Team Air Liquide Senior Design Project 2007 Process Improvement of Resin Application System Phase IV Group Presentation Pete John Adam Willoughby-Knox Kevin Malik Laura Shultz

Who is Air Liquide MEDAL? Products –Hollow fiber membranes for N 2 generation, CO 2 removal, and H 2 purification Applications –Oil & Gas, Laboratories, & Aerospace Industries

Our Project: Create an automated process to coat fibers with epoxy for filter end caps Epoxy end caps Process Improvement of Resin Application System

Motivation 60 bundles lost last year –Average $25,000 per bundle – $1,500,000 loss Adverse Product Performance –Defects & Poor Recovery Rate Labor Allocation Issues –Second technician needed

Current Process technician paints ends with the special epoxy and a plain paintbrush.

Problem Definition: How to automate resin application? How to create a good epoxy infiltration? Current Process Issues: Gas leaks Resin wicks down the length of the fibers Effects the efficiency of purification. Number of Machine Operators Resin Waste/Mess Resin very viscous hard to work with Variability results in loss of bundles.

Problem Definition What characteristics define good resin application? What system constraints exist? –Resin material properties –Resin dispenser –Loom feed rate & layup process –Multiple products must be produced on the same machine –Factory setup –Wicking effects & porosity

1.Prevent gas leaks 2.Consistency in quality 3.Reduce amount Machine Operators 4.Reduction of Resin Waste 1.Minimal voids in resin 2.4 in band width 3.1 operator 4.Directly supply resin onto loom Initial Metrics & Target Values

Initial Design Path Resin Applicator Resin Application Band Fiber Filter Spool Resin Infiltrator 2 Components

Resin Application System Liquid Control Systems Continuous feed pump Specified nozzle for initial dispense width Control system accommodating different sized bundles

Infiltration System Initial Flow Front Conveyer Motion Infiltrated Fibers

Design Parameters Flow Rate Initial Dispense Width Roller Material Roller Pressure on Loom

Flow Rate Cup #Weight before useWeight after useResin amount used Total Resin used Cup #Weight before useWeight after useResin amount used Total Resin used Left Side Right Side Recorded Mass (m) V = feed rate of loom l = length of total bundle sheet Recorded Mass (m)

Roller Material Defined

Roller Material Tested

Roller Material Selection

Parameters Defined Flow Rate Initial Dispense Width –Same bandwidth (4 inches) Roller Material –Epoxy Glide Roller by Wooster (R232-4) Roller Pressure on Loom –Adjusted before motion initiated

Updated Performance Requirements Updated Target Values 1No significant voids 2One technician to oversee 3No break of roller contact g/min flow rate 5Resin at 40 degrees C

Prototype Description Loom Machine Fibers

Prototype Description Store-Bought Roller Frames Adjustable Primary Arm Rotatable Secondary Arm Pivot Point

Prototype Description Resin Gun Adjustable Primary Arm Rotatable Secondary Arm Store-Bought Roller Frames

Prototype Testing Adjustable Primary Arm Rotatable Secondary Arm Resin Gun

Post Treatment Processes Resin cure Ends machined Clean cut to open fiber ends Chemical Post-Treatment

Testing Analysis Evaluation Techniques Wicking Hardness Optical Photographs Leak Test

Wicking Prototype Operator-Painted Variable Wicking Operator-Painted Even Wicking Prototype

Hardness Test

Magnified Images 100x Ideal Surface Micro-Void Interface Void

Leakage Test Glass beads used to detect leaks in the bundle

Continued Analysis Post-Production Process –Post-Production Testing Nitrogen Recover Rate Final Leak Test → Success End-Cap Dissection

Updated Requirements and Final Solution Liquid Control Systems –Automated Flow Rate –Heated Resin Lines –Ratio Monitoring Fixed Frame –80\20 Aluminum –Adjustable –Stable & Rigid

Final Implementation Resin application system provided by Liquid Controls

Final Implementation

Future Considerations Fastener Maintenance –Important for secondary applicator Immobile Joints –Preventative maintenance Agitator to further infiltrate fibers –Mechanical, pneumatic, ultrasonic –Maintenance issues

Cost Analysis $ Materials Cost Less than $1,500 Developmental Budget $24,350 Labor

Potential Savings 60 bundles lost last year –Average $25,000 per bundle – $1,500,000 loss $112,000 solution cost – $109,866 Liquid Controls, $1,500-$2,000 for frames Potential first year savings + $1,388,000 - $1,588,000 Eventual savings per year + $1,588,000 - $1,788,000

Questions

Appendices