CONSOLIDATION UNIT

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THE CONSOLIDATION SYSTEM 

Process reliability, constant quality, and flexibility – these are the key success criteria of Fill´s newly developed consolidation unit. The flexible machine concept enables consolidation of fiber mats with targeted fiber orientation and thickness differences (local reinforcing layers) in the mat in one cycle. At the same time, the system integrates seamlessly into upstream or downstream processes, thereby substantially increasing efficiency in volume production of tailor-made tape solutions. 

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Wilhelm Rupertsberger Head of Competence Center Plastics
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The concept

The tape layer package is laid in a tool, which is then closed and transferred to the heating station fully automatically. A contact heater 

is used to increase the temperature to that required to achieve a molten state of the material. 

Thermal activation and a constant consolidation pressure cause currents that combine the neighboring layers with one another. This is followed by a quick switch to the cooling station, where the laminate is cooled back down to a solidified state. 

Use of multiple tools in the machine allows the process steps to be performed in parallel, making short cycle times possible. 

Features

  • Integration in the forming process with negligible cycle-time impact (< 60 seconds/component) 

  • Mats with different wall thicknesses can be processed 

  • Tempering in near-net shape enables short reaction times 

  • Low energy losses thanks to rapid tool transfer between heating and cooling station 

  • High heating/cooling rates (optionally up to 450 °C) 

  • Combined component loading and removal point (ideal for automation) 

  • Ergonomic design for manual loading 

  • Compact design 

Specifications

Component length (mm)

860

Component weight (mm)

360

Component length (mm)

1,100

Component weight (mm)

610

Min. closing force (kN)

2

Max. closing force (kN)

31

Max. temperature (° C)

350

Min. closing force (kN)

9

Max. closing force (kN)

68

Max. temperature (° C)

350

Min. closing force (kN)

13

Max. closing force (kN)

310

Min. closing force (kN)

56

Max. closing force (kN)

677

Length (mm)

5,800

Width (mm)

2,500

Height (mm)

2,700

Siemens S7-1500

Automation solutions

High-temperature version (up to 450° C)

Process data acquisition

Technical specifications subject to change.

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