11. composite cylinder type4 (sigfried eckert).pdf

Open House 2012

The challenge to make a composite

cylinder Type 4

Siegfried Eckert

Cost calculation

The design process

Production process

Agenda

www.kautex-group.comPage 2

Cost calculation

Vision

Bonn, 22.03.2012

Composite cylinder Type 4 applications

www.kautex-group.com

Bonn, 22.03.2012

� Light weight (over 50% weight saving)

� Translucent wall

� Easy to handle and stackable

� The valve is very well protected against impact

� Easy to clean.

Main advantages of LPG composite cylinder type 4


� Easy to clean.

� Very good behavior in fire

� The material is UV resistant to effects from sun, rain, temperature variations

and handling

� Increased vehicles range and optimum safty

� Light weight - up to 75% weight saving over comparable steel cylinder

� Very good behavior in fire

� Very good behavior in impact accident

� Crash tested by leading OEM

Main advantages CNG composite cylinder type 4


� Crash tested by leading OEM

� Corrosion free inside and outside

Parts of a composite cylinder Type 4

Liner Boss part Composite


Polyethylene,

Polyamide

Steel, Aluminium

different kind of plastics

Epoxy or VE Resin

Glass fiber, div.type

Carbon fiber

Bonn, 22.03.2012

Design – An issue of patents

� Over 19 patents for the liner -

boss interface exist in the market.

� For entering the market as a new

player.

� Special solutions are necessary!


Bonn, 22.03.2012

� EN 12245 Transportable gas

cylinder- Fully wrapped composite

cylinders

� EN 14427 Transportable refillable

composite cylinder for LPG

� And others

Regulatory requirements for LPG


� And others

Bonn, 22.03.2012

� EN R110 Regulation for Motor Vehicles

using compressed natural gas (CNG) in

their propulation system

� EN ISO 11439 High pressure cylinder

for on board storage of natural gas as

fuel for automotive vehicles

Regulatory requirements for CNG


� And others

Bonn, 22.03.2012

Regulatory requirements for composite cylinders

� ISO 11119-3 Gas cylinder of composite

construction. Fully wrapped fiber

reinforced composite cylinder with

non-metallic liners

� And others


Bonn, 22.03.2012

Movie Water-boiler


Certification and test regulary

A variety of tests are required depending

on the vessel application and the specific

standards for which the vessel is

designed.

Most important tests are:

� Burst test


� Temperature test

� Impact or drop test

� Bonfire test

Bonn, 22.03.2012

Certificate for production start

customer


Bonn, 22.03.2012

Cost calculation

The design process

Production process

Agenda


Cost calculation

Vision

Bonn, 22.03.2012

Fully automatic production line


Bonn, 22.03.2012

Plastic liner - the heart of the composite cylinder


Bonn, 22.03.2012

blow molded without flash filament winded LPG cylinder

Liner - the heart of composite cylinder (1/2)


Bonn, 22.03.2012

PWDS - Partial Wall Thickness Distribution System


Bonn, 22.03.2012

Liner - the heart of composite cylinder ( 2/2)

PWDS


Bonn, 22.03.2012

Filament winding process

� Automatic loading by robot

� Low non - productive time by

automatic cut and park fiber

� Controlled windig process

� Optimized fiber impregnation


� Curing process according to the

resin parameter

Bonn, 22.03.2012

Filament winding process


Bonn, 22.03.2012

Experience in testing (1/2)

Test regulary for hydrostatic test

� 1,5 x working pressure

� Test time 30 sec

� For LPG application 30 bar

� For CNG application 350 bar


� For CNG application 350 bar

Bonn, 22.03.2012

Experience in testing (2/2)

Test regulary for burst test

� LPG Cylinder 67,5 bar

� CNG Cylinder 560 -780 bar

depending on the fiber material


Bonn, 22.03.2012

Cost calculation

The design process

Production process

Agenda


Cost calculation

Vision

Bonn, 22.03.2012

How much does the product cost?

� We calculate the price!


Bonn, 22.03.2012

� Applications

� Quantity

� Design shape (length, width)

� Material for liner

� Material for boss part

Customer´s briefing


� Material for boss part

� Material for composite

Bonn, 22.03.2012

Cost breakdown

Country specified cost for energie, building and …


Bonn, 22.03.2012

Preliminary calculations of the liner and composite

� Liner materials

� Fiber materials

� Resin materials

� Boss part solutions

� Filament winding technologies


� Filament winding technologies

We took an average of the calculation

of different material!

Bonn, 22.03.2012

Overview bill of material

� Calculation for a CNG cylinder

� Working pressure: 200 bar

� Volume: 38 liter

� Max. 100.000 part/year

� Fiber: modified glass


� Fiber: modified glass

� Production in Russia

� Total cost per cylinder: € 104.-

Bonn, 22.03.2012

Cost calculation

The design process

Production process

Agenda


Cost calculation

Vision

Bonn, 22.03.2012

� Light weight (weight saving)

� More gas on board

� Very good behaviour in fire

� Very good behavior in impact

accident

Advantages of LPG / CNG composite cylinder


� Corrosion free (inside and outside)

Bonn, 22.03.2012

We like to realize your vision for composite cylinder applications


Bonn, 22.03.2012

Thank you very much for your attention.Thank you very much for your attention!Any questions?


Bonn, 22.03.2012

11. composite cylinder type4 (sigfried eckert).pdf

Documents

heart of composite cylinder

composite cylinderwww

transportable gas cylinder

composite cylinders

composite cylinders

high pressure cylinder

comparable steel cylinder

liner boss