Tii tilTraining material - TRIMIS · Tii tilTraining material Contract No. NMP2-CT-2006-026673. 2 4...

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T i i t i lT i i t i lTraining materialTraining material

Contract No. NMP2-CT-2006-026673

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P t ti 4P t ti 4Presentation 4Presentation 4

h l Ih l ITechnology IntegrationTechnology IntegrationDemonstrationDemonstrationDemonstrationDemonstration


ObjectivesObjectives33

jj

To apply the knowledge developed and collected within the project to an industrial ‘demonstrator’.

The PEGASUS methodology can apply to any plastic car component but this demonstrator is based on a completely new rear part of a Smart* car.

I t t d t l d- Integrated rear quarter panel and complete rear lamp assembly

* Smart is a Daimler AG company* Smart is a Daimler AG company

Demonstration Demonstration ––R l / f d d iR l / f d d i

44Rear panel / fender designRear panel / fender design

Product DesignProduct DesignRear lamp Fender Fender with

integrated rear lampintegrated rear lamp

Demonstrator StepsDemonstrator Steps55

pp

Technology integration:• DesignDesign• Rear light assembly• Moulding of rear panel• Painting• Assembly • Testing• Testing• Economic and environmental

impact

Incorporating: Intrinsic colouring nano-pigments, conductive pathways, overmoulding, de-bond on command adhesive

Design Design 66

gg

Product development:Product development:

• Product design: To design the new component i i h diff Th f i lintegrating the different parts. The functional requirements were fed into the IDEE and the optimal materials and processing routes identified.

• IDEE supports mould design based on simulations such as MouldFlow, processing parameters, Life Cycle and cost analysisCycle and cost analysis.

• Product manufacturing: To manufacture the newly designed component using the new materialsdesigned component using the new materials developed within the project and the options obtained from IDEE analysis.

Design Design 77

gg

P d t d l tProduct development:

P f l ti Th Raw materials• Process performance evaluation: The technical, economic and environmental aspects were determined and

Raw materials

compared against a benchmark.

• The new part was designed to replace

End of lifeProduction…

• The new part was designed to replace an existing car component . This allowed comparison of the results with the e isting part here all the

Use phase Implementation

the existing part where all the information is already available.

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T h l i t tiT h l i t tiTechnology integration Technology integration LEDs in Automotive LEDs in Automotive

LightingLighting

Technology integration Technology integration ––LEDs in Automotive LightingLEDs in Automotive Lighting

9LEDs in Automotive LightingLEDs in Automotive Lighting

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LEDs used instead of conventional lights, this has become increasingly popularduring the project for the following reasons:

• LEDs considered as alternative lighting due to space and cost savings• Expected LED-life is comparable to part-life, no need for intermediate repair

Significant reduction in energy consumption (compared to conventional• Significant reduction in energy consumption (compared to conventionallamps)• Better for the environment, LEDs contain no mercury or heavy metals

Pegasus new technology: Conductive path and Over MouldingLines of injected conductive polymer, connect pins from the plug to the LEDs

LEDs are overmoulded for increased integrationLEDs are overmoulded for increased integration

Technology integration Technology integration ––Mould for LEDs overmouldingMould for LEDs overmoulding

10Mould for LEDs overmouldingMould for LEDs overmoulding

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Issues related to the integration of temperature and pressure ‘sensitive’ LEDsin polymer processes required investigation.

A simple mould (designed to be used in a micro injection machine) wasA simple mould (designed to be used in a micro injection machine) wasdesigned to evaluate LEDs resistance to injection moulding temperatures andpressures.

LEDs placed inside the pcavity

Technology integration Technology integration ––11LED tLED trialsrials 11

Experiments showed that:LEDs withstand injection temperatures and pressuresTolerances in LEDs dimensions are acceptable.p

A compound from EU Sixth Framework project PolyCond, contract numberNMP2-CT-2005-515835 was the one that presented the best results withNMP2-CT-2005-515835, was the one that presented the best results withmaximum output intensity of the LEDs.

Technology integration Technology integration ––LLEDs LayoutEDs Layout

12LLEDs LayoutEDs Layout

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LED array had to:

• Fit existing part geometryFit existing part geometry• Cover entire area• Meet brightness regulations

Number of LEDs needed Red/orange Amber

Turn - 7 to 14

Stop 5 to 10 -p

Rear fog 10 to 20 -

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T h l i t tiT h l i t tiTechnology integration Technology integration Conductive pathwayConductive pathway

Technology integration Technology integration --Conductive PathConductive Path

14Conductive PathConductive Path

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Metallic pins from the plug

Studies with LED overmouldingproves that it is possible to

from the plugp pinject the entire conductive pathwith a conducting polymer.

However, in this case the partgeometry meant that theconductive pathway would be

ftoo narrow for a completesolution.

