effective filament winding pipes production

EFFECTIVE FILAMENT WINDINGMETHOD TO OPTIMIZE THE RAWMATERIALS CONSUMPTION IN

PIPES PRODUCTION

MATERIAL WASTE IN FILAMENT WINDING

TTTTTHEEEE WASTEEE VOLUMEME (((RINGSSS INNNNN DFW)

TTTTTHEEEE WASTEEE CANNOTTT BEEE RECYCLED

DDDDIFFICULTIESSS TOOO PUTTT WASTEEE INNN LANDFILL

HHHHHIGHHH DISPOSALLL COSTS

EEENVIRONMENTALLL POLLUTION


DIFFERENT TYPES OF “WASTE”

WWWWASTEEE RESULTINGGG FROMMM LOSSESSS DURINGGG THEEE PROCESS

WWWWWWASTEEE DERIVINGGG FROMMM PRODUCTTT SCRAPS

SSSSCRAPPP DERIVINGGG FROMMM NONOON-NN--CONFORMMM PRODUCTS

LLLLOSSESSS DUEEE TOOO OVERDOSAGES

LOSSES DUE TO OVER-DESIGNED PRODUCTS

LL SSESSO SS DUDD EE OTTOO OVERDOSAGESOO

LLLLLLLL SSSSSSSSEEESSOOOO SS DUDD EE OOOOTTTTTTOOOOOOOO OOOOVVVEOO EERRR- ESIGGGGNNNNEDDDDEDEDD DDDDD PRODUCTSSSSPP


ECONOMICAL FACTS

WWWWASTEEE RESULTINGGG FROMMM LOSSESSS DURINGGG THEEE PROCESS

WWWWASTEEE DERIVINGGG FROMMM PRODUCTTT SCRAPS

LLLANDFILLLLL DISPOSALAL COSTOSST: 250€/€€//////TON

AAAAAAVERAGEEE RAWWW MATERIALALL VALUEUUE: 1300€/€€////TON

CCCASEEE STUDYDDY: Y: COMPANYYY PRODUCINGGG ABOUTUUT 5000 00 TONOON/NN//YEAR

WASTE PERCENTAGE: 7% ABOUT 350 TON

LANDFILL DISPOSAL: 87,500€ VALUE OF THE SCRAP: 455,000€ !!!!!!!!!!!

CCC SSASEE TUDSS DDYY: OMPANYOCOC YY PRODUCINGPP GG ABOUAA UUT 500055 00 OOTOOONNN/ EAREYEYY

WWWWWWWWWWWWWW SSSSTTSSSASS EE PPPPEEERCENTAGGGPPPPPPPP GGGGGGGEEEE 77%%%% 7: AAAAAAAAAAAAAAAAAAAA OOOOUUUUOOOBOOOUUT 33335555000033333333 00000000 ONOTO

LL NDFFFFILNAN LLLLLL DISPOSADD AAL 88887,,,,5555000000008:: €€€€ VVVVVVVVVVV LULAL EE OOOOOOFF HHHHTT EEE CCCCRAAAASSSSS AAAAP 444455555555,0000000000004444: €€€€ !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!


ECONOMICAL FACTS

SSUMMARIZING

WE ARE PAYING ALMOST 90.000€ TO SOMEONE ASKING HIM: “CAN YOU PLELLEEEEASE WE ARE PAYING ALMOST 90 000€ TO SOMEONE AWE ARE PAYING ALMOST 90.000€ TO SOMEONE ATROW IN LANDFILL SOMETHING LIKE 455K€???”

IT IS NOT FUNNY!!! IIIITTTT IIIISSS NNOOOOTTTT FFFFUUUUNNNNNNNNYYYY!!!!!!!!!!!!


