Pultrex Ltd. (Manningtree, Essex, U.K.) reports that the Russian Nanotechnology Centre of Composites (NCC, Moscow, Russia) has placed an order for custom-built pultrusion and filament winding processing lines from Pultrex. Both the filament winder and the pultruder are capable of manufacturing large composite parts in a range of thermoset resins, including polyurethane. This order is a capital investment of more than £1.1 million and expands the Russian NCC’s R&D service offering to include these two key composites processing technologies; significant future growth is expected in new composite applications using filament-=wound and pultruded parts. The two machines are now being built at the Pultrex factory in, Essex and are scheduled to be delivered and fully operational at the NCC in Moscow by March 2014.
The NCC, founded at the end of 2011 as an engineering innovation centre specializing in composites, is a joint venture between CJSC, the Fund for Infrastructure and Educational Programs (FIEP), a member of RUSNANO Group, and DowAksa Advanced Composites Holdings BV.
The production, research and testing facilities of the NCC are located in Technopolis Moskva (Moscow). These facilities cover the production and testing of a wide range of composite products (GFRP, CFRP, basalt FRP, aramid-based FRP), using modern multi-functional production equipment which includes: a filament winding line; a pultrusion line; an SMC/BMC press; a clean room for prepregging; automatic cutting machines for fabrics and prepregs; a hand and spray lay-up area; injection moulding machines; a painting section; a mechanical treatment section and a metal workshop. Alongside these production facilities is a fully equipped mechanical tests laboratory; an NDT laboratory and a construction building laboratory.
The turnkey filament winding production unit ordered is a Pultrex MODWIND 2S-4NC 12000L filament winding machine (2-spindle, 4-axis) with fully integrated Siemens Sinumerik production control and data acquisition CNC system that includes full raw material traceability. The machine’s dimensions and specifications provide production flexibility to fabricate filament-wound components up to 12m/39.4 ft long and with a maximum diameter of 1.6m/5.25 ft in a single spindle format, or a 600-mm/23.6 inches maximum diameter with two spindles in use.
Other production features of the Pultrex MODWIND 2S-4NC 12000L include shrink tape application, 16 electronically controlled fiber tension controllers with built-in fiber break detection, plus a 100-fiber bookshelf creel assembly that can direct up to 100 individual fibers to the resin impregnator. Two interchangeable resin bath systems are being provided: a two-drum option with 10 fibers per drum with a 6-liter resin tank, or a larger single drum capable of handling 100 fibers with a 20-liter resin tank. A hydraulic mandrel extractor is also included in the package.
The pultrusion line the Russian NCC has specified is a Pultrex Px1000-20T pultrusion machine with 20 tonnes pulling capacity in continuous mode and 40 tonnes in tandem mode with two synchronized and programmable linear-controlled, three-clamp puller units. At the end of the line will be a roller take off table with an automatic continuous coiling unit for drums up to 2m/6.6 ft in diameter. The pultruder also has proprietary CNC integrated manufacturing systems (IMS) to provide numeric machine control, data acquisition and full traceability of product. The pultrusion machine has been designed by Pultrex to process all the traditional pultrusion resins: vinyl ester, polyester, acrylic vinyl ester, epoxy and phenolic, as well as two-component thermosets.