Composite Pressure Vessel

Introduction

The project on development of composite pressure vessels was launched in March 2002 under the Advanced Composites Programme of TIFAC in partnership with M/s. Kineco Pvt. Ltd., Panaji and with technology support from IIT-Bombay. The project aimed at developing filament wound pressure vessels for the following applications

• Under carriage FRP tanks (450 mm dia) with 2.00 bar operating pressure to be fitted in railway passenger coaches for water supply to the toilets.
• Two sizes of pressure vessels (500 mm & 600 mm dia) for water treatment application; operating pressure : 3.50 bar.

All the above three vessels were designed as per BS 4994. For fabricating composite pressure vessels with dished/hemispherical ends, multiple axes filament winding facility was found essential. As an integral part of the project, TIFAC had decided to support development of a multiple axes CNC filament winding facility. Development and fabrication of first such facility in the country was taken up by CNC Technics Pvt. Ltd., Hyderabad. Within a short period of 8 months, 4-axes (with one additional X-axis) CNC filament winding system has been designed, developed & fabricated. The system has the following unique features

• The filament-winding machine is powered & controlled by SIEMENS 840 D control system.
• Pressure vessels/pipes with diameter ranging from 50 mm – 4.00 metres can be wound on the system.
• Length of the job being wound can vary from 1.00 metres – 9.50 metres.
• While the first spindle can wind diameters ranging from 50 mm – 1500 mm at high rotational speed, the second spindle can rotate diameters up to 4.00 metres at relatively slower speeds. The second spindle can hold component and mandrel weight up to 6.00 tonnes.
• The unique design of the cross axis allows the winding pattern to be unaltered from 50 mm – 4.00 metres dia.
• The main filament winding carriage feeding the impregnated glass fibre moves at a very high speed of 60 metres per minute.
• The creel stand for fibreglass rovings accommodates 24 spools and has adjustable mechanical tensioning device at its spool. The tension can be accurately controlled for each roving.
• The drum type resin bath with micrometric adjusting doctor's blade can control resin pick-up accurately. Top wetting rollers assure proper wetting of rovings and squeeze blades remove excess resin. A temperature controller and a hot water pump controls the resin bath temperature within ± 2°C enhancing the pot life of epoxy resins.
• The CNC control system is enclosed in a fully sealed panel, which has a piggyback air conditioner and can work in any environment.

Development and fabrication of such a highly advanced & sophisticated machine has been the major milestone of the TIFAC project. This is a world-class machine, which can also be used for making missile components including rocket motor casings. This being an advanced technology, is closely guarded and protected under MTCR by USA, France and other countries.

The multiple axes filament winding system developed by CNC Technics has been priced at around one third the price prevailing in the international market, if at all import is allowed. The Company has entered into a tie-up with a US agency for exporting these multiple axes machines to mainland USA.

The Advanced Composites Programme has been instrumental in developing the indigenous capability of such a sophisticated machine while actually targeting at composite products & applications.

For further information please contact

Asian and Pacific Centre for Transfer of Technology,
APCTT Building,
C-2 Qutab Institutional Area,
P.O.Box - 4575
New Delhi - 110 016
India