CASE STUDY FINAL RESULT

BBYYY IMPLEMENTATIONNN OFFF AAAA COMPLETEEE METHODDD UNDERRR THEEE NAMEEE OFOF “EFFECTIVE FILAMENT BYYY MPLEMENTAMIMBYYY MPLEMENTAMIMWINDING”

ATIOAENTA” ” THE

ONNN OOOFF AAAA CATIOEEEEEE COMPANY

OMPLETCOCCYYYYYYYYY SAVED

E METMMETEEDDDDDD ABOUT

THODDD UNDUUTUUUTHODDD UNDUUTHOUTUTUT 25%

UNDUU%%%% %%%%% OF

R TDERRRDDFFFFFF THE

E NAMNNHTT EEEEEEEEEEE TOTAL

E OOOOAMEEALALALLLL RAW

EFFECTIVOFWWWWWWWWWWWW MATERIALS

E FTIVSSSSSS WASTE

ILAMITTTLAMLAMTETETE.

25% % XXX 350 00 TONNN = 87,5 55 TON

TOTAL COST SAVING: > 135,000€ !!! ……………… EVERY YEAR!!!

%% ,

TTTTTT TTTTAAAATTTTOOOO ALL CCCCOOOOSSSSCCC SSSSTTTTTTTT AAAAVVVVIIIINNNNSSSSSSSS NNNNGGGG >> 111133335555,000000000000>: €€€€ !!!!!!!!!! ……………………… EEVVVVEEEERRRYYYY YYYYEEEEAAAARRRR!!!!!!!!!!!!

EFFECTIVE FILAMENT WINDING METHOD

USUAL MISTAKE: E: THEEE WASTEEE ISSSSS THEEE RESINNN DRIPPINGGG FROMMM MYYY PARTRTT DURINGGG PRODUCTIONNN ANDUSUATHE

AL MISSUAEEEEEE SCRAP

STAKEMISPPPPPP AFTER

: THKEE:RRRRRR THE

E WASTWW EEHHTHEEEEEEEEEEEE FINISHING

TISSSSGGGGGG OF

RHTT EEFFFFFFFF THE

INNN DRIPDDRESRREEEEEEEE PRODUCT

PPINGGPCCCPPINGGPPINCTCTCT.

YYYOURRR PARTRTT NEEDSSS TOOO BEBE ENGINEERED, D WILLLLL BEEE MANUFACTUREDDD BYBYY HUMAN RESOURCES Y URO RR PARPPTHROUGH

ARRTHHHHHH A

T NEEDNN SS OTTOO BBBE ENEETAAAT NEEDNN SS OTTOO BBBE ENEENNNTAAAAAAAAA PROCESS

NGNE ENEESSS USING

GINEEREDD ILWW LLL BGG

GINEEREDD, ILWW LLL BGING MACHINES

BBBEEBILLLL BSSSSSS AND

E MANUFACTUMMEDDD

MANUFACTUMMMMMDDD MOLDS

REDUCTUSSSSSS THAT

BBBBYYEDDDATATATTTT NEED

HUMAN RESOURCEHHDDDDDHUMAN RESOURCEHHHUHH

DDDDD MAINTENANCE, ES ERCE

EEE, YOUTHROUWILL

UGHHH AAAAA PRPPROULLLLLL TRANSFORM

OCESSSSS SINGSINGSSUSUS GGGG MACHMACHMMMMOMMMOCESSS SINGSUS GG MACHMMOC

MMM RAW MATERIALS INESHCH

SSSSSS ANDSS NNANDDNESS

DDDDDD FINALLYMOLDD MMM

YYYYYYYYYY YOUDSSSOLD

UU WILLHAHHATT NEENNS TH

LLLLLLLLLL CHECKDDEED

KKKKKK THEMAINTENANMAINTENANMMMM

HHHHHMAINTENANMMMMMEEEEE QUALITY

NCEE, NNANYYY

,Y YY BEFORE

OUOO, YO,EEEEEEEEEE TOWIL

PUTRANSTTLLL

TTTTTTTT YOURFORMMM RAWRRNS

RRRRRR PRODUCTW RAW

CTCTCTTTT INMAW

NNNNNN THEATERIALSMA

EEEEEE MARKETS NDNANDD FALSSS

ETETETTTT EARNINGFINAFFGGGGGGGGG A

LYYY YYALAAAAAAAAAA PROFIT

YOUYOUYY UUUU WWYYFFFFFYOUUU WYOUUUFITFITFIT.

