Highly-automated production of PUR/honeycomb-core components
A Korean automotive components supplier recently began series production of sunroof linings with a sandwich structure The complete production system for the high-strength components was supplied by KraussMaffei. The high level of automation across the system is reducing labour costs while delivering high product quality and short cycle times.
Sunroof linings, automotive interior components, need to combine high strength with low weight. This property mix is achieved by producing the lining as a sandwich structure – a spacer layer of honeycomb-structure cardboard between outer layers of glassmat. The sandwich structure is sprayed with PUR and pressed into shape. Formerly production used to involve manually building up the sandwich structure in the mould. After PUR spraying and pressing, the finished component was unloaded, again manually. After each cycle, the mould had to be cleaned and sprayed with release agent.
In developing the new production system, KraussMaffei looked to automate as many steps as possible. The system is designed as a rotary table with three processing stations. At the first station, fixing frames holding the preassembled honeycomb spacer and glassmats are positioned in the mould. The fixing frame holds the sandwich structure taut, preventing wrinkles and creases. In the second station, a robot manipulates a KraussMaffei airless spray mixing head, saturating the glassmats with PUR. In the third station the component is pressed into its final shape and unloaded from the mould by a robot. The PUR reaction mix contains an internal release agent, eliminating the need for the cleaning and release agent spraying previously necessary after each cycle. The highly automated system is reducing labour costs and increasing productivity and delivering consistently high product quality.
KraussMaffei supplied the entire production system – metering system, PUR sprayhead, rotary table, robots, mould carriers and moulds. KraussMaffei has received firm enquiries from automotive suppliers in Germany and Taiwan interested in similar production systems.
