Final Report Summary - COMPROME (Monitoring, Optimisation and Control of Liquid Composite Moulding Processes)
The main limitation of the currently existing Liquid composite moulding (LCM) manufacturing technologies in the fabrication of high quality, affordable and highly integrated aerospace structures lies in their inability to combine the available information (accurate simulations, measurements, experience and knowledge) that deals with the integrated process (resin flow and cure) into a global control system. To circumvent this limitation, the COMPROME project proposed not just the refinement and integration of existing control approaches, but the development of a revolutionary control system applicable to the production of composite materials through a wide range of LCM methods.
The proposed novel global IPC scheme brings full benefit from the use of monitoring devices and the utilisation of the existing process knowledge. The benefits to aerospace manufacturers include the manufacturing cost-effectiveness, while the global nature of the control scheme allows the fabrication of large and complex components (free of joints and bonds), thus contributing to increased safety and weight saving in the aircraft. The system promotes closed mould processing techniques, which possess significant environmental benefits due to reduced emissions in the production area.
The main output of the reporting period is the development of an integrated (flow and cure) process control system applicable in several LCM applications. The operational components of the new system are:
(i) the optimisation algorithm for the flow and cure control linked to flow simulation and cure modelling tools;
(ii) the multi-channel monitoring system with capability to handle several flow and cure sensors;
(iii) the rules for sensors and actuators placement in process tooling's; and
(iv) the experience from the lab scale implementation of every component individually.
The integrated sensors are applicable to autoclave, RTM and infusion process environment. Tests show the robustness of sensor elements and the utility in providing quality control in composites processing.
The proposed novel global IPC scheme brings full benefit from the use of monitoring devices and the utilisation of the existing process knowledge. The benefits to aerospace manufacturers include the manufacturing cost-effectiveness, while the global nature of the control scheme allows the fabrication of large and complex components (free of joints and bonds), thus contributing to increased safety and weight saving in the aircraft. The system promotes closed mould processing techniques, which possess significant environmental benefits due to reduced emissions in the production area.
The main output of the reporting period is the development of an integrated (flow and cure) process control system applicable in several LCM applications. The operational components of the new system are:
(i) the optimisation algorithm for the flow and cure control linked to flow simulation and cure modelling tools;
(ii) the multi-channel monitoring system with capability to handle several flow and cure sensors;
(iii) the rules for sensors and actuators placement in process tooling's; and
(iv) the experience from the lab scale implementation of every component individually.
The integrated sensors are applicable to autoclave, RTM and infusion process environment. Tests show the robustness of sensor elements and the utility in providing quality control in composites processing.