A metallic insert will be used to connect the LEDs but the path from thisinsert to the metallic pins of the plug will be injection moulded usingconductive polymer.

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T h l i t tiT h l i t tiTechnology integration Technology integration Part designPart design

Technology integration Technology integration --P t D iP t D i

16Part DesignPart Design

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Bright blue areas are newdevelopments to the housing forthe integration into the fenderthe integration into the fender.The PMMA lenses had to betrimmed to fit the new housing.

Plug

Li fLines of conductive

path

Technology integration Technology integration ––P t D iP t D i


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Pegasus new technology: Debond-on-command

After injection mouldingj gof the housing part(with the LEDs and theconductive path), thedebond - on -command glue isapplied to the housing.It is then placed incontact with the lens,thus obtaining theR Li ht tRear-Light part.

TechnologyTechnology integrationintegration ––Part DesignPart Design


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Number of Individual Parts: 8Existing Rear-Light Number of Individual Parts: 8

Lamps Foam ringp25,35g

Positioner PMMA - 23,5g Metallic conductor

Aluminium - 41g

Foam ringEPDM - 12,93g

Light separatorPA6/MT30 - 16,6gLens/cover

PMMA - 225,72g

Aluminium 41g

Lamps supportPP T20 48 5gHousing

PC/ABS - 362,66gPP T20 - 48,5g

Technology integration Technology integration ––Part DesignPart Design

19Lens/Cover

Injection Processing Sequence

Part DesignPart Design19

InjectionHousing Injection

Nickel Bath

FINAL PART

g12 Steps

Nickel Bath to Housing

PositionerInjection

Welded Part Assembled to Foam Ring and Lamps

Support (Lamps previously placed)

Injection

Light Separator

Welding of Housing and Lens/Cover Existing Rear-

LightSeparator InjectionPositioner and Light

Separator assembled to

Housing

Foam Ring ExtrusionAssembly and Fixation

of Metallic Conductor in Lamps Support

(Fixation by pins deformed by means of

Lamps Support InjectionMetallic

Conductor Production

heat)



LED R Li ht

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LED Rear-Light Number of Individual Parts: 5

HousingPP 257 12g

LED with powerpathes Aluminium 21 92g

Conductive pathPC/PBT 10

Lens/cover PMMA - 179,64g PP - 257,12gAluminium - 21,92g PC/PBT - 10,7g


21Processing Sequence

Part DesignPart Design21

g5 StepsMetallic Conductor

ProductionLED Rear-Light

Metallic Conductor and Led’s WeldingFINAL PART

Position of Set Welded and Pins Plug likeLens/Cover Position in the E d P d A bl Position of Set Welded and Pins Plug like

inserts in the mouldExtracted Part and Assembly by Debond on Command

Glue

Conductive Path Injection by Auxiliary Unit

Housing Injection

Simultaneous = 1 Step

Technology integration Technology integration ––Moulding processMoulding process

22Moulding processMoulding process

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C-Frame

Secondary injection unit (forinjection unit (for the conductive path)

C-Frame structureHousing part

cavitycavity

Ejection side of the

Injection side of the machine

Main injection unit Conductive

machine

Main injection unit (for the housing part) Rotating central block

f th ld ( t ti

path cavity

of the mould (rotation of 180º)

TechnologyTechnology integrationintegration ––Moulding processMoulding process


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1 2

1 – LEDs are placed inside the mould b b t

2 – The mould closes and the housing isinjected (by main injection unit)

3

by a robotj ( y j )

simultaneously to the injection of theconductive polymer (by secondaryinjection unit)

3 4

3 – The mould opens and the central block rotates 180º 4 - The housing part (with the LEDs g (

and the conductive path) is ejected and the cycle re-startsSteps 1 and 4 are simultaneous

Technology integration Technology integration ––Moulding processMoulding process


Technology integration Technology integration ––t tt t

2525next stepsnext steps

• Light cluster automated moulding process operational• Light cluster automated moulding process operational during June 2010.

• Prototype manufacture to be carried outPrototype manufacture to be carried out• Parts supplied for demonstrator and testing

Technology integration Technology integration ––t tt t 2626contactscontacts

F i H tt (U Mi h )

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• Ferrie van Hattum (U.Minho.)[email protected]

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ffMoulding of rear panelMoulding of rear panel


Demonstration Demonstration -- ManufacturingManufacturing2828

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P t d i d i th t t f th j t i• Parts designed using the outputs from the project in order to perform process evaluation.

• This included findings from flow line studies.

• The polymer was intrinsically coloured using the orange nano pigment compound developed duringorange nano-pigment compound developed during Pegasus.

• Several options of integrating the rear lamp into the fender were possible.fender were possible.

