Rafael Ortiz - NVH foam equipment for automotive applications

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NVH foam equipment for automotive applications

By Rafael Ortiz

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Rafael Ortiz - NVH foam equipment for automotive applications

  1. 1. NVH  foam  equipment  for  automo1ve  applica1ons     RAFAEL  ORTIZ   Solu/ons  Group  Manager   @rafaelor/z00    
  2. 2. Voice  of  the  customer   Noise:  percep/on  is  everything   Source:  J.D.  Powers  2006  New  Car  Buyer  Survey  
  3. 3. Quietness  and  quality   Overall  vehicle  sa1sfac1on  directly  correlates  to  overall  interior  quietness  sa1sfac1on.     10 9,66 9 8,89 Ra/ng  Vehicle  Overall  Quality   8,25 8 7,67 7,07 7 6,25 6 5 <5 6 7 8 9 10 Ra/ng  Overall  Interior  Quietness  Source:  J.D.  Powers  2006  New  Car  Buyer  Survey  
  4. 4. NVH  percep/on  “The  noise,  vibra/on  and  harshness  (NVH)  reduc/on  bring  to  the  customer  not  only  the  percep/on  of  quality  but  durability,  solidity  and  higher  general  sa/sfac/on”   Source:  J.D.  Powers  2006  New  Car  Buyer  Survey  
  5. 5. NVH  applica/on    Resonance   occurs   within   the   car  sec/ons:  pillars,  cowl  bars,  wheel  wells  &  side  panels.    Many  automo/ve  manufacturers  use  acous/cal  foam  to  minimize  noise  coming  from  /res,  wind,  exhaust  and  engine.    
  6. 6. NVH  foam  cavity  filling   Baffles   Injected  foam  Two-­‐component   polyurethane   foams.   Close   cell  formula/on   1   to   5   pcf   density   range.   Designed   to  block   noise,   water   &   wind,   forming   a   high  performance  acous/cal  seal  and  preven/ng  the  noise  from  resona/ng.      
  7. 7. Acous/c  baffles   Specific  tooling  for  each   part  Low-­‐up  front  capital       Unreliable  expansion    Simple  approach       Sealing  performance  Licle  in-­‐plant  space    constraints   Specific  baffle  per   vehicle,  many  part   numbers,  high  inventory   &  slow  /me  to  market  
  8. 8. Acous/c  baffles  Baffles  are  costly  to  design,  manufacture  &  install  and  oeen   result  in  a  less  than  op/mal  solu/on  
  9. 9. Injected  foam  3D,  robust  seal  and  improved  NVH      Flexible:  used  on  mul/ple   High  up-­‐front  capital  vehicle  lines  and  carry   costs  over  to  future  lines         Poten/al  facili/es  space  Low  material  cost  and   constraints  reduced  or  eliminated    tooling  costs   Cost  of  ownership      Can  adjust  foam  volume  and  shot  loca/ons  as  required  
  10. 10. Manual  applica/on  
  11. 11.  Automa/c  applica/on  
  12. 12. NVH  equipment  challenges   High  up-­‐front  capital  costs   Custom-­‐designed  polyurethane  processing   equipment  for  NVH  foam  is  expensive     Poten1al  facili1es  space  constraints     These  sizeable  polyurethane  processing   machines  take  up  a  large  amount  of  space     Cost  of  ownership   Custom  repair  parts  are  expensive.   Specialized  technicians  usually  travel  to   conduct  on-­‐site  maintenance  and  repairs  
  13. 13. NVH  Solu/ons  –  Betacell   Specialized  custom  design            Long  lead  /mes,  specialized  service  parts          Costly  repairs   Complicated  for  plant  personnel    Longer  trouble  shoo/ng  for  repairs    More  down  /me                      Controls  are  customized  by  cell,  longer  training            Specialized  maintenance            Difficult  to  service  in  field   Foot  print  must  be  considered                      Variable  ra/o:  rotary/linear  pumps                      Automa/cally  adjusts  for  wear                    Risk  of  dispensing  out  of  ra/o  tolerance                        Different  pump  types  –  more  repair  parts                      
  14. 14. HFR  The  Graco  HFR  metering  system  is  a  standard  modular  design  with  precision  dispensing  capabili/es.    Advanced  &  reliable:  High  quality  meter,  mix  and  dispense  system  that  offers  more  technology  and  func/onality.    Affordable:  a  low  ini/al  investment  allows  you  to  use  acous/cal  foam  applica/ons  where  it  may  not  have  been  possible  before.  Lower  price  than  tradi/onal  custom  systems.      Global  distribu1on    
  15. 15. Installa/on  size   BetaCell   Machine:                 141”W   x   40”D   x   103”H   Control   Panel:                   95”W   x   20”D   x   56”H   HFR     Machine:                         48"W   x   34"D   x   59"H   Tanks   Stands                       26"W   x   35"D   x   70"H   Mix-­‐head  Power  Pack                          26"W  x  20"D  x  57“H  
  16. 16. Reducing  maintenance  costs  ROTARY  TECHNOLOGY   PISTON  TECHNOLOGY  Rotary  rebuilds  are  expensive   HFR  offers  Z  series  pumps  and  require  circula/ng  mix   Rebuild  at  the  facility  heads  to  mantain  pressure.   Elimina/on  rebuilds  8.000  –  12.000  €  investment.   No  need  of  back-­‐up  pumps  Annual  rebuild:  2.500  €  Addi/onal  mix  head  to  maintain  produc/on  while  mix  head  is  rebuilt:  8.000  €  
  17. 17. Durability,  accuracy,  reliability  •  Standardized  and  Modular  System   –  Closed  loop  metering  system   –  +/-­‐  1%  accuracy   –  1:1  –  24:1  ra/o   –  Up  to  50  lb/min  @  3000psi  •  Graco  Control  Architecture   –  Standard  USB  Logs   –  Op/onal  Gateway   •  Discrete  I/O   •  Ethernet  IP   •  DeviceNet   •  Profibus   •  ProfiNet  
  18. 18. Shot  Accuracy   20 cc/s - 120 cc Shot 10 cc/s - 120 cc Shot 190 185 185 180 +1% 180 +1% 175 175 170 170Weight (g) Weight (g) 165 165 160 160 155 -1% 155 -1% 150 145 150 140 145 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Shot Number Shot Number Xbar - 1% Xbar Shot Xbar + 1% Xbar - 1% Xbar Shot Xbar + 1%
  19. 19. Conclusions  Customer  percep/on:    SILENCE  =  QUALITY    NVH  solu/ons  are  a  trend  in  automo/ve  industry    New  HFR:  easy  to  use  &  mantain,  affordable,  smaller,  flexible  and  accurate.    Becer  ROI  (injec/on  vs  baffles)  

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