NVH foam equipment for automotive applications By Rafael Ortiz

1. NVH
foam
equipment
for
automo1ve
applica1ons
RAFAEL
ORTIZ
Solu/ons
Group
Manager
@rafaelor/z00

3. Voice
of
the
customer
Noise:
percep/on
is
everything
Source:
J.D.
Powers
2006
New
Car
Buyer
Survey

4. 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

5. 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

7. 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.

8. 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.

9. 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

10. Acous/c
baffles
Baffles
are
costly
to
design,
manufacture
&
install
and
oeen
result
in
a
less
than
op/mal
solu/on

11. 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

12. Manual
applica/on

13. Automa/c
applica/on

14. 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

15. 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

16. 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

17. 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

18. 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
€

19. 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

20. Shot
Accuracy
20 cc/s - 120 cc Shot 10 cc/s - 120 cc Shot
190 185
185 180
+1%
180 +1%
175
175
170 170
Weight (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%

21. 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)