Door: Peter Verschut

Programmanager “Automated Composites”

Production Engineering Department

Light Weight onwikkelingen in de Transport Sector

22 november 2012

Inhoud

• STODT Toekomsttechniek

• Historie (Aerospace & Space) – Compression Moulding

• Composieten in de Transport sector – Kipper project

• Automatisering

• “High Tech Factory”

• Toekomst

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• STODT founded in 1984 in Almelo; as from 2009 settled in the former Stork foundry in Hengelo

• Headcount: 30 employees

• Flexible shell: 130 freelance trainers and self-employed consultants

• Customers: > 1000 small and medium-sized companies in the manufacturing industry

Company profile

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“STODT aims at keeping a strong manufacturing industry in The Netherlands”

STODT improves the primary processes by:

• Training

• Consulting

• Conducting innovation projects

Composites and related processes:

Production Engineering Department

Mission

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Historie (Aerospace & Space)

• Vanaf 1960 - nu – Thermoharde composieten, vooral prepregs i.c.m. autoclaaf of via

Resin Transfer Moulding met droge vezels

• Kennis & Kunde

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Historie (rond 1985-1990)

• Behoefte naar reductie

van kosten naast

verhoging van

eigenschappen.

• Stijgende arbeidskosten

in het Westen

• Revolutie noodzaak!

• Thermoplastische

composieten

• Geautomatiseerde

processen

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-

0,20

0,40

0,60

0,80

1,00

Aerospacebefore 1995

Aerospaceafter 1995until today

Transport(Glass)

Transport(Carbon)

Cost Structure High Tech Composite Products

Materials Labor

Compression Moulding (example)

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Projectomschrijving: • Nieuwe kipper moet bestand zijn tegen vervoer van asfalt met

temperatuur van ca. 180 graden • Kipper mag niet meer dan 50 % meer kosten dan stalen kipper

Composieten in de Transport Sector (Kipperproject)

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Kipperproject (Realisatie proces)

Materials - Fibers - matrix

- Environment

Engineering - Strength & stiffness

- Lay-up sequence

Production - Parts

- Assembly - Automation

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But even more important:

Engineering

Manufacturing Material

Suppliers

Kipperproject (Partners)

Advantages

Fast payback time Lighter than Steel

Heat resistant to asphalt Better isolation (temperature and

sound)

Suitable for sand, gravel, rubble etc.

Much more durable than aluminum

Long life

Fuel saving up to 8%

Environmentally better than aluminum

Also suitable for Agricultural goods

Kipperproject

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Advantages

Easy to clean

Smooth surfaces , low wear

Repairable

Noise reduction at loading/unloading

LCA (Life Cycle Analysis) is much better

CO2 reduction through less transports and fuel consumption

Tipper truck is eligible for EIA grant (Energy Investment Deduction)

Can be painted into all possible colors with advertising, striping, etc.

Dump truck does not rust

Green image

etc.

Kipperproject

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Kipperproject

Calculations have shown that:

• The composite VOLVO concept truck produces more than 100,000 euro extra in return over the lifecycle!! – (Roughly) every kilogram weight reduction will save € 50,-

• Moreover, fuel savings not included!

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‘Proof of Concept’

• Process: – Advanced Tape Placement and

Winding

• Material: – Nylon with E-glass fibre reinforcement

(Vf=50%)

Automatisering

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• Main processes: – Tape Winding & Tape Placement

– Machining (drilling, milling and grit

blasting)

– Assembling composite

components

• Welding

• Riveting

• Bonding

– Coating

• Ancillary Processes: – Material logistics

– Product logistics

– Cleaning products and moulds

– ERP planning and control

24/7 process

“High Tech Factory”

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Toekomst composiet transport branche

• Risicospreiding

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Bedankt voor uw aandacht

Voor meer info: Peter Verschut

Programmanager “Automated Composites” Production Engineering Department Gieterij 212 7553 VZ Hengelo +31 (0)6 36 17 33 95 p.verschut@stodt.nl

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