fuel systems for leviii and pzev vehicles. fuel... · •tank only partial open for inserting of...

Fuel Systems for LEVIII and

PZEV vehicles

Jürgen Moitzheim

Open House 2012

www.kautex-group.com

Discussion on emissions

Agenda

New Technologies for Plastic Fuel Tanks

Outlook

Summary

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Where did it all come from?

The C-ARB promoted the P-ZEV legislation. (ARB Air Resources Board [California-ARB] C-ARB)

Partial Zero Emissions Vehicle (P-ZEV) is a standard for low emission vehicles

(LEV), 90% lower than the average of new vehicles even without producing

exhausted gases.

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1990: LEV (Low-Emission- Vehicle) standards.

1999: LEVII, became operative.

2010: LEVIII asks for more stringent emission standards for vehicles.

2020: LEV applications increase their portfolio with ULEV+50 & +70 and

SULEV20

Where is it going to?

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Discussion on emissions

Agenda

New Technology for Plastic Fuel Tanks

Outlook

Summary

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New Technology for Plastic Fuel Tanks

• In Mold Take Out + Ring insert iMTO+

• In Mold Deflashing iMD

• In Mold Heated Pinch iMHP

• Integrated Slosh Wall Insert iSWI

• Technology for LEVIII and PZEV C3LS®

• Integrated PFT Production Line iPPL

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iMTO+ In Mold Take Out + Ring insert

• Saves additional

worker

and/or robot for

ring insert.

• Must have for iMD

• Positioned and

reproducible hand

over to next

manufactory step.

• Constant product

quality

• Precondition for

iPPL

Advantage

and

Benefit

Source: VITEC

www.kautex-group.com

• Saves additional

worker

and/or robot for

ring insert.

• Must have for iMD

• Positioned and

reproducible hand

over to next

manufactory step.

• Constant product

quality

• Precondition for

iPPL

Advantage

and

Benefit

iMTO+ In Mold Take Out + Ring insert

Source: VITEC

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iMD - In Mold Deflashing

• No manual de-

flashing

• No risk to injure

worker and/or PFT

• No risk for sticking

flash to product

(tank)

• Constant product

quality

• Must have for iPPL

Advantage

and

Benefit

Source: VITEC

www.kautex-group.com

iMD - In Mold Deflashing

• No manual de-

flashing

• No risk to injure

worker and/or PFT

• No risk for sticking

flash to product

(tank)

• Constant product

quality

• Must have for iPPL

Advantage

and

Benefit

Source: VITEC

www.kautex-group.com

iMHP - In Mold Heated Pinch

• Better product

quality

• Reduced HC

emission at pinch

line

• Better

pinch line

conformity

Advantage

and

Benefit

without iMHP

with iMHP

Source: VITEC

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iSWI – Integrated Slosh Wall Insert

• Better product

quality

• Less sound

emission from

tank

• Reproducible

process

• No manual

operation

Advantage

and

Benefit

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iSWI – Integrated Slosh Wall Insert

• Better product

quality

• Less sound

emission from

tank

• Reproducible

process

• No manual

operation

Advantage

and

Benefit

Source: TI Belgic

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C3LS® – Technology for LEV3 and PZEV

• LEV3 and PZEV

require reduced HC

emission from the

tank system

• Several technologies

already in place

• All are covered by

patents

• Kautex

Maschinenbau

invested resources

and money

• C3LS® patented in

many countries

The

Challenge

Source: VITEC

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C3LS ® – Technology for LEV3 and PZEV

• Two sheet extrusion

• Not easy to retrofit

on existing blow

molding equipment

• Expensive and

complex twin sheet

die tooling

• Cost intensive mold

with middle core

• Difficult wall

thickness adjustment

• Product change

needs long time (1-2

days)

• Increased flash ratio

INERGY

TSBM

Source: INERGY

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C3LS ® – Technology for LEV3 and PZEV

• Similar to INERGY

TSBM

• Two sheet extrusion

• Not easy to retrofit

on existing blow

molding equipment

• Expensive and

complex twin sheet

die tooling

• Cost intensive mold

with middle core

• Difficult wall

thickness adjustment

• High flash ratio

Textron

NGFS

Source: TEXTRON

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C3LS ® – Technology for LEV3 and PZEV

• Starts with a round

parison

• Mold with pre-

chamber

• Pre blown tank

cutting in two halfs

within the mold.

• Components

inserted with robot.

TI Automotive

TAPT

Source: TI Automotive

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C3LS ® – Technology for LEV3 and PZEV

• Starts with a round

parison

• Tank only partial

open for inserting of

components

• Components

inserted with robot

• Easy to retrofit

• LEV3 and non LEV3

tanks can be

produced on one

machine.

• License with regional

exclusivity possible

Kautex Maschinenbau

C3LS®

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iPPL – Integrated PFT Production Line

• Consistent product

quality

• High overall

efficiency

• Flexible concepts for

easy and fast product

change

• One interface and

single responsibility

• Participate from our

over 20 years expert

knowledge

Advantage

and

Benefit

cycletime: 102 sec.

parts: 35 / h

inline production

offline production

A 20 - 30 sec deflashing

B 15 sec transport and scaling

C 15 sec transport loading

10-140 sec cooling time

10 sec unloading

D 5 sec transport

E 10 sec loading

80 sec welding time

10 sec unloading

1 manual load HDPE

2 manual load EVOH

3 manual load masterbatch

4 manual load purging material

5 manual load adhesive material

conveyor

Blow moulding KBS2-120 Coex under water

post-Cooling

tank storage

device

welding

machine

assembly

station

leackage

test

pump

tester

tank storage

device

to the

store

deflash

table

flash

conveyor

regrind

dryer silo

dryer

EVOH

dryer silo

regrind

silo

HDPE

silo

regrinder

A

scale

B

E

D

C

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iPPL – Integrated PFT Production Line

• Consistent product

quality

• High overall

efficiency

• Flexible concepts for

easy and fast product

change

• One interface and

single responsibility

• Participate from our

over 20 years expert

knowledge

Advantage

and

Benefit

Source: VITEC

www.kautex-group.com

iPPL – Integrated PFT Production Line

Advantage

and

Benefit

69%

Overall Equipment Effectiveness (mixed equipment)

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iPPL – Integrated PFT Production Line

Advantage

and

Benefit

Overall Equipment Effectiveness (balanced/selected equipment)

89%

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Discussion on emissions

Agenda

New Technology for Plastic Fuel Tanks

Outlook

Summary

www.kautex-group.com

Outlook

The low emission market still focuses on HC emissions.

The specific legislations in every region supports lower emissions long term.

Kautex reacts and will introduce the next generation on C3LS® soon.

Source: CARB 2011

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Discussion on emissions

Agenda

New Technology for Plastic Fuel Tanks

Outlook

Summary

www.kautex-group.com

Summary

Kautex Maschinenbau needs to be in tight exchange with the tank suppliers

and OEM„s.

Plastic fuel tanks are following the requests of OEM‟s and 1.Tiers.

“Intelligent” automation is the base for constant quality and highest efficiency.

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Thank you very much for your attention