temp regulation etc..) EQUIPMENT OPERATIONNAL EQUIPMENT OPERATIONNAL LOGISTICS ( several sections + shipment) Paste. Applicator skills Thickness control. Repairing Repairing Post treatment Finishing 23

Matwind/ 2011 - Axson/ BUE JNGentili

……

CONSTRUCTION of LARGE MASTER MODEL EXTRUDABLE PASTE SOME APPLICATION ISSUES EXTRUDABLE PASTE - SOME APPLICATION ISSUES....

APPLIED TO LARGE AREAS > 10 M2…..

1° Thickness Control = Machine + operator skills + type of nozzles

The application itself : nozzle verticale The application itself : nozzle verticale Overlapping seams

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Matwind/ 2011 - Axson/ BUE JNGentili

CONSTRUCTION of LARGE MASTER MODEL EXTRUDABLE PASTE SOME APPLICATION ISSUES EXTRUDABLE PASTE - SOME APPLICATION ISSUES....

APPLIED TO LARGE AREAS > 10 M2…..

2° Exhotermy / Material Dilatation - Shrinkage prévention

The application itself : dilatation lines

+/- 20mm

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Matwind/ 2011 - Axson/ BUE JNGentili

CONSTRUCTION of LARGE MASTER MODEL EXTRUDABLE PASTE SOME APPLICATION ISSUES EXTRUDABLE PASTE - SOME APPLICATION ISSUES....

APPLIED TO LARGE AREAS > 10 M2…..

3° Post curing….for higher stability + Temperature resistance (depending on li ti ) application) Heating Blankets or Heating tunnel ( bagging ) Heating Blankets or Heating tunnel ( bagging )

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Matwind/ 2011 - Axson/ BUE JNGentili

CONSTRUCTION of LARGE MASTER MODEL EXTRUDABLE PASTE TROUBLE SHOOTING EXTRUDABLE PASTE - TROUBLE SHOOTING....

Each scanned trouble claim for Each scanned trouble claim for well known solution (Experience). Extruding on large dimension 1 4 is complex ! 2 5 2 3 6 27

Matwind/ 2011 - Axson/ BUE JNGentili

CONSTRUCTION of LARGE MASTER MODEL REPAIRING /COMPLETING / PREPARING REPAIRING /COMPLETING / PREPARING 1. Repairing cracks holes voids cavities……Material on itself !!! 2. Repairing small surface defects : porosities >>>>Polyester putty 3. Sanding when needed. 4. Wax + semi permanent or permanent solution application. p p pp

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Matwind/ 2011 - Axson/ BUE JNGentili

CONSTRUCTION of LARGE MASTER MODEL FINISHING > PREPARING FOR MOULDING Note FINISHING > PREPARING FOR MOULDING Note The ultimate finishing of the master model is possibly done by spraying / ulltra thin layer of different type of materials like : ulltra thin layer of different type of materials like : Vinylester spray filler or Gelcoat, P l l t l t Polyvalent lacquer system. Polyurethane Paint system High Gloss. Epoxy coat sprayable…… After paste surface deep cleaning + eventual sanding, for, Making sure of Air Tightness Surface absolute regularity Glossy and Shiny for better release and mould quality Glossy and Shiny for better release and mould quality

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Matwind/ 2011 - Axson/ BUE JNGentili

MODEL

CONSTRUCTION of LARGE MASTER MODEL EXTRUDABLE PASTE MACHINES

2-components epoxy thixotropic system Pumping Metering dispensing

MODEL

EXTRUDABLE PASTE - MACHINES

Following plates using gear pumps Static mixing nozzle for easy maintainance Some interesting options… So e te est g opt o s

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Matwind/ 2011 - Axson/ BUE JNGentili

CONSTRUCTION of LARGE MASTER MODEL CNC 5 Axis Center

MODEL

CNC 5 Axis Center

MODEL

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Matwind/ 2011 - Axson/ BUE JNGentili

MOULD

CONSTRUCTION of LARGE MASTER MODEL READY FOR MOULDING !!!

MOULD

READY FOR MOULDING !!!

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Matwind/ 2011 - Axson/ BUE JNGentili

New release Axson brochure for wind blade manufacturing

MOULD

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Matwind/ 2011 - Axson/ BUE JNGentili

WINDMILL PLUGS and MOULDS CONCLUSION

OPEN DISCUSSION - QUESTION THANK YOU ALL 34

Matwind/ 2011 - Axson/ BUE JNGentili