SENSOR AND REAL-TIME-PROCESS-SIMULATION GUIDED AUTOCLAVE PROCESS CONTROL FOR COMPOSITE PRODUCTION

Abstract

In this paper a new architecture for process control for autoclave composite manufacturing is being presented. Its aim is to match the challenges of high volume production of composite parts for aircrafts, but also for other applications such as wind turbine rotor blades and automotive structure parts. The process control is based on sensors, process simulation and a learning process database. All this information is gathered in a central communication system, where the data is processed and evaluated and finally decisions are taken if and how the process needs to be influenced. The goal is to ensure the desired quality and prevent scrap parts while reducing process time and resources. The described modules are still in development, but most of them are mature to be integrated into the process. Currently the modules and the communication center are being put together and the first test runs are in preparation. An overview is given about especially developed or adapted sensors, gathering important information about the processed part, with the focus on cure monitoring. This paper shows the development of a process simulation able to run in parallel to the real autoclave process in order to support the control decisions. All data of performed processes are saved in a database, where they are analyzed and used as experience for future processes. Finally the most important step is to evaluate the information and to take action in case of a critical process state.