Online optimisation and active control of the cure process of thick composite laminates

This paper addresses the development of an active control tool for the in-situ optimisation of the cure process of thick composite parts. The methodology integrates a cure process model with real time monitoring data exploring potential temperature dwells that accelerate the curing while avoiding undesirable thermal gradients. The cure process simulation is based on a Finite Element (FE) model solution validated in the curing of a thick composite flat panel with an average absolute error of about 1.8 degrees C. The active control tool interacts PID controller of an oven setting a new cure temperature periodically. The implementation of active control tool during the curing of a thick carbon fibre/epoxy cable has the capability to determine in real time optimal solutions minimising process duration whilst also satisfying constraints in temperature overshoot. A process duration reduction of about 70 % can be achieved compared to a nominal cure cycle with a maximum temperature overshoot lower than 9 degrees C. The active control tool can replace off-line optimisation tools exploiting in situ with real time monitoring to drive the process and minimise the effects of uncertainty.

Automated summary

This paper presents the development of an active control tool for in-situ optimization of the cure process of thick composite parts. The tool integrates a cure process model with real-time monitoring data to explore temperature dwells that can accelerate curing while avoiding thermal gradients. The active control tool, which interacts with a PID controller of an oven, can significantly reduce process duration and temperature overshoot compared to a nominal cure cycle.