E-PROPS HI-TECH CARBON PROPELLERS



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MANUFACTURING OF E-PROPS PROPELLERS

 

 

 

 

The E-Props propellers are fully made in France, in the E-Props workshops, in Provence. The 1700 m² worshops are equiped with 12 CNC machining centers. The company has developed more than 140 propellers models (2018-01-16).

 

E-Props propellers CARBON range are designed and manufactured to be very light and strong. Materials and manufacturing process have been validated by many tests.

 

 

hélice e-props en composite

 

 

helices e-props propellers the strongest on the market

 

 

 

BLADES

- made in carbon braid, with continue fibers between upper and lower surfaces of the blade

- epoxy resin

- foam core with internal spar (D-Box)

- blade's foot with titanium ring inside

- 100% carbon, no metallic part = no galvanic corrosion

- internal shielding of the blades : injection at the leading edge of a special resin with Nanostrength® (ARKEMA product : high kinetic energy absorption capacity) => See the page LEADING EDGE PROTECTION

- the epoxy resin is including a high resistance to UV additive (UVA and UVB). Blades are polished with a perfect finition.

- unique ref number on each blade for traceability (RFID chip inside)

 

The HCF (Helical Continuous Fibers) process, specifically designed by E-PROPS, ensures an exceptional strength of the 100% carbone + epoxy resin blade, from leading edge to trailing edge, from blade's foot to tip.

 

tresse carbon carbon braid tresse carbon carbone braid

special high-resistance carbon braid, with thousnads of carbon wires

 

 

cannelure hélice EPROPS NGDinterieur pale e-props carbonepied de pale hélice e-props ng-dtor acier pied de pale hélice E-PROPS NG-D

foam core with internal spar, titanium ring

 

 

e-props serial number on the blade foot

 

 

HELICES E-PROPS HI-TECH CARBON PROPELLERS

 

 

HUB

- full carbon + high temperature epoxy resin

- blades and hubs are made in the samed material : no problems of interference, no galvaic corrosion

- Nord-Lock washers secure bolted joints

 

moyeu e-props hub

carbon hub with aluminium flange

 

 

modélisation moyeux carbone e-props simulation sofflerie numérique

analyzsis of the hub

 

 

PROCESS

Blades and Hub : RTM (Resin Transfer Molding) manufacturing. This process is used by Airbus for some critical carbon parts on the liner aircraft. It is realized by following a strict cycle of temperatures. The baking of carbon parts allows to improve certain properties, in particular mechanical and of resistance under hot conditions (carbon hubs : max T° resistance = 120°C for reduced engines and 170°C for direct drive engines).

The workshop has two rooms : a medium-temperature / small steam room capacity and a high-temperature / big steam room capacity, both managed by computer.

 

 

hélice e-props carbone pour ULM et paramoteurs

 

 

 

To assure a strict quality control and the reproducibility of the production, the components are exactly weighed very throughout the manufacturing. 15 weighings are necessary for a propeller for Ultralights / Aircraft.

 

E-PROPS ensures the production monitoring by RFID and KANBAN method. These methods and tools optimize the manufacturing quality, reassure and fluidify the supplies, allow the real-time follow-up of the production process, the traceability of all the manufacturing steps, and offer a set of successful and reliable indicators.

 

 

E-PROPS suivi RFIDE-PROPS suivi KANBAN

E-PROPS : production monitoring by RFID and KANBAN

 

 

The E-PROPS team has designed and built from scratch an innovative machining centre to allow the dimensional analysis, the rectification and the finish of the carbon parts automatically, without dismantling of the part. It is equipped with a directional spindle on 5-axis programmed according to the digital definition of the part, with a wide tool store. The precision of measure by the scanner laser is of 5/100th of millimeter.
The scanner sweeps the carbon part, the program recognizes it according to ts database, then the different tools come to make all the finishing work: deburring, cut, drilling, sanding and polishing. All the stages between the molds and the stock are automatic.

 

E-PROPS CNC Machining Center with Laser Scanner

functionning video

 

 

 

3-blades propeller carbon for rotax 912 s pusher weight 2,9 kg E-PROPS

Excalibur 3 - 130 propeller diameter 172 cm - weight = 2,9 kg with flange

 

 

- Centrifugal load test of a carbon E-Props propeller (propeller for direct drive engine)

Results : safety coefficient = 7,2. The system carbon hub + blade can hold 6 times the maximal load during 1 hour without any damages (EASA CS-P asks only 2 times for certified propellers).

 

 

 

high efficiency propellers

 

 

 

série de pales NG-D

 

 

carbone e-props helices propellers

 

E-PROPS HI-TECH CARBON PROPELLERS