resources of hd composite zrt....2020/10/01 · manipulators 2 x 6 axis fanuc m-710ic/45m robot...
TRANSCRIPT
Resources
of
HD Composite Zrt.
Reinforced with Innovation
HD Composite is a 100% Hungarian-owned company, based in Budapest, specialized in designing and
manufacturing of fiber-reinforced composites as well as providing related services. We are working not
only with already well-established processes, like compression molding, RTM, or hand lamination, but in
the frame of our research and development programs we are dealing with new, forward-thinking complex
technologies like combined T-RTM, which may determine the future of the industry.
We are focusing primarily on automotive, energy and defense sectors. Our portfolio covers engineering
services, like mechanical calculations, product- and mold- design, as well as development of automated
polymer composite manufacturing lines.
Our experienced team is committed for continuous improvement and working hard on the above-mentioned
tasks to leave a mark on the industry. HD Composite is going to implement new QM and ERP systems and
invest more than 4000k EUR in equipment and facility extension in 2020, by creating a new factory in
Várpalota, Hungary.
HD Composite
Our current development and
production facility is located in
Budapest and consists of:
• 526 sqm production area with 4 x
3,5 t overhead cranes,
• 450 sqm climatized development
area
• 180 sqm lamination workshop and
• 180 sqm grinding workshop.
All buildings are equipped in
accordance with local environmental
regulations.
The chemical warehouse is an
external tempered ATEX building.
HDC facility in Budapest
Polyester resin mixing and dosing system
(in operation in HDC from January 2021)
System parameters
500 Liter resin tank with autom. refilling system, agitator and heater
20 Liter catalyst tank
Servo controlled Catalyst/Hardener Ratio system
Remote Pendant Operator Screen
On-board Vacuum System
In-line PID Resin Heater
Catalyst/Hardener and Resin Flow Measurement System
Vacuum level Monitoring with Pre-Injection Vacuum Test
Data Recording (USB/UTP)
Static mixing head with automated cleaning system
High-flow Head option
Epoxy resin mixing and dosing system
System parameters
200 Liter resin tank with automated refilling system, agitator and
heater
Additive (ATH) dispenser
Degasing
2 x 60 liter hardener tanks
Servo controlled Resin/Hardener Ratio system, 100:10 – 100:100
Remote Pendant Operator Screen
On-board Vacuum System
In-line PID Resin Heater
Hardener and Resin Flow Measurement System
Vacuum level Monitoring with Pre-Injection Vacuum Test
Data Recording (USB/UTP)
Static mixing head with automated cleaning system
High-flow Head option
(in operation in HDC from January 2021)
Vacuum pumps, mold tempering units
System parameters
Nominal pumping volume 63 m³/h
Ultimate pressure 0,1 hPa (mbar)
Vacuum tank 120 l
BUSCH R5 RA 0063 F
(in operation in HDC)
WittmannTEMPRO plus 250
System parameters
Heating capacity max. 12 kW
Pump capacity (50 Hz)1 kW, max. 7 bar,
max. 45 l/min
Maximum temperature 250 °C
Gelcoater
System parameters
Continuous adjustable catalyst ratio
Recirculation of gelcoat and catalyst
Static mixer in the gun
Reduced solvent consumption
Flushing with a mix of solvent and air
Reduced material wastage
Even flow of catalysed material
Light weight spray gun
Pumps can be added as needed
Capacity: Up to 6 litres / min, depending on viscosity,
hose length/ diameter and nozzle orifice
Max. working pressure: 144 Bar (2169 psi)
MIPG-24/HV Multicolour Gelcoater(in operation in HDC)
System parameters
Width/depth/height (mould carrier 0° position
open)
2,340 / 3,270
/ 4,280 mm
Mould clamping platen bottom (FAPU)
Platen length 1,300 mm
Platen depth 1,300 mm
Compression injection stroke 0 - 3 mm
Compression speed 0.5 - 3 mm/s
Upper mould clamping frame (FAPO)
Platen length max. 1,300 mm
Platen depth min. 700 mm
Platen depth max. 1,300 mm
Parallel stroke (hydraulic) 250 mm
Clamping force 3,800 KN
Weight of mould total max. 7,000 kg
Weight of upper mould half total max. 3,000 kg
HP RTM Mould Carrier
(in operation in HDC)
Power tools and equipment for mold manufacturing
Optimum S 181 G
industrial cutting
machine
Weld-Impex
Weldi-MIG 300
welding machine
Scheppach
BASA3 Band saw
JET Dust
collector
(in operation in HDC)
and many more…
System parameters
Cut Length (mm)- Machine 3100
Length (mm)- Pick-off Table 3100
Cut Width (mm) 3200
Performance (Watts) 2500
Cutting tools
• drag knife,
• rotating disc,
• oscillating knife,
• power milling
Identification of cut parts Ink jet printing
Blackman & White VERSA TECH 2 ™
Digital Flatbed Cutter
Automated Cutting Machine
(in operation in HDC)
Axes strokes(mm)
Quick
positioning
speed
Quick
acceleration
Bi-directional
accuracy (P)
Unidirectional
repeatability
(Ps)
X = 15.500 85 m/min 2,0 m/ s2 0,112 mm 0,040 mm
Y = 4.000 85 m/min 2,0 m/ s2 0,050 mm 0,025 mm
Z = 2.500 45 m/min 3,0 m/ s2 0,045 mm 0,021 mm
C = +/- 300° 9000°/min 500°/s2 26 arcsec 16 arcsec
A = +/- 110° 9000°/min 500°/s2 26 arcsec 16 arcsec
Main Characteristics
Electrospindle power (S1) 20 kW from 10.600 rpm/min.
