Fiber Composite Sensor Integration for Process Monitoring
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Solution Overview
Problem
Existing methods for producing fiber composite components face challenges in accurately monitoring production processes due to sensor contact issues and limitations in non-contact measurement methods, leading to potential internal inhomogeneities and mechanical performance problems.
Innovation Solution
Integration of a sensor device with a flexible circuit carrier and sensor module into the fiber composite component, which detects acceleration signals during production steps and performs spectral analysis in the frequency domain to derive and evaluate process parameters, optimizing production and ensuring component quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are introduced into the production tool for process monitoring, then the ability to detect production states is improved, but the sensors leave traces on the end product and may lose contact due to resin shrinkage
Solution Approach 1:
The patent uses the fiber reinforcement itself as an intermediary carrier for the sensor device. Instead of introducing separate sensors into the tool, the sensor is integrated into the fiber reinforcement structure, which then becomes part of the final component. This eliminates the need for separate sensor insertion and avoids the problems of sensor contact loss and contamination traces.
Solution Approach 2:
The sensor device is nested within the fiber reinforcement structure. The sensor is placed inside or among the fiber layers before resin injection, embedding it directly into the component structure. This nesting approach allows the sensor to remain in constant contact with the curing resin while becoming an integral part of the final product without requiring separate mounting.
2Reliability
If non-contact measurement methods are used, then the problem of sensor contact loss is avoided, but these methods cannot always be realized
Solution Approach 1:
The fiber reinforcement acts as an intermediary that physically connects the sensor to the curing resin, enabling contact-based measurement without requiring the sensor to be exposed or accessible from outside the mold. This intermediary structure allows reliable electrical or physical contact to be maintained throughout the curing process.
Solution Approach 2:
The sensor is positioned locally within specific regions of the fiber reinforcement where critical measurements are needed. This localized integration allows the sensor to measure specific parameters (such as resin infiltration, curing degree, or void formation) at key locations without requiring global non-contact measurement methods.
3Measurement precision
If spectral analysis in the frequency domain is performed on acceleration signals, then the visibility of features is improved, but the complexity of signal processing increases
Solution Approach 1:
The spectral analysis provides feedback about the production process state by identifying characteristic frequency patterns in the acceleration signals. This feedback mechanism allows real-time monitoring of resin injection, fiber impregnation, and curing processes, with the frequency domain transformation serving as an intermediate step to extract meaningful process information from the raw sensor data.
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 approach allows for real-time monitoring and optimization of production processes, enhancing the detection of acceleration signals and improving the visibility of features in the frequency domain, thereby reducing internal inhomogeneities and improving mechanical performance and reliability of the fiber composite components.
Implementation Method 1
Detecting an acceleration in relation to a production step, in particular to closing the tool and/or introducing the matrix into the tool cavity and/or impregnating the textile layers in the tool, and/or opening the tool, by means of the sensor device or the sensor module of the sensor device
Data Source
AI summary
A method for producing a fiber composite component is disclosed. A sensor device having a flexible circuit carrier and/or a sensor module is integrated in the fiber composite component. The method comprises: loading a tool configured to produce the fiber composite component with textile layers and the sensor device; closing the loaded tool and compressing the textile layers and the sensor device; introducing a liquid matrix into the closed tool and impregnating the textile layers to produce the fiber composite component; detecting an acceleration in relation to the closing of the tool and/or the introducing of the liquid matrix, using at least one of the sensor device and the sensor module of the sensor device; and determining a process state and/or a process parameter based on a spectral analysis of the detected acceleration in a frequency domain.