Fibre Bragg Grating Sensors for Composite Moulding Flow Monitoring
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Solution Overview
Problem
Current methods for producing fibre-reinforced composite components, such as those used in aircraft structures, face challenges in real-time monitoring of matrix material flow during production, especially with closed moulding tools where visual monitoring is not possible, limiting the control and quality assurance of the manufacturing process.
Innovation Solution
An apparatus employing optical Fibre Bragg Grating sensors integrated into optical fibres to monitor the flow of matrix material through the moulding tool, enabling real-time detection of temperature changes and flow front progression, which allows for precise control of the material flow and quality assurance, regardless of whether an open or closed moulding tool is used.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensor-based measuring principles (ultrasonic, capacitive, temperature, or pressure sensors) are used to monitor material flow in closed moulding tools, then measurement capability is provided, but real-time detection is not achieved because sensors can only detect changes in physical measured quantities associated with the actual advance of the flow front
Solution Approach 1:
The patent replaces mechanical sensor-based measurement systems with an optical measurement system. Optical fibres with integrated Fibre Bragg Grating sensors are inserted into the moulding tool, and light reflection characteristics are used to directly detect the position of the flow front in real-time, eliminating the time delay inherent in mechanical sensor response.
Solution Approach 2:
The patent changes the measurement parameter from physical quantities (temperature, pressure, capacitance) to optical parameters (light reflection wavelength). The Fibre Bragg Grating sensors detect flow front position by measuring changes in reflected light wavelength, enabling true real-time detection without the response delays of traditional sensors.
2Loss of time
If visual monitoring with CCD camera is used for open moulding tools, then real-time flow monitoring is achieved, but this method is not applicable to closed moulding tools
Solution Approach 1:
The patent creates a universal monitoring solution that works for both open and closed moulding tools. The optical fibre-based Fibre Bragg Grating sensor system can be deployed in any moulding tool configuration, providing real-time flow front detection capability regardless of whether the tool is open or closed, thus achieving multi-functionality.
Solution Approach 2:
The patent introduces optical fibres as an intermediary element that can be inserted into the moulding tool to bridge the monitoring capability to the material flow. These optical fibres act as mediators that transmit flow front position information from the material to the external measurement system, enabling monitoring in previously inaccessible closed tools.
3Reliability
If traditional sensor systems are used to detect material flow, then measurement is possible, but the device complexity increases and reliability decreases due to the limitations of sensor-based principles
Solution Approach 1:
The patent replaces complex mechanical sensor systems with a simpler optical system. Instead of using multiple types of physical sensors (ultrasonic, capacitive, temperature, pressure), the invention uses optical fibres with integrated Fibre Bragg Grating sensors that directly detect flow front position through light reflection, reducing device complexity while improving reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution provides reliable and accurate real-time monitoring of material flow, enhancing the production quality and efficiency by allowing immediate adjustments to the flow rate and temperature, thus ensuring consistent and high-quality fibre-reinforced composite components.
Implementation Method 1
an optical fibre into which at least one Fibre Bragg Grating sensor for detecting a parameter that is characteristic of the flow of material through the material supply line and/or the filling region is integrated
Implementation Method 2
The fibre Bragg grating is constituted by a section of the optical fibre in which the refractive index of a fibre core varies periodically, so that light of a certain wavelength is reflected by the Bragg grating structure
Implementation Method 3
an optical fibre arranged in the region of the material supply line and/or the filling region of the moulding tool
Data Source
AI summary
An apparatus for producing a component includes a material storage tank for receiving a liquid material (M), a molding tool in which a filling region to be filled with material (M) from the material storage tank is formed, and a material supply line which connects the material storage tank to the filling region of the molding tool. In the region of the material supply line and/or the filling region of the molding tool an optical fiber has been arranged, into which at least one Fibre Bragg Grating sensor for detecting a parameter that is characteristic of the flow of material through the material supply line and/or the filling region of the molding tool is integrated.