REALITY: ALL OF THE PHASES IN BOLD GIVE A CONTRIBUTION TO SAVE RAW MATERIALS HAVINGLESS WASTE.RRRREEEEAAAALLITTYYYYYYYY: LLALLL OOOFF HHHHTTTTTT EEE PHHHHASEPP SS NNINNN BOLLLLDDDDBB DDDDDDDD GGGGIVGG EE AAAA CONTRIBBBBUTTTTIIIOOOONCC NNNNNNN OTTOO AVSS EE RAAAAWWWWRR WW MMMATERIALMMMMMMM SS HHAAAAVVVVINGHHREALLLESLESLES

LITTYYALLSSSSSS WWWWAAASSSSWWWWAASSSSWWWAAASSSSSSSSWWWWWW

: LLALLL:TTTTT: LLALLL: LLALTETETETETE.


ANALISYS ANALISYANALISSYSSSSSS SS STRATEGY YYYYY Y PROFIT

ENGINEERING--- RRREVIEWWW OFFF PIPESSS DESIGNNN PROGRAM

--- CCCORRECTTT INTERPRETATIONNN OFFF EXPERIMENTALCCCCC RREODATA

- OPTIMIZATION OF SAFETY FACTORS

- UPDATE TEST CAMPAIGN

--- OOOOO TIMIZATIONTPT NN OOOFF AFETYSS YY FACTORSFF

------ UUUUUUUUUUUU DAAAATTTTDPD EEE ESTT TT CCCAAAAMMMMPAAIIGGGNNCC



HUMAN RESOURCES--- TTTTRAININGGG OFFF THEEE OPERATORS

--- IIIINVOLVEMENTTT OFFF THEEE OPERATORSSS TOOO THEIII VOLVEMVNVPROCESS

ENEMSSSSSS KEY

OOOFF HTT EE OOONTTYYYYYYYY FACTOR



PROCESS--- OOOPTIMIZATIONNN OFFF THEEE WINDINGGG PROCESS

--- UUUSINGGG PINNN RINGSSS MATHEMATICS



MACHINES--- IIIIMPROVEEE AUTOMATION

--- MMMONITORINGGG THEEE FLOWWW RATES



MOLDS--- QQQUALITYYY OFFF THEEE SURFACES

--- NNNNEWWW SHAPESSS FORRR THEEE INVERSION

--- DDDDDDDEVELOPMENTTT OFFF INVERSIONNN TOOLSLS (PIN RINGS)DDDD VELOPMENVEV TT OOOFF NVERSIONNIN NN OOLTT LS PIN RINGS)((



MAINTENANCE--- SSSSPAREEE PARTSSS MANAGEMENT

--- AAAAAUTOMATEDDD DIAGNOSIS

--- MMMMMAINTENANCEEE PLANNN DEVELOPMENT--- MMMMMM NTENANCIAI EE PLANPP NN DEVELOPMENTDD


ANALISYS ANALISYAANNAALLIISSYYSSSSSSSS STRATEGY YYYYYY PROFIT

RAW MATERIALS--- RRRIGHTTT CHOICE

--- CCCORRECTCCT SSSSSTORAGE

--- CCCCCORRECTTT HANDLING

- ONLINE RECOVER

--- CCCCC RRECO TT HANDLINGHH

--- OOOOOOOOOOOOOOOOOOOO LLLINNNNLLLLNNNNLLLL EEEEEEEE RRRREEEECCCCOOOOVVVVERRRRRRRRRRRR


ANALISYS ANALISYAANNAALLIISSYYSSSSSSSS STRATEGY YYYYYY PROFIT

QUALITY CONTROL--- OOONNN THEEE RAWWW MATERIALS

--- OOONLINEEE CHECK

--- FFFFINALLL PRODUCTTT QUALITYYY CHECK

- HANDLING QUALITY CHECK

--- FFF ANIN LL PRODUCPP TT QUALITYQQ YY CHECKCC

--- HHHHHHHHHHHHHHHH NNNNDDDDLLLLIIIINNNNGGGGNNNNAANNN GGGGGGGG QQQQUUUUAAAALLLIIIITTTTYYYYQQQQQQQQ YYYYYYYY CCCCHHHHEEEECCCCKKKKCCCCCCCC