Maximum revolution speed 24.000 rpm
Connection shaft HSK 63 A
Torque (S1) 63 Nm
Carbon fiber dust protection Yes
CMS CONCEPT 40/155/25 PX5
High Speed 5 axes CNC Machining Centre
(in operation in HDC from Nov. 2020)
Creaform MetraSCAN 3D
portable optical CMM 3D scanner
System parameters
Accuracy Up to 0.040 mm (0.0016 in.)
Volumetric Accuracy0.060 mm + 0.025 mm/m
(0.0024 in + 0.0003 in/ft)
Resolution 0.050 mm (0.0020 in.)
Measurement Rate 205,000 measurements/s
Part Size
Range (recommended)0.2–6 m (0.7–20 ft.)
Scanning Area 225 x 250 mm (8.8 x 9.8 in.)
Light Source 3 laser crosses
Certifications
EC Compliance (Electromagnetic
Compatibility Directive, Low
Voltage Directive, RoHS 2
Substance Restrictions
Directive), IP50, WEEE
3D scanning system
(in operation in HDC from January 2021)
Curing and drying oven
System parameters
Length (mm) 5500
Height (mm) 2200
Width (mm) 2200
Max temperature (°C) 160
Accuracy ± 2°C
Heating speed 3°C/min.
Control unique treatment steps
Vaccum and press. air manifolds 12 pcs.
Forced cooling by venting
(in operation in HDC from January 2021)
T-RTM mixing and metering machine
System parameters
Dosing by gear pumps
Raw material tank 2 x 25 l; 0-10 bar
Capacity level measurement min. 1%
Temperature control max. 150 °C (200 °C)
Vacuum pump min. 3 mbar
Mixing head, mix ratio 5-95%
Injection flow rate 2 x 6,25-135 g/s
Insulated meter pipe; heating jacket max. 3 bar; max. 150 °C
High pressure metering pump max. 200 bar
(in operation in HDC)
KraussMaffei Rim Star Nano 8/8
T-RTM mixing and metering machine
System parameters
Dosing By piston pumps
Raw material tank 2 x 25 l; 0-10 bar
Capacity level measurement min. 1%
Temperature control max. 150 °C (200 °C)
Vacuum pump min. 3 mbar
Mixing head, mix ratio 5-95%
Injection flow rate 2 x 0,65-62,5 g/s
Insulated meter pipe; heating jacket max. 3 bar; max. 150 °C
High pressure metering pump max. 200 bar
(in operation in HDC)
KraussMaffei Comet 0,2 - 4 Nano
Automated RTM preforming system
System parameters
Preform 3D geometry max. 1250 x 1250 x 250 mm
Preform thickness max. 15 mm
No. of preforming tools 2 (180° turntable)
Upper tool size; mass max. 1300 x 1300 x 800 mm; 300 kg
Lower tool size; mass max. 1300 x 1300 x 700 mm; 300 kg
Tool complexity 16 different cylinders
Preforming temperature max. 150 °C
Manipulators 2 x 6 axis Fanuc m-710ic/45m robot
Reach of manipulators 2606 mm
Load capacity of
manipulators45 kg
(in operation in HDC)
Fanuc, Siemens, HDC
• Computer-aided design
• 3D scanning
• Prototyping
• Mold- and tool design
• Unique machine parts
• Special purpose machines and equipment
• Automated process line development
• Complex composite parts
Software systems, engineering capabilities
• Computer-aided engineering
• Engineering calculations
• Finite element simulation
• Structural composite parts analysis
• Composite optimization
• Bonded joints simulation
• Specimen tests
• Validation
ERP
Management Systems, Certificates
Certified Systems
ISO 45001:2018
ISO 14001:2018
ISO 9001:2018
Our recent expansion is in Várpalota, Hungary.
The phase 1 construction starts in spring 2020 and
will take app. 12 months on our 123 000 sqm
industrial land.
New composite R&D and production center
Phase 1. facility consists of:
• 2500 sqm production area
with 2 x 10 t overhead
cranes,
• 220 sqm storage
• 450 sqm office
• 90 sqm gel coating cabinet
• 90 sqm post processing /
grinding workshop.
• etc…