COMPROME - Aeronautics Days 2006
COMPROME - Aeronautics Days 2006
COMPROME - Aeronautics Days 2006
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<strong>COMPROME</strong>EC funded research projectFP 6 - <strong>Aeronautics</strong> & SpaceMonitoring, Optimisation and Controlof Liquid Composites Moulding ProcessesPresented by Dr. George MaistrosINASCO Hellas & <strong>COMPROME</strong> ConsortiumAST3-CT-2003-502900:Monitoring, Optimisation and Control of LiquidComposite Moulding Processes<strong>Aeronautics</strong> <strong>Days</strong> <strong>2006</strong>Vienna, 19-21 June 06
Project partners:<strong>COMPROME</strong> Consortium1. INASCO Hellas (co-ordinator)2. Technika Plastika SA3. Polyworx vof4. ISOJET Equipements5. Israel Aircraft Industries Ltd.6. INASMET Fundacion7. KEMA Nederland b.v.8. National Technical University of Athens9. Bombardier UK10. Kok & van Engelen Composite Structures b.v.11. Laser Zentrum Hannover‣ Complementarity of expertise‣ Balanced research developmentand industrial application‣ 7 countries‣ 2 A/C manufacturers‣ 5 SMEs‣ 3 Research institutes‣ 1 University‣ Total budget: 3.26 MEuro‣ Total funding: 1.82 MEuroAST3-CT-2003-502900:Monitoring, Optimisation and Control of LiquidComposite Moulding Processes<strong>Aeronautics</strong> <strong>Days</strong> <strong>2006</strong>Vienna, 19-21 June 06
Current trends in manufacturing aerospace partsIndustry drivers for aerospace components productionusing Liquid Composite Moulding (LCM) techniques:‣ Weight ‣ Parts complexity and integration ‣ Manufacturing costs ‣ Quality Integrated (flow and cure) Process Control (IPC)Integrated (flow and cure) Process Control (IPC)In LCM will serve needs and satisfy demands !AST3-CT-2003-502900:Monitoring, Optimisation and Control of LiquidComposite Moulding Processes<strong>Aeronautics</strong> <strong>Days</strong> <strong>2006</strong>Vienna, 19-21 June 06
The elements of integrated process controlReal-time robustmonitoring ofmaterial propertiesin LiquidCompositeMoulding (LCM)processes bymeans of toolmounted sensorsand linkedprocess simulationtoolsAST3-CT-2003-502900:Monitoring, Optimisation and Control of LiquidComposite Moulding Processes<strong>Aeronautics</strong> <strong>Days</strong> <strong>2006</strong>Vienna, 19-21 June 06
Benefits to aerospace industryIPCContinuous and robust monitoring of material propertiesin Liquid Composite Moulding (LCM) processes bymeans of permanently attached in-mould sensors andlinked process simulation toolsImproved Quality‣ Composite materials with‘process signature’‣ Secured closed mould fillingprocedures‣ Increased production reliabilityCost effectiveness‣ Reduction of scrap‣ Shorter process cycles‣ Efficient process development‣ Elimination of post-process testingAST3-CT-2003-502900:Monitoring, Optimisation and Control of LiquidComposite Moulding Processes<strong>Aeronautics</strong> <strong>Days</strong> <strong>2006</strong>Vienna, 19-21 June 06
Main target<strong>COMPROME</strong> Project ObjectivesDevelop a revolutionary control system applicable to the production ofcomposite materials through a wide range of LCM methodsDevelopment plan1. an integrated, durable and tool-mounted dielectric sensor2. modular monitoring system with embedded knowledge3. process control strategy interacting with simulation tool and actuators4. global integrated process control (IPC) system5. the manufacturing aerospace components with cost-effectiveness andimproved qualityAST3-CT-2003-502900:Monitoring, Optimisation and Control of LiquidComposite Moulding Processes<strong>Aeronautics</strong> <strong>Days</strong> <strong>2006</strong>Vienna, 19-21 June 06
<strong>COMPROME</strong> Innovative CharacterMain innovations‣ integrated, durable and tool-mounteddielectric sensor cluster‣ multi-sensor real-timemonitoring system‣ interfacing composites process simulation toolswith actuators and the monitoring system‣ intelligent guidance of the manufacturing stage at a predefinedpath of global process conditions towards given final stateAST3-CT-2003-502900:Monitoring, Optimisation and Control of LiquidComposite Moulding Processes<strong>Aeronautics</strong> <strong>Days</strong> <strong>2006</strong>Vienna, 19-21 June 06
