Open House 2012

The challenge to make a composite cylinder Type 4

Siegfried Eckert

Agenda

The design process

Production process Cost calculation

Cost calculation

Vision

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Composite cylinder Type 4 applications

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Main advantages of LPG composite cylinder type 4

Light weight (over 50% weight saving) Translucent wall Easy to handle and stackable The valve is very well protected against impact Easy to clean. Very good behavior in fire The material is UV resistant to effects from sun, rain, temperature variations and handling

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Main advantages CNG composite cylinder type 4

Increased vehicles range and optimum safty Light weight - up to 75% weight saving over comparable steel cylinder Very good behavior in fire Very good behavior in impact accident Crash tested by leading OEM Corrosion free inside and outside

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Parts of a composite cylinder Type 4

Liner

Boss part

Composite

Polyethylene, Polyamide

Steel, Aluminium different kind of plastics

Epoxy or VE Resin Glass fiber, div.type Carbon fiber

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Design An issue of patents

Over 19 patents for the liner boss interface exist in the market. For entering the market as a new player. Special solutions are necessary!

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Regulatory requirements for LPG

EN 12245 Transportable gas cylinder- Fully wrapped composite cylinders EN 14427 Transportable refillable composite cylinder for LPG And others

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Regulatory requirements for CNG

EN R110 Regulation for Motor Vehicles using compressed natural gas (CNG) in their propulation system EN ISO 11439 High pressure cylinder for on board storage of natural gas as fuel for automotive vehicles And others

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Regulatory requirements for composite cylinders

ISO 11119-3 Gas cylinder of composite construction. Fully wrapped fiber reinforced composite cylinder with non-metallic liners And others

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Movie Water-boiler

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Certification and test regulary

A variety of tests are required depending on the vessel application and the specific standards for which the vessel is designed. Most important tests are: Burst test Temperature test Impact or drop test Bonfire test

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Certificate for production start

customer

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Agenda

The design process

Production process Cost calculation

Cost calculation

Vision

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Fully automatic production line

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Plastic liner - the heart of the composite cylinder

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Liner - the heart of composite cylinder (1/2) blow molded without flash filament winded LPG cylinder

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PWDS - Partial Wall Thickness Distribution System

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Liner - the heart of composite cylinder ( 2/2)

PWDS

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Filament winding process

Automatic loading by robot Low non - productive time by automatic cut and park fiber Controlled windig process Optimized fiber impregnation Curing process according to the resin parameter

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Filament winding process

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Experience in testing (1/2)

Test regulary for hydrostatic test 1,5 x working pressure Test time 30 sec For LPG application For CNG application 30 bar 350 bar

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Experience in testing (2/2)

Test regulary for burst test LPG Cylinder 67,5 bar CNG Cylinder 560 -780 bar depending on the fiber material

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Agenda

The design process

Production process Cost calculation

Cost calculation

Vision

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How much does the product cost?

We calculate the price!

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Customers briefing

Applications Quantity Design shape (length, width) Material for liner Material for boss part Material for composite

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Cost breakdown

Country specified cost for energie, building and

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Preliminary calculations of the liner and composite

Liner materials Fiber materials Resin materials Boss part solutions Filament winding technologies We took an average of the calculation of different material!

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Overview bill of material

Calculation for a CNG cylinder Working pressure: 200 bar Volume: 38 liter Max. 100.000 part/year Fiber: modified glass Production in Russia

Total cost per cylinder: 104.-

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Agenda

The design process

Production process Cost calculation

Cost calculation

Vision

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Advantages of LPG / CNG composite cylinder

Light weight (weight saving) More gas on board Very good behaviour in fire Very good behavior in impact accident Corrosion free (inside and outside)

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We like to realize your vision for composite cylinder applications

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Thank you very much for your attention! attention. Any questions?

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