Automation Options for Custom-Made Composite Part Production

Abstract

This project analyses the feasibility of the integration of an automation system for custom-made composite part production at the superyacht equipment manufacturer Rondal BV. An analysis of the current prepreg production is performed to understand the automation opportunities and production requirements. Nesting, kitting, protective film removal and the laminating of the plies as well as de-bulking preparation for the laminate were identified as potential automation areas. The analysis also considers the labour time and cost efficiency of the production.
Various automation techniques currently applied in other composite manufacturing industries have been considered and analysed for their feasibility to the Rondal product manufacture. The focus of the analysis was to keep the current manufacturing steps, while reducing labour hours and lead time. The proposed system has also been assessed in terms of its future advancement by considering its current state of development within the industry. Based on this analysis the most appropriate automation solution is the “Pick and Place (P&P) cell” concept. Its capabilities and flexibility recommend it as a suitable candidate to be implemented in the automated manufacture of the variety of Rondal products.
Challenges of each individual equipment within the P&P cell and their interactions are described in detail. Predictions for the automation equipment except for the film removal tool where able to be obtained through literature and interviews with experts in the industry. Due to the lack of available literature information fitting this specific application, on the protective film removal process, a large proportion of this project was dedicated to the development of this tool. In contrast to previous developments, this project uses shock cooling as a solution to detach the protective film from the prepreg.
Implementation of a P&P cell concept was further investigated by the ability of the robot to reach all equipment without affecting the work flow throughout the Rondal workshop. Regulations and other layout restrictions have been considered for the final layout proposal. In order to align the manual and the automation process effectively, common mechanized process steps have been integrated for the use of both approaches.
The effectiveness of the chosen automation system was demonstrated by analysing cost and time statistics of the on-site process, as well as observations of a computer-assisted process simulation. As a result, lead time saving of up to 5 work days per product type as well as labour time reduction of up to 50% were determined. However, the economic analysis showed that the investment into the P&P automation system is not feasible given the current volume of production. On the basis of these conclusions, recommendations have been made to Rondal, proving potential production changes that could lead to an effective integration of automation at their facilities.