EXAMPLE: OPTIMIZATION OF WINDING PROCESS

TOOO CHOOSEEE THEEE BESTTT WINDINGGG PATTERNNN INNN ORDERRR TOOO OBTAINNN THEEE MINIMUMMM RAWTOOO CHOOSCCMATERIAL

EE HTT EE BESBB TT WINDWWOSELLLLLL CONSUMPTION

Money saving:THE

gEE QUANTITYYY OFFF PROCESSEDDD MATERIALALL ISSSSS LOWER

LOWERRR TIMEEE TOOO PRODUCEEE THEEE PIPE

THEEE QUANTITYYY OFFF SCRAPSSS TOOO BEEE DISPOSEDDD ISSSSS LOWER

The method does not modify the mechanical properties of the pipe.


PPIPEE PRODUCTIONN USINGG DISCONTINUOUSS FILAMENTT WINDINGG ISSS TOTALLYCONTROLLEDDD BYYY FOURRR MAINNN GEOMETRICCCC PARAMETERS

NDINRSRS:

IINTERNALL DIAMETERR OFF THEE PIPEE (I( .((I E.EEE. . DIAMETERR OFF THEE MOLDLD)

BBBANDWITH

LLENGTHH OFF THEE PIPEE INCLUDINGG SCRAPS

NNUMBERR OFF HELICALS

It is a common practice that the lenght of the finished pipe (without scraps) is the total lenght of the pipe including scrapes minus two times the bandwith.

The winding path is composed by a central zone with constant winding angle and twotransition zones with constant friction coefficient at each extremity of the centralzone.

EXAMPLE: OPTIMIZATION OF WINDING PROCESSOOONCEEE THEEE ABOVEEE FOURRR PARAMETERSSS HAVEEE BEENNN DEFINEDEED, D, THEEE QUESTIONNN ISSSIS: S: WHATATT AREE THEEE SKIPPP INDEXXX ANDO CCNC

THEHTT EE ABOVAACEE T

EEEEEEE FRICTIONE FOURFF RR PARAMPPOVEE

NNNNNN COEFFICIENTMETERRAM

TTTTTT WHICHHAVHH EE BRSS

HHHHHH MINIMIZEENNNBEEBB

EEEEEEEEE THEEFINEN DEDD

EEEEEE RAWDD, HHTHTT EE QUEQQNEEED

WWW,

WWW MATERIALESTIONNN SSISS: HWWWQUE

AAALLL CONSUMPTIONHAATT ARAAH

OOOHAATT ARAAHAATT

ONONON?

Friction coefficient

Raw

ma

teria

lSkip index 1Skip index 2Skip index 3Skip index 4

EXAMPLE: OPTIMIZATION OF WINDING PROCESSTTTTOTALL LENGHTT INCLUDINGG SCRAPSPS: 12440 0 MM

MMOLDD DIAMETERER: 1500 0 MM

BBBBANDWITHTH: 220 0 MM

NNUMBERR OFF HHHELICALSLS: 15

TTTEXXEX: 4,8 8 GG/G//M

NNNUMBERR OFF ROVINGSGS: 48

The difference between the worst solution and the best solution is 47 kg, i.e. a difference of 18% of rawmaterials consumption!

By using pin rings

CONCLUSIONS

THE QUANTITY OF RAW MATERIALS WASTE IS AFFECTED BY ALL THE PHASESEEEEES OF THE INDUSTRIAL THE QUANTTPROCESS

IMPLEMENTATION OF STRATEGIES IN ALL THE PHASES ALLOW TO SAVE UP P TO 25% OF WASTE

THE SAVING OF RAW MATERIALS WASTE GIVES IMPORTANT ECONOMICAL ADVVVVVVANTAGES

THE SAVING OF RAW MATERIALS WASTE GIVES IMPORTANT ENVIRONMENTAL L ADVANTAGES

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effective filament winding pipes production

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