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Proceso inteligente de monitorización y control de calidad online para fabricación de composites

Resumen

Tipo:
Oferta Tecnológica
Referencia:
TOGR20150717002
Publicado:
09/09/2015
Caducidad:
08/09/2016
Resumen:
Una pyme griega especializada en monitorización de procesos en el campo de fabricación de composites avanzados ha desarrollado una serie de soluciones llave en mano que incluyen sensores, unidades de medida y software de adquisición de datos para la monitorización inteligente de procesos, tanto los relacionados con el desarrollo como con la producción de composites avanzados. El sistema ofrece información en tiempo real de los parámetros importantes de procesos de relleno y curado para optimizar el proceso de fabricación in situ. Se buscan socios en las industrias aeroespacial, de automoción y energía eólica, así como organismos IDT, para establecer acuerdos de investigación y comercialización con asistencia técnica.

Details

Tittle:
Intelligent process monitoring and online quality control for composites manufacturing
Summary:
Greek SME active in the area of process monitoring for advanced composites manufacturing has developed a series of turn-key solutions including sensors, measurement units and data acquisition software for intelligent process monitoring both for the development and the production of advanced composites. The SME is seeking industrial partners from aerospace, automotive and wind energy sectors or RTD organizations for commercial agreement with technical assistance or research cooperation agreement.
Description:
The Greek SME offers a reliable and intelligent monitoring solution for the mass production of composite parts. The system provides real-time information of important parameters in regard of the filling and curing processes aiming to optimize the manufacturing process on-site. In order to achieve this result, special sensors are placed in the mold providing information on mixing ratio, resin arrival, viscosity build-up, degree of cure and glass transition temperature.

Although, dielectric analysis is considered from the scientific point of view as the most mature technology to be used for cure monitoring, is inherently suited only for laboratories, in contrast to the proposed system that is the only reliable solution for industrial use. The novel technology provides instantly the electrical resistance of the resin, while dielectric analysis always needs significant data processing before providing meaningful process parameters. It also operates with a single sensor enjoying speed and accuracy at high level, while dielectric analysis in most cases, uses multiplexing and deals with more than one sensor. Further, it is compatible with the widest range of sensors, ensuring that industrial users can have the optimal sensor for each application, etc.

In regard of flow monitoring, the proposed system is also the only dedicated solution for reliable resin arrival and temperature monitoring, since it checks and ensures continuously the connection between the monitoring system and the sensors, and provides directly resin arrival time-stamp for each sensor, while it is also capable to handle an infinite number of sensors.

The system has already been used in an R-Y-D and experimental phase by major industrial manufacturers producing lightweight structural parts for wind blades, cars, aircrafts, trains, boats etc. Further, company´s research partnerships include prestigious research centers and universities all over Europe.

The Greek SME is seeking industrial composite manufacturers addressing to aerospace, automotive and wind energy sectors or RTD organizations for commercial agreement with technical assistance or research cooperation agreement.

The company has developed a complete and unique series of intelligent monitoring systems including a wide range of sensors, measurement units and data acquisition software specially developed for advanced composites manufacturing. Moreover, the company provides turn-key solutions for process automation, prototype manufacturing systems and consulting services for composites manufacturing.
Advantages and Innovations:
The proposed system helps industrial composite manufacturers to reduce manufacturing costs:

-Decreases the cure cycle by up to 35%. Cure cycle is the time required to mold a composite part. A Decrease in the cure cycle effects on an increase on the parts each mold can produce resulting to increase of productivity and to decrease of labor and energy costs.

-Decreases the development phase time by up to 30%. In order to specify the curing process, current practices are based on trial-and-error. Being able to exactly monitor the process the system can minimize the period required to arrive to the optimal curing process. Furthermore, the filling phase can be monitored and optimized while increasing considerably the process knowledge. At the same time data for checking and updating the simulation software is also a significant advantage.

-Reduces the scrap of expensive materials by 5%. Trial-and-error involves the use of resins and carbon fibres that have to be scrapped. The absence of control during production may also lead to increased scrap rates.

The system also enables industrial composite manufacturers to improve product quality:

-Optimizes the manufacturing process. The use of process monitoring in the development phase will improve the optimal process set-up.

-Provides real-time and in-situ quality control traceability features. The monitoring of the product itself and not of the mould during production can provide the unique advantage of production traceability leading to further process optimization based on the actual conditions.

However, existing competition uses recipes in the production of composite parts, measuring only the temperature of the mould and curing time.
Stage of Development:
Already on the market
IPs:
Secret know-how

Partner sought

Type and Role of Partner Sought:
The Greek SME is seeking industrial composite manufacturers addressing to aerospace, automotive and wind energy sectors or RTD organizations for commercial agreement with technical assistance or research cooperation agreement.

Client

Type and Size of Client:
Industry SME 11-49
Already Engaged in Trans-National Cooperation:
No
Languages Spoken:
English

Keywords

Technology Keywords:
02007005 Composite materials