High Volume Automotive Applications Addressed by the Braiding Technology
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1 High Volume Automotive Applications Addressed by the Braiding Technology JEC World Conference 2017 Dr. Andreas Erber Paris March, 2017 DC0 Öffentlich - (erberan)
2 Business Unit Composites Fibers and Materials Our solutions serve key markets Unique integrated value chain Markets Fibers Materials Engineered Solutions Broad portfolio of high-performance products - Acrylic Fibers - Stretch Broken Yarn - Oxidized Fibers - Chopped & Milled Fibers - Carbon Fibers Production technologies along the fiber value chain - Woven Fabrics - Preforms - Non crimp Fabrics (NCF) - Prepregs & TowPregs - Nonwovens - Tapes & Organo Sheets - Braidings - Wet Friction Materials Lightweight and Application Center (LAC) In-house bridge between SGL products and customer applications in the development of fiber reinforced composite components - Engineering solutions and manufacturing prototypes (e.g. CFRP Parts) Acrylic Fibers Automotive Aerospace & Defense Wind Industrial Page 2 JEC World Conference 2017 DC0 Öffentlich - (erberan)
3 Business Unit Composites Fibers and Materials Production network covers the whole value chain Ort Ried Gardena Arkadelphia Precursor and acrylic fibers Carbon fibers Materials Composites Page 3 JEC World Conference 2017 DC0 Öffentlich - (erberan)
4 Carbon fiber in automotive series production BMW i - Born Electric New electric vehicle concepts with pioneering design Overall concepts dedicated to battery electric mobility BMW i3/i8 Series Structural design aligned with composite requirements BMW i3. Large scale production of carbon fibers and composites BMW i8. Source: BMW Group Page 4 JEC World Conference 2017 DC0 Öffentlich - (erberan)
5 SGL Group s composites in the automotive industry Lightweight expertise for the BMW Group CFRP supply chain Carbon Fiber Textiles and Composite Precursor Production Recycling Components BMW i3/ i8 Production BMW i3/i8 Series - Japan - - USA - - Germany - - Germany - - Germany - 2 Moses Lake 1 Otake 5 Leipzig Mitsubishi Rayon-SGL Precursor SGL Group BMW Group 3 Wackersdorf 4 Landshut Source: BMW Group Page 5 JEC World Conference 2017 DC0 Öffentlich - (erberan)
6 SGL Group s textile material toolbox based on carbon and glass fibers Tailored Textiles UD textile Local reinforcement Nonwoven material Random orientation Based on secondary fibers and textiles Textiles Carbon and Glass fibers based Various semi-finished materials as a toolbox approach Bindered textiles for preforming Fabrics Various textile architectures Laminar reinforcement Preforms Comprising different textiles Local reinforced Page 6 JEC World Conference 2017 DC0 Öffentlich - (erberan)
7 Braiding technology Everyday Life Principle of hand braiding Braided bakery product Source: TU Munich Page 7 JEC World Conference 2017 DC0 Öffentlich - (erberan)
8 Braiding technology Machine principle - history 15 th March 1748 first reference of machine braiding 1780 first operational braiding machine 1898 significant advancement of the horn gear arrangement Braiding machine from Japan n.chr. Source: TU Munich Page 8 JEC World Conference 2017 DC0 Öffentlich - (erberan)
9 Transmission shafts by braiding technology Example: Commercial aircraft high lift system Biaxial fiber architecture Radial braiding machine (64 carrier) Source: University Stuttgart Triaxial fiber architecture High lift system of a commercial aircraft Source: Liebherr Aerospace Lindenberg GmbH Differential design: Braided transmission shaft with metallic flanges Source: University Stuttgart Page 9 JEC World Conference 2017 DC0 Öffentlich - (erberan)
10 Integral design of transmission shafts Composite flanges Integral versus differential design F Flanges offer a huge lightweight potential F Principle of flange manufacturing tool Braiding of flange; step #1 Braiding of flange; step #2 Source: PhD Thesis A. Erber Page 10 JEC World Conference 2017 DC0 Öffentlich - (erberan)
![Versagenslast Failure load [Nm] Gewicht Weight [g] Integral design of transmission](/docs-images/75/71948765/images/11-0.jpg "shafts Composite flanges Challenge bearing stress 500 400 300 Failure")
11 Versagenslast Failure load [Nm] Gewicht Weight [g] Integral design of transmission shafts Composite flanges Challenge bearing stress Failure Versagenslast load Weight Gewicht 3 x M Non-reinforced Unverstärkt Spiral Spiralverstärkung reinforcement Radial Radialverstärkung reinforcement 200 Non-reinforced flange; 3 x M6 Spiral reinforcement Radial reinforcement Source: PhD Thesis A. Erber Page 11 JEC World Conference 2017 DC0 Öffentlich - (erberan)
12 Industrialized braiding technology BMW 7 series side roof frame Significant weight-savings through lightweight chassis New BMW 7 Series Source: BMW Group Page 12 JEC World Conference 2017 DC0 Öffentlich - (erberan)
13 Industrialized braiding technology BMW 7 series side roof frame Industrialization of a hybrid component within a multi-material body in white design. Braided side roof frame as reinforcement of a steel sheet Overbraiding of a thermoplastic core RTM process (thermoset matrix) Source BMW Group Page 13 JEC World Conference 2017 DC0 Öffentlich - (erberan)
14 Serial production at SGL Kümpers Braiding of the side roof frame preforms Source: SGL Kümpers GmbH Page 14 JEC World Conference 2017 DC0 Öffentlich - (erberan)
15 Lightweight and Application Center (LAC) Understanding customer needs Concept development Design and simulation Prototyping and testing Application of SGL products in customer processes Characterization of SGL materials for design and process engineering of customer applications Design and simulation for composite parts Demonstration of automation and serial production capability Prototyping and low volume production according customer requirements Page 15 JEC World Conference 2017 DC0 Öffentlich - (erberan)
16 Lightweight and Application Center (LAC) Understanding customer needs Example: Braided transmission shaft Material and preform simulation Process simulation Design and optimization System simulation Material cards for customer simulation Material characterization with respect to processing Design of structural components, modules and tools Weight and cost engineering of components Design tools (CAD) Laminate design (FEA) Process simulation Digital manufacturing Source: PhD Thesis A. Erber Page 16 JEC World Conference 2017 DC0 Öffentlich - (erberan)
17 Lightweight and Application Center Understanding customer needs Thermoplastic pultrusion Filament winding Robot based winding Wet pressing Thermoforming Pick & Place Technologies Virtual reality: Robotic cell as an example Process Technology Page 17 JEC World Conference 2017 DC0 Öffentlich - (erberan)
18 Business Unit Composites Fibers and Materials We are taking lightweight design to the next level together with our automotive customers. Source: BMW Group Page 18 JEC World Conference 2017 DC0 Öffentlich - (erberan)
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