Fuel Systems for LEVIII and PZEV vehicles. Fuel... · •Tank only partial open for inserting of...
Transcript of Fuel Systems for LEVIII and PZEV vehicles. Fuel... · •Tank only partial open for inserting of...
Fuel Systems for LEVIII and
PZEV vehicles
Jürgen Moitzheim
Open House 2012
www.kautex-group.com
Discussion on emissions
Agenda
New Technologies for Plastic Fuel Tanks
Outlook
Summary
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Where did it all come from?
The C-ARB promoted the P-ZEV legislation. (ARB Air Resources Board [California-ARB] C-ARB)
Partial Zero Emissions Vehicle (P-ZEV) is a standard for low emission vehicles
(LEV), 90% lower than the average of new vehicles even without producing
exhausted gases.
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1990: LEV (Low-Emission- Vehicle) standards.
1999: LEVII, became operative.
2010: LEVIII asks for more stringent emission standards for vehicles.
2020: LEV applications increase their portfolio with ULEV+50 & +70 and
SULEV20
Where is it going to?
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Discussion on emissions
Agenda
New Technology for Plastic Fuel Tanks
Outlook
Summary
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New Technology for Plastic Fuel Tanks
• In Mold Take Out + Ring insert iMTO+
• In Mold Deflashing iMD
• In Mold Heated Pinch iMHP
• Integrated Slosh Wall Insert iSWI
• Technology for LEVIII and PZEV C3LS®
• Integrated PFT Production Line iPPL
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iMTO+ In Mold Take Out + Ring insert
• Saves additional
worker
and/or robot for
ring insert.
• Must have for iMD
• Positioned and
reproducible hand
over to next
manufactory step.
• Constant product
quality
• Precondition for
iPPL
Advantage
and
Benefit
Source: VITEC
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• Saves additional
worker
and/or robot for
ring insert.
• Must have for iMD
• Positioned and
reproducible hand
over to next
manufactory step.
• Constant product
quality
• Precondition for
iPPL
Advantage
and
Benefit
iMTO+ In Mold Take Out + Ring insert
Source: VITEC
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iMD - In Mold Deflashing
• No manual de-
flashing
• No risk to injure
worker and/or PFT
• No risk for sticking
flash to product
(tank)
• Constant product
quality
• Must have for iPPL
Advantage
and
Benefit
Source: VITEC
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iMD - In Mold Deflashing
• No manual de-
flashing
• No risk to injure
worker and/or PFT
• No risk for sticking
flash to product
(tank)
• Constant product
quality
• Must have for iPPL
Advantage
and
Benefit
Source: VITEC
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iMHP - In Mold Heated Pinch
• Better product
quality
• Reduced HC
emission at pinch
line
• Better
pinch line
conformity
Advantage
and
Benefit
without iMHP
with iMHP
Source: VITEC
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iSWI – Integrated Slosh Wall Insert
• Better product
quality
• Less sound
emission from
tank
• Reproducible
process
• No manual
operation
Advantage
and
Benefit
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iSWI – Integrated Slosh Wall Insert
• Better product
quality
• Less sound
emission from
tank
• Reproducible
process
• No manual
operation
Advantage
and
Benefit
Source: TI Belgic
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C3LS® – Technology for LEV3 and PZEV
• LEV3 and PZEV
require reduced HC
emission from the
tank system
• Several technologies
already in place
• All are covered by
patents
• Kautex
Maschinenbau
invested resources
and money
• C3LS® patented in
many countries
The
Challenge
Source: VITEC
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C3LS ® – Technology for LEV3 and PZEV
• Two sheet extrusion
• Not easy to retrofit
on existing blow
molding equipment
• Expensive and
complex twin sheet
die tooling
• Cost intensive mold
with middle core
• Difficult wall
thickness adjustment
• Product change
needs long time (1-2
days)
• Increased flash ratio
INERGY
TSBM
Source: INERGY
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C3LS ® – Technology for LEV3 and PZEV
• Similar to INERGY
TSBM
• Two sheet extrusion
• Not easy to retrofit
on existing blow
molding equipment
• Expensive and
complex twin sheet
die tooling
• Cost intensive mold
with middle core
• Difficult wall
thickness adjustment
• High flash ratio
Textron
NGFS
Source: TEXTRON
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C3LS ® – Technology for LEV3 and PZEV
• Starts with a round
parison
• Mold with pre-
chamber
• Pre blown tank
cutting in two halfs
within the mold.
• Components
inserted with robot.
TI Automotive
TAPT
Source: TI Automotive
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C3LS ® – Technology for LEV3 and PZEV
• Starts with a round
parison
• Tank only partial
open for inserting of
components
• Components
inserted with robot
• Easy to retrofit
• LEV3 and non LEV3
tanks can be
produced on one
machine.
• License with regional
exclusivity possible
Kautex Maschinenbau
C3LS®
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iPPL – Integrated PFT Production Line
• Consistent product
quality
• High overall
efficiency
• Flexible concepts for
easy and fast product
change
• One interface and
single responsibility
• Participate from our
over 20 years expert
knowledge
Advantage
and
Benefit
cycletime: 102 sec.
parts: 35 / h
inline production
offline production
A 20 - 30 sec deflashing
B 15 sec transport and scaling
C 15 sec transport loading
10-140 sec cooling time
10 sec unloading
D 5 sec transport
E 10 sec loading
80 sec welding time
10 sec unloading
1 manual load HDPE
2 manual load EVOH
3 manual load masterbatch
4 manual load purging material
5 manual load adhesive material
conveyor
Blow moulding KBS2-120 Coex under water
post-Cooling
tank storage
device
welding
machine
assembly
station
leackage
test
pump
tester
tank storage
device
to the
store
deflash
table
flash
conveyor
regrind
dryer silo
dryer
EVOH
dryer silo
regrind
silo
HDPE
silo
regrinder
A
scale
B
E
D
C
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iPPL – Integrated PFT Production Line
• Consistent product
quality
• High overall
efficiency
• Flexible concepts for
easy and fast product
change
• One interface and
single responsibility
• Participate from our
over 20 years expert
knowledge
Advantage
and
Benefit
Source: VITEC
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iPPL – Integrated PFT Production Line
Advantage
and
Benefit
69%
Overall Equipment Effectiveness (mixed equipment)
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iPPL – Integrated PFT Production Line
Advantage
and
Benefit
Overall Equipment Effectiveness (balanced/selected equipment)
89%
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Discussion on emissions
Agenda
New Technology for Plastic Fuel Tanks
Outlook
Summary
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Outlook
The low emission market still focuses on HC emissions.
The specific legislations in every region supports lower emissions long term.
Kautex reacts and will introduce the next generation on C3LS® soon.
Source: CARB 2011
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Discussion on emissions
Agenda
New Technology for Plastic Fuel Tanks
Outlook
Summary
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Summary
Kautex Maschinenbau needs to be in tight exchange with the tank suppliers
and OEM„s.
Plastic fuel tanks are following the requests of OEM‟s and 1.Tiers.
“Intelligent” automation is the base for constant quality and highest efficiency.
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Thank you very much for your attention