Malitronic MULTIAXIAL - Союз производителей …uncm.ru/files/uploaded/Holding_Company_Compozit/conf_11...Malitronic® MULTIAXIAL flexible and highly productive approaches

Malitronic® MULTIAXIAL

flexible and highly productive approaches to the

production of semi- finished carbon-fibre-fabrics

Swen Petrenz / key account manager carbon technology

KARL MAYER MALIMO Textilmaschinenfabrik GmbH / Chemnitz

Content:

- buisness unit technical textiles – overview portfolio

- summary

- the Karl Mayer company

flexible and highly productive approaches to the

production of semi- finished carbon-fibre-fabrics

- process and potentials to create Non-Crimp-Fabrics (NCF)

Shepshed

Obertshausen

Chemnitz

Mönchengladbach

Hongkong

Changzhou

Fukui Mezzolombardo

Greensboro

KARL MAYER Worldwide

Company Overview

Uzwil

Warp Preparation

Technical Textiles

Warp Knitting

KARL MAYER

GROUP

Parts Manufacturing

• Multiaxial machine

• Biaxial machine

• Weft insertion machine

• Stitch bonding machine

For the production of:

• Composites

(fiber glass and carbon)

• Coated fabrics

• Nonwovens

• Lace machines

• Tricot machines

• Raschel machines

For the production of

• Rigid, elastic, and

semitechnical fabrics

• Warpers for warp

knitting

• Beaming machines

• Sectional warping

machines

• Warp sampling

machines

• Sizing machines

• Assembling machines

• Indigo dyeing range

Machine

• Creels

• Wide range of

Technologies

• Parts manufacturing

• CFRP competence

Tailor-made solutions, worldwide service network and training academies in Europe and China

KARL MAYER Business Units

Warp Knitting

Warp Preparation

Technical Textiles

Parts and Components

Portfolio KARL MAYER MALIMO

Warp knitting machines with weft insertion Stitch- bonding- machines

RSP MSUS

RS MSUS-G

RS MSUS-V

RS MSUS

HKS MSUS

continuous weft

insertion

cut to length weft insertion

BIAXIAL

MULTIAXIAL

Malitronic®

BIAXIAL

MULTIAXIAL

Wefttronic®

• CFRP has already shown their lightweight potential

• Automation and series manufacturing is necessary for an ecological and

economical production

• The biggest potential savings are gained by reduction of process costs

Motivation

Motivation

Key Goals of Automation of Composite Processes

source: connectra

Motivation

General Process Flow - Composites Moulding

source: connectra source: connectra

Motivation

General Process Flow - RTM

source: krauss maffei

fabric

fabric preform

moulding injection

Component part

resin

Motivation

General Process Flow - RTM

source: connectra

fabric

fabric preform

moulding injection

Component part

resin

Conclusions about NCF

• Significant cost savings during storage and curing process

– No need for tight climate controls during storage and downstream processes

– No need for expensive autoclave process to cure parts

• High grade of playability

– Individual carbon layers can shift to one another

• Super large and complicated shapes are possible

– No parts size restrictions due to autoclave sizes

• One step process from the carbon package to the fabric is possible

• High grade of flexible and fast fabric design changes

Malitronic® MULTIAXIAL

Malitronic® MULTIAXIAL 100“

continuous weft insertion cut to length weft insertion - Cut & Lay

• raw material is endless fixed in PIN-

PIN transport- system, what

continuously moved to the knitting unit

• Glas, Aramid, Carbon, Basalt, …

• hybrid- structures possible

• medium to heavy grammage

• 3K up to 24 K (50K)

• raw material is cut to length and cutted tape-

sequences are fixed in a PIN- field- system, what

contineously moved to the knitting unit

• mainly to produce carbon fibre products

• light- weight to heavy grammage

• 3K up to 50K (60K)

• Less waste with a high output

high fabric quality

high output up to 4,8 m/min

Malitronic® MULTIAXIAL

Malitronic® PIN- PIN

continuous weft insertion

Malitronic® MULTIAXIAL

• raw material is endless fixed in PIN-

PIN transport- system, what

continuously moved to the knitting unit

• Glas, Aramid, Carbon, Basalt, …

• hybrid- structures possible

• medium to heavy grammage

• 3K up to 24 K (50K)

Malitronic® PIN- PIN

continuous weft insertion

Malitronic® MULTIAXIAL

• raw material is endless fixed in PIN-

PIN transport- system, what

continuously moved to the knitting unit

• Glas, Aramid, Carbon, Basalt, …

• hybrid- structures possible

• medium to heavy grammage

• 3K up to 24 K (50K)

Malitronic® PIN- PIN

continuous weft insertion

Malitronic® MULTIAXIAL

• raw material is endless fixed in PIN-

PIN transport- system, what

continuously moved to the knitting unit

• Glas, Aramid, Carbon, Basalt, …

• hybrid- structures possible

• medium to heavy grammage

• 3K up to 24 K (50K)

Malitronic® PIN- PIN

continuous weft insertion

Malitronic® MULTIAXIAL

• raw material is endless fixed in PIN-

PIN transport- system, what

continuously moved to the knitting unit

• Glas, Aramid, Carbon, Basalt, …

• hybrid- structures possible

• medium to heavy grammage

• 3K up to 24 K (50K)

