Team Air LiquideSenior Design Project 2007

Process Improvement of Resin Application System

Phase IV Group Presentation

Pete John

Adam Willoughby-Knox

Kevin Malik

Laura Shultz

Who is Air Liquide MEDAL?

Products–Hollow fiber membranes for N2 generation, CO2 removal, and H2 purification

Applications–Oil & Gas, Laboratories, & Aerospace Industries

Our Project:

Create an automated process to coat fibers with epoxy for filter end caps

Epoxy end caps

Process Improvement of Resin Application System

Motivation

• 60 bundles lost last year– Average $25,000 per bundle– $1,500,000 loss

• Adverse Product Performance– Defects & Poor Recovery Rate

• Labor Allocation Issues– Second technician needed

Current Process

technician paints ends with the special epoxy and a plain paintbrush.

Problem Definition:

How to automate resin application?

How to create a good epoxy infiltration?

Current Process Issues:•Gas leaks•Resin wicks down the length of the fibers•Effects the efficiency of purification.•Number of Machine Operators•Resin Waste/Mess•Resin very viscous hard to work with•Variability results in loss of bundles.

Problem Definition

• What characteristics define good resin application?

• What system constraints exist?– Resin material properties

– Resin dispenser

– Loom feed rate & layup process

– Multiple products must be produced on the same machine

– Factory setup

– Wicking effects & porosity

1. Prevent gas leaks

2. Consistency in quality

3. Reduce amount Machine Operators

4. Reduction of Resin Waste

1. Minimal voids in resin

2. 4 in band width

3. 1 operator

4. Directly supply resin onto loom

Initial Metrics & Target Values

Initial Design Path

Resin Applicator

Resin Application

Band

Fiber Filter SpoolResin

Infiltrator

2 Components

Resin Application System

Liquid Control Systems

•Continuous feed pump

•Specified nozzle for initial dispense width

•Control system accommodating different sized bundles

Infiltration System

Initial Flow Front

Conveyer MotionInfiltrated Fibers

Design Parameters

• Flow Rate

• Initial Dispense Width

• Roller Material

• Roller Pressure on Loom

Flow RateCup # Weight before use Weight after use Resin amount used

1 802.6 49.7 752.92 794.8 46.6 748.23 793.7 656.4 137.3

Total Resin used 1638.4

Cup # Weight before use Weight after use Resin amount used1 792.3 47.1 745.22 798.9 193 605.93 - - -

Total Resin used 1351.1

Left Side

Right Side

l

mVm

Recorded Mass

(m)

V = feed rate of loom

l = length of total bundle sheet

Recorded Mass

(m)

Roller Material Defined

Roller Material Tested

Roller Material Selection

Parameters Defined

• Flow Rate

• Initial Dispense Width– Same bandwidth (4 inches)

• Roller Material– Epoxy Glide Roller by Wooster (R232-4)

• Roller Pressure on Loom– Adjusted before motion initiated

s

gm 03.217

Updated Performance Requirements

Updated Target Values1 No significant voids2 One technician to oversee3 No break of roller contact4 200-230 g/min flow rate5 Resin at 40 degrees C

Prototype Description

Loom Machine

Fibers

Prototype Description

Store-Bought Store-Bought Roller FramesRoller Frames

Adjustable Primary Arm

RotatableRotatableSecondary ArmSecondary Arm

Pivot Point

Prototype Description

Resin GunResin Gun

Adjustable Primary Arm

RotatableRotatableSecondary ArmSecondary Arm

Store-Bought Store-Bought Roller FramesRoller Frames

Prototype Testing

Adjustable Primary Arm

RotatableRotatableSecondary ArmSecondary Arm

Resin GunResin GunResin Resin GunGun

Post Treatment Processes

• Resin cure

• Ends machined

• Clean cut to open fiber ends

• Chemical Post-Treatment

Testing Analysis

Evaluation Techniques

•Wicking•Hardness•Optical Photographs•Leak Test

Wicking

Prototype

Operator-Painted

Variable Wicking

Operator-Painted

Even Wicking

Prototype

Prototype Operator

70.75 70.05

70.50 70.00

66 58

76 78

6.51 25.00

2.55 5.00

Average

Median

Minimum

Maximum

Variance

Standard Deviation

Hardness Test

Magnified Images 100x

Ideal SurfaceMicro-VoidInterface Void

Leakage Test

Glass beads used to detect leaks in the bundle

Continued Analysis

• Post-Production Process– Post-Production Testing

• Nitrogen Recover Rate• Final Leak Test → Success• End-Cap Dissection

Updated Requirements and Final Solution

• Liquid Control Systems– Automated Flow Rate– Heated Resin Lines– Ratio Monitoring

• Fixed Frame– 80\20 Aluminum– Adjustable– Stable & Rigid

Final ImplementationResin application system provided by Liquid Controls

Final Implementation

Future Considerations

• Fastener Maintenance– Important for secondary applicator

• Immobile Joints– Preventative maintenance

• Agitator to further infiltrate fibers– Mechanical, pneumatic, ultrasonic– Maintenance issues

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08/29/07 09/05/07 09/12/07 09/19/07 09/26/07 10/03/07 10/10/0710/17/07

10/24/0710/31/07

11/07/0711/14/07

11/21/0711/28/07

12/05/07

Ti

me

(

h)

Date

Labor Tracking (08/29/07 - 12/06/07)

Design & Analysis Labor Project Management LaborFabrication Labor Test & Evaluation Labor

Cost Analysis

$400.62 Materials CostLess than $1,500 Developmental Budget

$24,350 Labor

Potential Savings

• 60 bundles lost last year– Average $25,000 per bundle– $1,500,000 loss

• $112,000 solution cost– $109,866 Liquid Controls, $1,500-$2,000 for frames

• Potential first year savings+ $1,388,000 - $1,588,000

• Eventual savings per year+ $1,588,000 - $1,788,000

Questions

Appendices