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Open House 2012
The challenge to make a composite
cylinder Type 4
Siegfried Eckert
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Cost calculation
The design process
Production process
Agenda
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Cost calculation
Vision
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Composite cylinder Type 4 applications
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� Light weight (over 50% weight saving)
� Translucent wall
� Easy to handle and stackable
� The valve is very well protected against impact
� Easy to clean.
Main advantages of LPG composite cylinder type 4
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� Easy to clean.
� Very good behavior in fire
� The material is UV resistant to effects from sun, rain, temperature variations
and handling
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� Increased vehicles range and optimum safty
� Light weight - up to 75% weight saving over comparable steel cylinder
� Very good behavior in fire
� Very good behavior in impact accident
� Crash tested by leading OEM
Main advantages CNG composite cylinder type 4
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� Crash tested by leading OEM
� Corrosion free inside and outside
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Parts of a composite cylinder Type 4
Liner Boss part Composite
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Polyethylene,
Polyamide
Steel, Aluminium
different kind of plastics
Epoxy or VE Resin
Glass fiber, div.type
Carbon fiber
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Design – An issue of patents
� Over 19 patents for the liner -
boss interface exist in the market.
� For entering the market as a new
player.
� Special solutions are necessary!
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� EN 12245 Transportable gas
cylinder- Fully wrapped composite
cylinders
� EN 14427 Transportable refillable
composite cylinder for LPG
� And others
Regulatory requirements for LPG
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� And others
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� EN R110 Regulation for Motor Vehicles
using compressed natural gas (CNG) in
their propulation system
� EN ISO 11439 High pressure cylinder
for on board storage of natural gas as
fuel for automotive vehicles
Regulatory requirements for CNG
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� And others
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Regulatory requirements for composite cylinders
� ISO 11119-3 Gas cylinder of composite
construction. Fully wrapped fiber
reinforced composite cylinder with
non-metallic liners
� And others
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Movie Water-boiler
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Certification and test regulary
A variety of tests are required depending
on the vessel application and the specific
standards for which the vessel is
designed.
Most important tests are:
� Burst test
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� Temperature test
� Impact or drop test
� Bonfire test
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Certificate for production start
customer
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Cost calculation
The design process
Production process
Agenda
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Cost calculation
Vision
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Fully automatic production line
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Plastic liner - the heart of the composite cylinder
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blow molded without flash filament winded LPG cylinder
Liner - the heart of composite cylinder (1/2)
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PWDS - Partial Wall Thickness Distribution System
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Liner - the heart of composite cylinder ( 2/2)
PWDS
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Filament winding process
� Automatic loading by robot
� Low non - productive time by
automatic cut and park fiber
� Controlled windig process
� Optimized fiber impregnation
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� Curing process according to the
resin parameter
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Filament winding process
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Experience in testing (1/2)
Test regulary for hydrostatic test
� 1,5 x working pressure
� Test time 30 sec
� For LPG application 30 bar
� For CNG application 350 bar
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� For CNG application 350 bar
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Experience in testing (2/2)
Test regulary for burst test
� LPG Cylinder 67,5 bar
� CNG Cylinder 560 -780 bar
depending on the fiber material
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Cost calculation
The design process
Production process
Agenda
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Cost calculation
Vision
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How much does the product cost?
� We calculate the price!
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� Applications
� Quantity
� Design shape (length, width)
� Material for liner
� Material for boss part
Customer´s briefing
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� Material for boss part
� Material for composite
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Cost breakdown
Country specified cost for energie, building and …
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Preliminary calculations of the liner and composite
� Liner materials
� Fiber materials
� Resin materials
� Boss part solutions
� Filament winding technologies
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� Filament winding technologies
We took an average of the calculation
of different material!
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Overview bill of material
� Calculation for a CNG cylinder
� Working pressure: 200 bar
� Volume: 38 liter
� Max. 100.000 part/year
� Fiber: modified glass
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� Fiber: modified glass
� Production in Russia
� Total cost per cylinder: € 104.-
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Cost calculation
The design process
Production process
Agenda
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Cost calculation
Vision
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� Light weight (weight saving)
� More gas on board
� Very good behaviour in fire
� Very good behavior in impact
accident
Advantages of LPG / CNG composite cylinder
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� Corrosion free (inside and outside)
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We like to realize your vision for composite cylinder applications
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Thank you very much for your attention.Thank you very much for your attention!Any questions?
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