<strong>COMPROME</strong> TechnologiesDielectric sensors for LCM manufacturinginterdigital sensing elementsElectric fieldElectrodeWL1.4DDt0.9-10.8-0.90.7-0.80.6-0.70.5-0.60.4-0.50.3-0.40.2-0.30.1-0.20-0.1electricfieldmodelling4.0E-043.6E-043.2E-042.8E-042.4E-042.0E-041.6E-041.2E-048.0E-05y (m)Sensordesigntooldurablesensorsrobust toolmounting4.0E-05Potential (V)0.0E+001.5E-053.0E-054.5E-056.0E-057.5E-059.0E-050.0E+00x (m)AST3-CT-2003-502900:Monitoring, Optimisation and Control of LiquidComposite Moulding Processes<strong>Aeronautics</strong> <strong>Days</strong> <strong>2006</strong>Vienna, 19-21 June 06
<strong>COMPROME</strong> TechnologiesMonitoring system for LCM manufacturing‣ modular architecture, multi-functional operation‣ connectivity to industrial equipmentResinelectricalpropertiesMonitoringstrategyMultiplexingof sensorsIndustrialmonitoringsystemprocessequipmentNetworkingcapabilitiesAST3-CT-2003-502900:Monitoring, Optimisation and Control of LiquidComposite Moulding Processespilot stage<strong>Aeronautics</strong> <strong>Days</strong> <strong>2006</strong>Vienna, 19-21 June 06
<strong>COMPROME</strong> Project StructureWP7[M8]Implementation tolaboratoryscale andevaluationWP1 [M2]Development offlow sensing systemWP3 [M4]Development ofcomponentsfor flow controlWP5 [M6]Realisation of process controlWP2 [M3]Development ofintegratedsensing systemWP4 [M5]Development ofintegrated controlsystemPeriod P1Period P2WP0[M1.1,M1.2,M1.3,M1.4]Each workpackagedeals with a singleitem in thedevelopment planWP8 [M9]PilotimplementationsWP6 [M7]Development of globalIPC systemProjectManagementPeriod P3WP9 [M10]Learnt lessons - exploitationAST3-CT-2003-502900:Monitoring, Optimisation and Control of LiquidComposite Moulding Processes<strong>Aeronautics</strong> <strong>Days</strong> <strong>2006</strong>Vienna, 19-21 June 06
<strong>COMPROME</strong> ResultsDielectric integrated sensors in RTMRTM flow & cure monitoring resultMould filling and resin cure effectsMould filling and resin cure effectsAccurate Accurate measurements measurements of ofresin resin arrival arrivalat at switch switch locations locationsgiving giving flow flow direction direction and and speed speedCorrelation Correlation between between DC DC resistance resistanceand and resin resin viscosity viscosityProved benefits: in situ resin flow measurementProved benefits: in situ resin flow measurementAST3-CT-2003-502900:Monitoring, Optimisation and Control of LiquidComposite Moulding Processes<strong>Aeronautics</strong> <strong>Days</strong> <strong>2006</strong>Vienna, 19-21 June 06
<strong>COMPROME</strong> ResultsDielectric cure sensors in RTI installationSensor installedin autoclave• study of aging effect on cure progress• resin arrival and cure progress leading to shorter process cycleAST3-CT-2003-502900:Monitoring, Optimisation and Control of LiquidComposite Moulding Processes<strong>Aeronautics</strong> <strong>Days</strong> <strong>2006</strong>Vienna, 19-21 June 06
<strong>COMPROME</strong> – Next steps‣ Dielectric sensors for flow and cure measurements are testedfor durability and robustness in RTM moulds, vacuum infusionand resin transfer infusion (RTI) processes‣ The aerospace resin systems proposed by the A/Cmanufacturers will be modelled to produce the material statetranslator‣ The required tools for flow and cure control are underconstruction‣ The lab scale RTM implementation is scaled up withintegrated control technology‣ The system installation at the end user pilot cases is about tostart based on the proposed fabrication applicationsAST3-CT-2003-502900:Monitoring, Optimisation and Control of LiquidComposite Moulding Processes<strong>Aeronautics</strong> <strong>Days</strong> <strong>2006</strong>Vienna, 19-21 June 06
Thank you for your attentionCurrent project outcomes are displayedat the <strong>COMPROME</strong> standnext to Gate 1 conference roomAST3-CT-2003-502900:Monitoring, Optimisation and Control of LiquidComposite Moulding Processes<strong>Aeronautics</strong> <strong>Days</strong> <strong>2006</strong>Vienna, 19-21 June 06
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