Real-Time RTM Resin Flow Control via Prediction Model
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Solution Overview
Problem
In resin transfer molding (RTM), process variables are manually adjusted without theoretical groundwork, leading to uneven resin distribution and potential defects due to non-homogeneous preforms and irregular fiber distribution, relying heavily on operator experience.
Innovation Solution
A method for real-time controlling resin flow using a prediction-control model and optimization algorithm to adjust filling pressure, which involves establishing training conditions, acquiring permeability and wave front positions, and using data mining and image capture devices to establish a prediction model for optimal filling pressure adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual adjustment of process variables is used, then operator experience can handle simple cases, but resin flow becomes uneven and product quality deteriorates due to lack of theoretical groundwork
Solution Approach 1:
The patent implements real-time feedback by measuring actual resin wave front positions and pressures during the molding process, comparing them with predicted values from the simulation model, and using this feedback to calculate and apply corrective pressure adjustments. This closed-loop feedback system transforms manual trial-and-error adjustment into a scientifically-guided process that maintains uniform resin flow and high product quality.
Solution Approach 2:
The patent dynamically changes the injection pressure parameter based on real-time process conditions. By calculating the difference between actual and simulated wave front positions, the system adjusts the injection pressure to compensate for deviations, ensuring that resin flow remains uniform even when process conditions vary. This transforms static manual pressure setting into dynamic parameter optimization.
2Device complexity
If average permeability is used for process control, then process setup is simplified, but local resin flow distribution becomes uneven causing defects
Solution Approach 1:
The patent segments the mold cavity into multiple measurement regions with distributed pressure sensors and wave front detection points. Instead of using a single average permeability value for the entire mold, the system obtains local permeability data from different regions and uses region-specific values for simulation and control. This segmentation approach captures local variations in resin flow behavior while maintaining manageable process control complexity.
3Manufacturing precision
If real-time local permeability measurement is implemented, then resin flow control precision is improved, but measurement system complexity and cost increase
Solution Approach 1:
The patent uses resin pressure as an intermediary parameter to indirectly measure permeability characteristics. Instead of directly measuring permeability which would require complex intrusive sensors in the preform, the system measures resin pressure at strategic locations and uses this pressure data, combined with simulation models, to infer local permeability information. This intermediary approach achieves precise resin flow control while avoiding the complexity of direct permeability measurement systems.
4Measurement precision
If simulation model with complete historical data is used, then prediction accuracy is improved, but data collection time and system complexity increase
Solution Approach 1:
The patent performs preliminary simulation modeling before actual production, creating a digital twin of the molding process that incorporates expected permeability values and process parameters. This pre-built simulation model provides baseline predictions that can be quickly compared with real-time measurements during production. By preparing the simulation framework in advance, the system achieves high prediction accuracy during actual molding without requiring extensive real-time data collection, thus reducing data collection time while maintaining precision.
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
Ensures consistent resin flow and improved product quality by maintaining a constant wave front velocity, reducing defects such as misruns and dry spots through data-driven adjustments.
Implementation Method 1
obtain the pressure Ps,a of the wave front at the detection position ys,a
Implementation Method 2
obtain the position of the wave front of the resin in the plane at a time point ti
Implementation Method 3
derived an equation according to the Darcy's Law, the continuous equation of incompressible fluid
Data Source
AI summary
The present invention is a method for real-time controlling a resin transfer molding process, which is used to control a filling pressure of a resin in a resin transfer molding (RTM) apparatus. In a pre-control RTM process, the current filling pressure, the current permeability and the wave front position at the current time point is input into a prediction-control model to acquire a predicted filling pressure at the next time point. The predicted filling pressure is used as the filling pressure to make the resin flow to the expected position of the wave front at the next time point, whereby to achieve stable quality of RTM products.