Polymer Days 2010 Fredrikstad November 24 25 2010

Polymer Days 2010 Fredrikstad November 24 - 25, 2010 What trends and perspectives for the automation of the composite market ? • What are the advantages of the automation of processes in the composites industry ? •

MATRASUR Composites Making composites easier o A Company of Norican Group Shaping Industry Supplying the composites market since 1972 o + 400 machines configurations o + 5 500 installed units o + 1 100 customers worldwide o 2

Automation in the Composites industry: Facts & perspectives Facts: o Composite products suffer from excessive labor costs Perspectives: o Automation potentials remain high and under investigated 3

Robotics : A new tool for the industrialization of composites Some figures: o o Number of robots installed per year Robot population per 10, 000 workers in the manufacturing industry 35000 30000 (s 35 000 ou rc e “W or ld 25000 20000 15000 10000 18 000 bo tic s 2 00 12 000 6 500 • Japan • USA • Germany • Italy (s 495 ou rc e “W ld • Japan • Germany 227 • Italy ) • France or 288 7” 3 000 5000 0 500 450 400 350 300 250 200 150 100 50 0 ro ro bo tic s 2 00 146 135 • France • USA 4 7” )

Composites & Industrialization Potentials for automation today: o Potentials offered by the industrialization of composites are high as they still remain poorly investigated to this date o This potential represents with no doubt the best source of improvement for competitiveness o Automation contributes to a sustainable development approach 5

Industrialize, yes, but How? o By rethinking the production methodology o By modernizing it o By considering current and future environmental requirements towards a sustainable development 6

Main steps of the industrialization process o Exhaustive audit of methods, technical resources and skills o Analysis of production goals (quantity, quality, economical, ergonomics, ecological aspects…) o Review of all technical solutions o Technical and economical choices > financing o Comprehensive engineering study and implementation planning o Implementation 7

Process Engineering Key elements o Multi-competent engineering resources: mechanics, automatism, robotics o Software: 2 D and 3 D Cad software, robotic dedicated software, Visual Basic o Feasibility studies and development o Complete integration & turn-key approaches o Programming capacities Internal or External resources 8

Developing competencies: Training on material and processes Production start-up support and follow-up Training on Maintenance Training on Mechanics & Hydraulics Training on Automatism & Programming 9

Industrializing Composites through Robotics Robotic solutions now available for : o Handling systems o o Release agent spray-up o o Gelcoat spray-up (single or o o o multi color) Barrier-Coat spray-up Resin spray-up Chopped lamination Paint spray-up o o Roll-out Insert positioning Adhesive lay down PU foam spray-up Resin cast on press Trimming, machining, surface grinding Fiber placement All workshop sectors are concerned! 10

Industrializing Composites through Robotics Traditional Mode versus Robotic Mode 11

Robotics for composites industries Industry fields already using Robotic solutions for composites: o o o o o Automotive industry: Spray-up, trimming, adhesives… Aerospace industry: Fiber placement, part trimming and finishing. . . Industrial parts: Spray-up, trimming, . . Boat industry: Gelcoat, barrier-coat and release agent spray-up Sanitary ware: Handling systems, spray-up, part trimming, insert positioning… Rail Industry: Trimming of parts for High Speed Trains (TGV) Water treatment: Spray-up of reservoirs and filters Swimming pools and Spas: Spray-up of pool shells, trimming Energy: Wind blades coating 12

Case studies o Turn Key robotic system for a GRP Pool manufacturing Plant o Industrializing production in a Small Size Company 13

Industrial production line for GRP pools : Encountered problems: o Creation of a new production site o Unexperienced staff with respect to the product o Limited workshop surface o Desire to have a highly automated solution o Desire to have a total control over production costs 14

Industrial production of GRP pools Industrialized process: o Robotic spray-up of release agent o Robotic multicolor gelcoat spray-up o Robotic barrier-coat spray-up o Robotic chopped laminate spray-up o Production flow management on carousel BEFORE/AFTER o 40 h Labor/ Pool brought down to: 13 h/Pool (-70%) (-12%) o Yearly raw material cost savings : 320, 000 € o Significant increase in: Product, quality, working conditions… 15

Spray-up robot for release agent, gelcoat barrier-coat Resin&fiberglass spray-up robot Part demoulding Transfer Automatic conveyor Curing zone 16

Case study 2 o Industrialization & (Very) Small Size Companies 17

Small Size Companies on the path of industrialization Problems faced: o Large variety of parts o Small series o Limited personnel o Company oriented towards “hand made” work o No 3 D drawings available o Undefined company strategy o Short term vision 18

at ic m to Au nit ru pe op Ch g din ee ial M at er l ial M ix Ro g t bo is Ax din ee gf vin Ro an e Cr th r 8 ea Lin t us xh a at ion ific nt de rt I ed E nt ro ll co Pa Se ns or Br idg e M at er nt ro nit co t. U T° oa rg elc ls tro on e vic de olo icl PC C fe ty ing nn xis h. A 7 t n tio ra Fil t e ur Ro ta tin g iti o os tp Pa r sa M ult on isi oll pf m pu tic An g din oa t. L Pa r los nc Sa fe E Robotic becomes accessible: Low Cost Robot now available 19

Robotic becomes accessible: Programming now simplified Step 1 Programming Step 2 Producing 20

Small size companies on the path of industrialization: Technological evolution step by step Phase 1: Robot for acrylic reinforcement with system based on teach-through robot Phase 2: Robot for part trimming and drilling with offline programming system 21

How robotics brings Sustainable Development Benefits to composites shops

Robotics : transforming composite workshops 23

Reducing production surface for significant energy costs reductions o VOC’s exposure at lowest (no personnel in lamination areas) o No more dangerous nor painful work stations o No more dust nor chemical residues in the workshop 24

Concentrated VOCs are easier to treat Effluent treatment now affordable (less air volume for a higher VOC concentration) o Photo-catalytic treatment o Charcoal filtration o Incineration o Etc. . 25

Minimized extraction volumes in smokestacks o Extraction directly from VOC source for a minimized extracted volume o Air exhaust from VOC source for ventilation control through sensor o Better control of VOC effluents preserves workshop surrounding environment 26

Robotics : transforming composite workshops ECONOMICAL ASPECTS o o Productivity, cost effectiveness, Raw material Savings Production Management Increased quality Reduced production surface Energy Cost reduction Competiveness ENVIRONMENTAL ASPECTS o o o Working Conditions significantly improved Reduced Air exhaust Volumes & VOCs in Stacks Affordable VOCs treatment Lower Energy requirement Affordable Regulation compliance 27

Robotics applied to composites: An unexpected opportunity for combining quality, productivity and sustainable development while satisfying the highest standards requirements 28

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