Title: Development of Scalable Dynamic Control Architectures for Flexible Composites Manufacturing Work Cells

Authors: Steven M. Shewchuk, Ben Halford, Michael P. Matlack, Andrew Sharpe, and Pete Massey

DOI: 10.33599/nasampe/s.19.1391

Abstract: A work center that has the ability to simultaneously micro-manage laminate temperature and pressure and the timing of each, as well as process or material specific inputs, necessitates digital control capability. Allowing material matrix choices in both thermoset and thermoset families increases the range of required thermal flexibility. A work center was physically produced to demonstrate efficient processing of thermoset, resin infusion, thermoplastic materials on a single asset with rapid process changeover.

The Production to Functional Specification (PtFS) equipment by Surface Generation is based on a high-frequency, synchronized process controller which integrates the timing of thermal changes (both heating and cooling), consolidation pressure changes, pixelated thermal control over the entire part area, process specific triggers (i.e. vacuum and consolidation gas pressure management), and positional control. All inputs and outputs are recorded and a consolidated data output is made available to the process engineer/user, creating a unique data record that can be subsequently characterized for both real-time and historic trends. The demonstrator’s operational design and development will be discussed including lessons learned on topics such as process variable selection, rapid tool change out with pixelated thermal control, required process specific input controls, digital workspace management, thermal uniformity, and consolidation control.

References: 1. Hahn, G.L. and Tsotsis, T.K. Rapid High Performance Molding (RAPM) for Small Parts.” SAMPE 2019 Conference Proceedings. Charlotte, NC, May 20-23, 2019. 2. Massey, Pete and Halford, Ben. “Symphony Suite Training Manual v2.pdf” 19 Sept 2017 3. Ryder, A. “Enhanced Thermal Control of Mould Tooling as an Enabler for Thermoplastic Overmoulding” SAMPE Europe Conference 2018, Southampton, UK 4. Tsotsis, T.K., Wiener, M., Cespedes-Gonzales, G., Kubitz, J., Calamito, D., and Cohen, L. J. “Fabrication of a Complex Part with Deep-Draw Sections by Resin Transfer Molding.” SAMPE 2019 Conference Proceedings. Charlotte, NC, May 20-23, 2019. 5. Luchini, T.J., Rodriguez, A.J., Rogers, S.A. Hahn, G.L. “Spring Frame Press Fabrication of Aerospace Production Components.” SAMPE 2019 Conference Proceedings. Charlotte, NC, May 20-23, 2019. 6. Schell, J.J., Shewchuk, S. M., Leach, D., McCrea, T., Mecham, S., Hahn, G. L. “Rapid High Performance Molding of Structural Thermoplastic Composite Parts.” SAMPE 2019 Conference Proceedings. Charlotte, NC, May 20-23, 2019.

Conference: SAMPE 2019 - Charlotte, NC

Publication Date: 2019/05/20

SKU: TP19--1391

Pages: 15

Price: FREE