AIR LIQUIDE

1
DESIGN SOLUTION
DESIGN SOLUTION
Design constructed and retrofitted to bundle
forming machine
BACKGROUND
Epoxy is hand-painted on the ends of fibers
during a looming process, forming rigid end-caps
as the epoxy cures. The process is inconsistent
and highly susceptible to operator error. Voids
form due to dry fibers, causing failure of the
bundle. Moreover, performance is adversely
affected due to inconsistent resin application
bands. A solution is required to improve failure
rates, product quality, and manufacturing
consistency. It is desirable to remove the human
element from the application process.
VALIDATION
VALIDATION
Leak Testing
Hardness Testing
A bundle was formed using the prototype. The
bundle was cured and subjected to various
post-production tests. The results were compared
to the current process. It was concluded that the
prototype offers better performance.

• 40 hardness measurements
• Ideal range 65-75 Rockwell
• Within range, greater consistency

• Bundle is pressurized
• Glass beads used to detect leak
• No leaks detected

CONSTRAINTS
Microscopy
Wicking

• 100x imaging
• Micro-voids should be minimal
• Smaller and fewer micro-voids

• Visual inspection
• Even resin band is desired
• Resin band is more even

• Resin catalyst must remain unchanged
• Existing machinery must be retrofitted
• Fiber alignment must not be compromised
• Factory layout may not be altered
• Approximately 100K - 200K solution budget
• 1,500 development budget

AIR LIQUIDE MANUFACTURING PROCESS IMPROVEMENT
SYSTEM Adam Knox Pete John Kevin Malik Laura
Shultz

• Liquid Controls resin system
• Heated transfer lines
• Automatic application
• Ratio monitoring
• Automatic shutoff
• Upgraded prototype design
• Optimized performance
• Increased rigidity
• Increased durability
• Bolted or welded to machine
• 80/20 Aluminum frame
• Maintenance Operation manual

DL-2 Control Unit
Twinmixer Applicator
METRICS TARGETS
IMPLEMENTATION
IMPLEMENTATION

• Last year, 60 bundles lost ? 1,500,000 lost
  revenue
• Startup cost 112K
• 50 labor savings
• Potential first year savings ? 1,388,000
  1,588,000
• Subsequent savings ? 1,588,000 - 1,788,000 per
  year

Updated Target Values Updated Target Values
1 No significant voids
2 One technician to oversee
3 No break of roller contact
4 200-230 g/min flow rate
5 Resin at 40 degrees C
VALUE IMPACT
VALUE IMPACT