JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 50

mould
thick-section fibre-reinforced thermoset and thermoplastic composite components and controlling crystallinity in semicrystalline materials such as PEEK. By adding this additional functionality, the tool is transformed and becomes part of an intelligent cure process allowing largescale components to be manufactured with tailored properties (physical & mechanical) using significantly less capital equipment and reduced processing time. calibration, input and output data were logged at 1-second intervals for the duration of each test. Affixation of these to the Invar 36 Active pins was achieved using high-temperature tape and the results also logged through the PC controller (Figure 2). Testing Trials were undertaken to examine the thermal performance of the SPT pin tool with four active pins using a variety of control strategies. Experimentation was conducted to determine the overall performance of the tool and test the ability to rapidly heat and cool whilst maintaining tight thermal control across the tool face. Further testing was undertaken to assess system performance in transient control situations where requirements switch rapidly from heating to dwell, dwell to cool and back to the higher set point (e.g. simulated production). The principle objective was to understand and overcome thermal inertia issues, which would hinder rapid cycling and potentially lead to large temperature variations across the tool face. The initial trials concentrated on achieving tight temperature tolerance across the tool face through the tuning of the virtual PID controllers. After a number of iterations to optimise performance (see Figure 3), the maximum and minimum temperatures achieved across the trial zone were 180.3°C and 179.5°C respectively. As can be seen in Figure 3 below, the four active control zones (orange) are heated (2, 3, 6, 7) and the remainder (blue) are passive (1, 4, 5, 8). With further optimisation of the control strategy, a tolerance of +0.3°C/-0.5°C was achieved against a target of +/-0.5°C. Additional trials at slower ramp rates were undertaken to validate Fig. 3: +/-0.5°C test the overall performance of the temperature range at 180°C process and confirm the ability of Analysis Results were exported into a customized Excel / VB environment for filtering and analysis for comparison against previous test data and theoretical models.

Experimentation
Linked to the tool using an umbilical utility system, the four-channel heating / cooling control box, which can be seen on the right in Figure 1, was used to drive the tests by feeding air into Fig. 1: Invar 36 mould tool used to conduct the specially-designed heating and cooling trials heated pins. The underside of the tool and heating / cooling box were instrumented with the outputs being transmitted via shielded K type thermocouples. Airflow was individually set using discrete control valves, with each pin fully controllable to maintain the set point temperature within a predefined tolerance via the KS 108 controller. Bespoke PC-based control was then used to manage set points and enable sophisticated control strategies and accurate thermal management.
Fig. 2: PC-driven KS108 controller

System architecture Previously, initial testing was undertaken on a single Active SPT Invar 36 pin which was used to examine the homogeneity of system thermal performance. Using the results from this empirical testing along with theoretical models, the Active SPT pin was superseded by a 61 pin, single-sided Invar 36 tool (Figure 1) on which the heating and cooling trials were conducted. Four heated pins were embedded in an array of passive pins with an outer ring of insulating pins (blue) to prevent heat soak into the surrounding bolster and improve thermal response.

50

Results

jec composites magazine / No64 April 2011

Data Acquisition Using a multichannel Data Taker DT80 logger, 15 channels of

Fig. 4: Temperature variation during the heating cycle



JEC COMPOSITES MAGAZINE - Issue #64 - April 2011

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #64 - April 2011

Cover
Edito
Point of view: fast expansion
Contents
Agenda of Events
COMPANY & BUSINESS
In Brief
Reinforcement - Red Composites: a real expertise in carbon fibre
Housing - Housetec: a young company with a background of 40 years’ experience
Asia - Hua Dong Fibreglass, an SME that exports worldwide
APPLICATIONS
Construction - Creative eye-catching design for a new Sheraton hotel
Marine - Multiplast builds the Groupama V070
Awards - ICERP-JEC Innovation Awards Programme 2011: eight companies rewarded
MARKET
Human capital - Latest appointments
Sports and Leisure - Rossignol Group: innovation and performance in winter skis applications
FEATURE WIND ENERGY
Reinforcement - WebCore Technologies: great ambitions in the wind industry
New rovings for wind turbine blade applications
Prepreg spar caps: a solution for today
Software - Industrial software for manufacturing large components such as wind blades
Leveraging an end-to-end solution for composite wind turbine blades
Laser placement - Manufacturing rotor blades with highest precision while reducing costs
Automation - A fully-automated manufacturing process for wind blades
Maintenance - An innovative, certified blade repair system
RESEARCH & DEVELOPMENT
Testing - Using nano-scratch testing to detec composite failure
Mould - Processing technology for the rapid production of advanced composites
TECHNOLOGY & INNOVATIONS
Robot - Robotic fibre placement machine helps reduce energy consumption
Process - A new industrialized construction process for transport infrastructures
Fibre placement - Tape laying and fibre palcement: complementary solutions
NDT - What’s new in non-destructive testing labs?
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Cover
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 2
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Edito
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Point of view: fast expansion
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 5
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Contents
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 7
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Agenda of Events
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - In Brief
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Reinforcement - Red Composites: a real expertise in carbon fibre
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Housing - Housetec: a young company with a background of 40 years’ experience
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Asia - Hua Dong Fibreglass, an SME that exports worldwide
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 13
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Construction - Creative eye-catching design for a new Sheraton hotel
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 15
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Marine - Multiplast builds the Groupama V070
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 17
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Awards - ICERP-JEC Innovation Awards Programme 2011: eight companies rewarded
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 19
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 20
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 21
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 22
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Human capital - Latest appointments
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Sports and Leisure - Rossignol Group: innovation and performance in winter skis applications
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 25
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 26
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 27
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Reinforcement - WebCore Technologies: great ambitions in the wind industry
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 29
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - New rovings for wind turbine blade applications
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Prepreg spar caps: a solution for today
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Software - Industrial software for manufacturing large components such as wind blades
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 33
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Leveraging an end-to-end solution for composite wind turbine blades
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 35
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 36
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 37
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Laser placement - Manufacturing rotor blades with highest precision while reducing costs
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 39
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Automation - A fully-automated manufacturing process for wind blades
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 41
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Maintenance - An innovative, certified blade repair system
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 43
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 44
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Testing - Using nano-scratch testing to detec composite failure
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 46
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 47
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 48
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Mould - Processing technology for the rapid production of advanced composites
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 50
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 51
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 52
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Robot - Robotic fibre placement machine helps reduce energy consumption
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Process - A new industrialized construction process for transport infrastructures
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 55
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - Fibre placement - Tape laying and fibre palcement: complementary solutions
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 57
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - NDT - What’s new in non-destructive testing labs?
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 59
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 60
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 61
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 62
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 63
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 64
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 65
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 66
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 67
JEC COMPOSITES MAGAZINE - Issue #64 - April 2011 - 68
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