Resin Infusion Timing Control for Multi-Mould Constant Flow
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Solution Overview
Problem
Current resin infusion processes struggle to simultaneously fill multiple moulds with a constant resin flow, leading to inefficiencies and increased manufacturing time, particularly in aerospace applications where weight and resistance balance are critical.
Innovation Solution
A method involving classifying moulds by volume, estimating filling times, and using a PID control loop to maintain a constant resin flow rate by adjusting the tank pressure, allowing for sequential and simultaneous filling of moulds while avoiding the need to control pipe diameters or distribution line sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sequential filling of moulds is used, then manufacturing time increases, but resin flow control becomes simpler
Solution Approach 1:
The system pre-calculates the filling time for each mould based on its volume and the constant flow rate, then schedules the opening of distribution line sections sequentially. This preliminary planning allows multiple moulds to be filled simultaneously without complex real-time control, as the timing is predetermined to ensure all moulds complete filling at the same time.
Solution Approach 2:
The system dynamically opens and closes distribution line sections in a controlled sequence. By making the distribution system dynamic rather than static, the process can adapt to different mould volumes and achieve simultaneous completion of filling for all moulds, thereby reducing total manufacturing time while maintaining constant resin flow from the tank.
2Productivity
If simultaneous filling of multiple moulds is implemented, then productivity increases, but control of resin flow rate becomes more difficult
Solution Approach 1:
The distribution system is segmented into multiple independently controllable line sections, each leading to a different mould. By segmenting the distribution network and controlling each section's opening/closing timing, the system can distribute resin to multiple moulds simultaneously while maintaining a constant overall flow rate from the resin tank, simplifying the control problem.
Solution Approach 2:
The system uses feedback from pressure sensors and flow meters to monitor the resin infusion process in real-time. This feedback allows the control system to adjust the timing of distribution line section openings and closings, ensuring that all moulds complete filling simultaneously while maintaining constant resin flow from the tank, thus improving ease of operation.
3Ease of operation
If pipe diameter control is used to regulate resin flow, then flow rate control is achieved, but device complexity and difficulty of automation increase
Solution Approach 1:
The system replaces mechanical pipe diameter adjustment (pinching/throttling) with a timing-based control system that opens and closes pre-positioned distribution line sections. This substitution eliminates the need for complex mechanical adjustment mechanisms, making the system easier to automate while maintaining precise control over resin flow distribution to multiple moulds.
Solution Approach 2:
The system introduces distribution line sections as intermediary elements between the resin tank and the moulds. These sections act as controllable gates that can be opened or closed at predetermined times, providing a simple binary control mechanism instead of continuous pipe diameter adjustment, thereby reducing device complexity while maintaining flow control capability.
4Manufacturing precision
If constant resin flow rate is maintained, then resin distribution uniformity improves, but ability to adapt to different mould volumes decreases
Solution Approach 1:
The system pre-calculates the filling time for each mould based on its volume and the constant flow rate, then schedules the opening of distribution line sections accordingly. This preliminary timing adjustment allows the system to maintain constant resin flow rate (improving distribution uniformity) while adapting to different mould volumes by varying the start time of each mould's filling process.
Solution Approach 2:
The system dynamically adjusts the timing of distribution line section openings based on mould volume requirements. By making the control system dynamic rather than static, it can maintain constant resin flow rate for uniform distribution while adapting to different mould volumes through temporal adjustment, thus resolving the contradiction between precision and adaptability.
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 enables efficient, simultaneous filling of all moulds, minimizing air bubbles and reducing manufacturing time, thereby improving the quality and efficiency of composite parts production.
Implementation Method 1
The method comprises performing the step of actuating on a pressure pump of the tank in order to achieve a target value of the pressure, P 0 , within the tank, this target value of the pressure, P 0 , within the tank allowing to keep a constant flow rate, Q, flowing out from the tank
Implementation Method 2
calculating a PID control command, u(t), derived from the calculated difference, e(t), and; inputting the control command, u(t), into an actuator acting on pressure pump of the tank
Implementation Method 3
establishing a predetermined value, Q, for the resin flow rate flowing out of the tank and which is to be kept constant; calculating a target pressure value, P 0 (or r(t)), in the tank, derived from the predetermined value, Q; measuring the actual pressure value, y(t) (or P(T)), within the tank
Data Source
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AI summary
Method of controlling a resin infusion process comprising infusing a resin flow from a resin tank (1) into a plurality of moulds (2); classifying the moulds (2) according to their respective volumes, and; sequentially filling the moulds (2) with resin, starting from the mould (2) with the highest volume; wherein the method involves estimating the time that it takes to completely fill with resin each mould (2) of the plurality of moulds (2), and; after having begun with the resin infusion into the mould (2) with the highest volume, starting the resin infusion in a further particular mould (2) when the estimated time remaining for the complete filling of the mould (2) with highest volume equals the estimated time for the complete filling of that further particular mould (2) of the plurality of moulds (2).