Malitronic® PIN- PIN

continuous weft insertion

Malitronic® MULTIAXIAL

• raw material is endless fixed in PIN-

PIN transport- system, what

continuously moved to the knitting unit

• Glas, Aramid, Carbon, Basalt, …

• hybrid- structures possible

• medium to heavy grammage

• 3K up to 24 K (50K)

Malitronic® PIN- PIN

continuous weft insertion cut to length weft insertion - Cut & Lay

• raw material is endless fixed in PIN-

PIN transport- system, what

continuously moved to the knitting unit

• Glas, Aramid, Carbon, Basalt, …

• hybrid- structures possible

• medium to heavy grammage

• 3K up to 24 K (50K)

• raw material is cut to length and cutted tape

sequenses are fixed in a PIN- field- system what

contineously moved to the knitting unit

• mainly to produce carbon fibre products

• light- weight to heavy grammage

• 3K up to 50K (60K)

• Less waste with a high output

high fabric quality

high output up to 4,8 m/min

Malitronic® C&L

Malitronic® MULTIAXIAL

Malitronic® MULTIAXIAL 100“

Malitronic® MULTIAXIAL C&L (Cut & Lay)

• High performance

• up to 600 mm weft insertion bandwidth

• up to 2.000 rpm in knitting process

• up to 4.8 m/min fabric throughput

• High grade of fabric quality

• High flexibility in machine specification and fabric construction

due to modular machine concept

• High grade of user- friendliness

• Exact reproducibility of fabric specifications

Malitronic® MULTIAXIAL C&L (Cut & Lay)

Process of production

Malitronic® MULTIAXIAL C&L (Cut & Lay)

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

Substrate fabrics Loose structures

Online – spreading Offline – spreading

Carbon Fiber Roving

• spreading during production

• direct unwinding from the creel

• bandwidth up to 200 mm

• 3K up to 24 K (50K)

possible Output: up to 1,6 m/min

• separate spreading process with special equipment

• spread tape as reference material

• bandwidth up to 600 mm

•12K up to 50K (60K)

possible Output: up to 4,8 m/min

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

Carbon Fiber Roving

Online – spreading Offline – spreading

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

Carbon Fiber Roving

Online – spreading Offline – spreading

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

Carbon Fiber Roving

Online – spreading Offline – spreading

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

Fiber Spreading Line

Offline – spreading

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

Details from producing tape in the fiber spreading line

Offline – spreading

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

Details from producing tape in the fiber spreading line

Offline – spreading

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

Details from producing tape in the fiber spreading line

Offline – spreading

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

Details from producing tape in the fiber spreading line

Offline – spreading

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

Carbon Fiber Roving

Online – spreading Offline – spreading

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

Carbon Fiber Roving Loose structures Substrate fabrics

foils nonwoven others

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

possible additional substrate fabric feeds

Nonwovens / Foils / Others

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

Substrate fabrics Carbon Fiber Roving Loose structures

Chop Powders Others

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

possible additional loose structure feeds Chop / Powders / Others

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

Substrate fabrics Loose structures

Online – spreading Offline – spreading

Carbon Fiber Roving

Weft insertion

130“ 133“ – 80“ max. ± 45°

100” 103” – 50” max. ± 45°

60” 65” – 30” max. ± 30°

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

Offline – spreading

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

High flexibility –

Quick change of weft angle

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

Fabric transport Elements

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

• reinforced, reliable feeding

• fixing of tapes in multiplex Pin - System

Transport Chain

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

• fully support of weft plies up to

the knitting unit

• synchronized movement to the

transport chains

Conveyor Belt

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

High flexibility –

Quick change fabric width

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

Possible space for creel

Warp - yarn feeding from tape reel –

supplied from fiber spreading line

Warp - yarn feeding from creel

Working from pre-spread tape reels

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

for tapes produced on fiber spreading line

rolling up device for separation paper

ST -Unwinding Frame

for Tape Reels

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

position of knitting yarn warp beams

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

With monitoring systems for yarn tension and end breaks

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

position of stitching head

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

-45°

90°

+45° 0°

Substrate

coating

knitting

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

2

3

5

4

6

7 1

Material flow

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

2

3

5

4

6

7 1

Material flow

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

2

3

5

4

6

7 1

Material flow

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

position for selvedge / panel cutting and suction unit

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

Cutting and Suction

• sheer cutting system

Tidland

• suction nozzle connected

to central vacuum

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

Cutting and Suction

• sheer cutting system

Tidland

• suction nozzle connected

to central vacuum

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

position for take-up and batching

Batching device

Input

material

Weft

insertion

Fabric

transport

Warp-yarn

feeding

Knitting yarn

feeding

Knitting

process

Take-up

batching

Cutting/

suction

Future Machine Integrations

• Advanced fabric defect detection for all layers

• Inline shape cutting processes

• Pre-adherence of thermoplastic films / layers

• Automated roll / piece packing and transport

• Inline connection to downstream processes

Malitronic® MULTIAXIAL strong points

High output

High fabric quality in laying:

High fabric quality:

High flexibility:

less weft waste:

modular concept

high OEE:

Mauersbergerstraße 2

09117 Chemnitz, Germany

Phone: +49 (0)371 8143-264

FAX: +49 (0)371 8143-32-264

[email protected]

Swen Petrenz key account manager carbon technology

KARL MAYER MALIMO

Textilmaschinenfabrik GmbH - Germany BUSINESS UNIT TECHNICAL TEXTILES

www.karlmayer.de