PART a: IDENTIFICATION OF R&D Result
· The project team
|Advisor’s Name:||Department of Technologies and Materials|
|Expecting date of valorization plan submission:||15.01.2012|
· Identification of R&D activity
|Author of the R&D result:||Dr. Eng. Dumitru Constantin|
|Company or University:||UNIVERSITY OF CRAIOVA, ROMANIA|
|Sector:||ENG – Engineering|
|Type of the R&D result:||Product|
PART B: VALORISATION PLAN
SECTION I: Testing
|1||Has the R & D result been tested?|
The following question is replied according to the reply in question 1
|1a||In what mode has the result been tested?• Prototype• Pilot Application• Alpha/BETA testing|
|1b.||Please describe and discuss the testing results|
|Describe what type of testing does the R&D result need?|
|Detailed commentThe result of present research is to design and develop the discharge tubes for sodium vapor lamps made of super-aluminum polycrystalline translucent materials of high purity (99 % Al2O3), by automatic iso-static pressing. Of a granulated powder of 1-30 μm alumina, iso-statically pressed at a pressure of 100 MPa and sintered at a temperature of about 1650 0C , translucent ceramic tubes were obtained with thin walls of 0.75 to 1.00 mm. For physical execution of the model, we use some special laboratories in the country (SINTEROM SA Cluj Napoca, MATPUR SA Bucharest).By analyzing the theoretical and experimental research, the following steps have emerged to enable work-out and practical implementation of a technological process for producing parts made of ceramic powders:
- Constructive and technological analysis of the part;
- Achieve optimal functional and technological parameters;
- Ensuring the sequence of operation cycle phases;
- Ensure production control;
- Testing and probing the functional testing model, industrial prototype, pilot batch, serial product
- Verification of performance and safety characteristics.Also, tests and assessments are developed to analyze product compliance with technical and economic parameters of performance and certification of product use safety.
|1d.||What is the time needed for testing?|
|Time for testing, probing testing and homologation is estimated to be 90 working days.|
|1e.||What is the cost needed for testing?|
|Product costs (research, design, prototyping) are estimated at 15,000 Euro. Costs related to testing, probing homologation of functional model are estimated to be 3700 Euro.|
SECTION 2: Current Stage of Development
To what extent does the development team have technical resources for supporting the production of a new product? (Researchers, human resources, hardware, etc. )
|University of Craiova is one of the most important institutions of higher education in South-West Oltenia Region, with managerial experience in scientific research; academic staff is involved in both fundamental and applied research in all areas, as well as consulting and expertise.The team is et up and has the required resources to ensure new product manufacturing (researchers, human resources, hardware, etc.) The team has a longtime experience both in research and in prototype development (physical models). The ” Laboratory of Design, production control and management”, “Laboratory of product manufacturing technology” are available with also other laboratories and workshops within the department. At the same time the existing base is available knowledge and information in the field.
The research team can implement completely the project at the proposed quality parameters, with appropriate funding, in due time. In support of this statement we bring these arguments:
The product is the result of research and experimentation activities conducted by a team of specialists who wish to further optimize and launch the product in current manufacturing. In this respect, the team is available for technical advice, so that potential partners can start manufacturing the new product.
|What are the technical issues that need to be tackled for full deployment, if needed?|
|Based on innovative technical solutions for the manufacturing launch of the product, the next steps are required for technical and technological development:
- working out the design concept and requirements;
- Product design and production;
- Prototype execution;
- Prototype testing, probing homologation (reports of analysis, tests, measurements);
- Design of manufacturing flow technology;
- Execution of zero series to verify if technological documentation and degree of equipping with tools and devices is ensuring the performances of the approved prototype.;
- Certification of series products .
Also, the installation and operating instructions are completed over the stage of manufacturing launch.
|What additional technical resources are needed for the production of this new product?|
|To manufacture the new product is required to find technical solutions for raw material dosage and supply, molding close-up, iso-static pressing to compress the material, decompressing in two steps, taking over the pressed parts and their automatically transfer from the working area.
