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Similar to Rafael Ortiz - NVH foam equipment for automotive applications
Rafael Ortiz - NVH foam equipment for automotive applications
- 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
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- 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)