Demonstration Demonstration -- MouldingMoulding tooltool2929

gg

T l D iTool Design:

3030

Painting Painting


Demonstration - Painting31

g

• Due to time constraints the• Due to time constraints the panels will be given the standard conventional clear coating currently used by g y ySMART.

• Ideally, a powder coating under development in the project would have been used. Once fully developed these coatings will offerthese coatings will offer advantages such as eliminating solvents, less wastage and smaller paint hshops. Clear Coat

Hydro based paint

Clear Coat

Black substrate KunststoffEingefärbt(MIC)

3232

Assembly Assembly


Demonstration Demonstration ––Li ht l t fittiLi ht l t fitti

3333Light cluster fittingLight cluster fitting

Th i t ti f th l i t th f d ld b d• The integration of the rear lamp into the fender could been done in a number of ways. To allow for this the mould was produced with different inserts so that the following integration possibilities could be trialled: – Over molding– Clipping– Clipping– Screwing– Gluing (with de-bond on command functionality)

• The demonstrator will have the light assembly clipped to the rear panel for the main testing programpanel for the main testing program

3434

ffPerformance testing Performance testing


Demonstration Demonstration ––P f t tiP f t ti

3535Performance testingPerformance testing

Th l ti f th tThe evaluation of the parts are made in four categories:

Dimensional testing– Dimensional testing – Functional testing

Dimensional testing after– Dimensional testing after functional testsRecycling– Recycling

T ti i t t i l SMART t d d d t i t ti lTesting is to typical SMART standards and to international standards for Europe, USA, Japan and Canada.

Demonstration Demonstration ––Di i l l tiDi i l l ti

3636Dimensional evaluationDimensional evaluation

• Dimensional Testing– A special frame was designed

t fi th t i thto fix the part in the same way as it is fixed to the car

– 3D data is collected by a probe y pperpendicular to the surface

– The measurement results are stored in a database in order tostored in a database in order to compare the different sets of production parameters and the diff t f i t ti thdifferent ways of integrating the rear lamp into the fender Measurement frame

Demonstration Demonstration ––F ti l t tiF ti l t ti

3737Functional testingFunctional testing

A range of physical and endurance tests are carried out on theA range of physical and endurance tests are carried out on the integrated rear lamp and panel, including:

– Lamps• Driving/Field tests• Driving/Field tests• Life tests

– PanelDriving/Field tests• Driving/Field tests

• Punch/Scratch/Crash tests– General

• Vibration Stability• Temperature Change Resistance• Thermal / Humidity Resistance• Impermeability• Resistance to salt spray• Freezing and de - icingg g

Demonstration Demonstration –– Dimensional Dimensional t ti d R lit ti d R li

3838testing and Recyclingtesting and Recycling

Dimensional testing• Repeated on rear panel after p p

functional testing to ensure there are no changes.

Recycling• Panels are to be assessed for

effectiveness of recyclability

Demonstration Demonstration –– SummarySummary3939

yy

The demonstration rear quarter panel including light cluster will beThe demonstration rear quarter panel including light cluster will be produced by the end of June 2010.

The demonstrator was designed in the Integrated DesignThe demonstrator was designed in the Integrated Design Engineering Environment (IDEE) developed during Pegasus. It also made use of the following innovative materials and processing techniques developed by Pegasus:Nano-pigmentsOver mouldingConductive pathwayConductive pathway De-bond on command adhesive.

The initial testing will be completed by December 2010 with fullThe initial testing will be completed by December 2010 with full testing completed by April 2011.

Demonstration Demonstration -- contactscontacts4040

C t t F ti l T ti

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Contact-Functional TestingDaimler AGMatteo VicedominiMatteo Vicedomini Engineering EP/REA - HPC X334Mercedes-Benz Cars DevelopmentMercedes Benz Cars Development Benz-Strasse - Tor 16 D - 71063 Sindelfingen

Telefon: 07031-90 88134 Telefax: 0711-305 21 537 25Telefax: 0711-305 21 537 25 E-Mail: [email protected]


C t t T li

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Contact-ToolingSchneider Form GmbHFeli HinkenFelix HinkenVertriebsleiter / Sales DirectorKirchheimer Str. 181Kirchheimer Str. 181D-73265 Dettingen/Teck

Telefon: +49 (0) 70 21 / 80 80-152Telefax: +49 (0) 70 21 / 80 80-80 E-Mail: f hinken@schneider-form deE-Mail: [email protected]


C t t Q lit A

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Contact-Quality AssuranceQS-Grimm GmbHKla s Ra berKlaus RauberProject ManagementWerner v. Siemens-Strasse 5Werner v. Siemens Strasse 5D-77656 Offenburg-Elgersweier

Telefon: +49 (0) 781 / 91 91 76-17Telefax : +49 (0) 781 / 91 91 76-25E Mail: klaus rauber@qs grimm deE-Mail: [email protected]

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