These conditions can be met by special equipment such as:
- Iso-static pressing tool;
- Dosing device;
- molding support block;
- high pressure installation (90-110 MPa);
- Manipulating device for transferring cylindrical componentsFor their implementation into system structure, further research is required by firms specializing in these areas.
|Overall assessment of the current stage of technical development.|
|Detailed commentAt the present stage of technical development, the discharge tubes within lamps with high pressure sodium vapor made of translucent polycrystalline super-aluminous materials of high purity, are known in Romania and internationally.
So far only a few countries possess the basic data and are manufacturing their quality tubes: USA, General Electric, Netherlands-Phillips, Germany-Feldmühle, France-Ceraver.
In Romania research have been carried out to develop special materials for various purposes, their results being largely applied in industry.To develop this technology for manufacturing the discharge tubes for lamps with sodium vapors, further research have to be made in the laboratory stage by specialized companies in this field aimed at: technological probes and experiments to develop super-alumina materials with high degree consolidation and sinterisation; setting-up suitable methods to carry out determinations on specific physical-mechanical characteristics.
Technological process of manufacturing the discharge tubes consists in following-up the main steps: cleaning the powders, grinding, mixture preparation, forming (shaping) of products in different sizes and shapes, preliminary drying and burning, sintering.
Also the manufacturing launch is of interest, ie promoting on domestic and international market.
SECTION 3: Deployment
|Define the demands for large scale production in terms of|
|After setting-up and testing the experimental model, selecting all suppliers of materials, components and subassemblies required necessary to achieve the product, as well as the quantities and delivery deadline, off they go to series production.
Purchase of materials and high-pressure unit is carried out from companies specialized in manufacturing such products.
|For manufacturing in series and mass production, the following items are required:
- Tools, devices and advanced specialized machines;
- (1) production line with 4 workstations;
- (1) final station of product control and homologation.
|Estimated human resource requirements for series and mass manufacturing will be:
- Staff working on production lines: 6 persons;
- Services personnel (supply, warehousing, handling, delivery): 4 persons;
- Technical staff: 3 persons;
- Marketing, administrative staff: 3 persons.
SECTION 4: Overall Assessment
|What is you overall assessment of the technical feasibility of the research result?|
|Technical parameters that are required to the new product are achievable and they are within the range of standardized (normalized) values, such as:- tube shape and dimensions (length, interior diameter, 114 × 8 × 0.75 mm;
- wall thickness)
- maximum closing force 300 kN
- Maximum iso-static pressure 100 MPa
- Testing Pressure, 120 MPa
- Maximum pressure in hydraulic system, 25 MPa
- working fluid: emulsion (water + oil)
Product testing is not problematic, there are laboratories authorized for this purpose, where, in addition to functional parameters checking-up, compatibility of sodium vapor lamps is checked-up too.
Assumed risks (technical, financial) related to the design and development of technological process of manufacturing discharge tubes for sodium vapor lamps, all are specifically referring to the following types:
In conclusion, the project can be considered to have low risk in technical terms. Thus, the designed product design can be proposed for obtaining his physical as well as experimental prototype. It is also of interest to launching it in series and mass manufacturing, namely to promoting it on domestic and international markets.
KEYWORDS QUANTITATIVE ASSESSMENT (0-5).
Please put X as appropriate.
|Adequacy of testing activity undertaken so far||X|
|Adequacy and availability of technical resources of the development team||X|
|Current development stage||X|
|Overall technical feasibility||X|
We agree that all informations contained in this form to be made public in the project „Inter-regional cooperation for valorization of research results – INTERVALUE”, by publication on the project website: http://www.urenio.org/intervalue/.
Suntem de acord ca informaţiile cuprinse în acest formular să fie făcute publice în cadrul proiectului „Inter-regional cooperation for valorization of research results – INTERVALUE”, prin publicarea lor pe site-ul proiectului, la adresa: http://www.urenio.org/intervalue/.