pps proceeding - Abstract Preview
pps proceeding
Symposium: S03 - Processing Methodologies
Oral Presentation
 
 

RTM Process Monitoring with Embedded Sensors

Damm Andreas (1)*, Bahroun Karim (1), Middendorf Peter (2)

(1) Robert Bosch GmbH - Baden-Württemberg - Germany, (2) Institute of Aircraft Design, University of Stuttgart - Baden-Württemberg - Germany

High influence of ambient conditions on material properties as well as complex failure mechanisms of the consolidated part, among others, are reasons why the breakthrough in the use of fiber-reinforced plastics in automotive mass production has not yet been achieved. With their small size, high robustness and low acquisition costs, micro electromechanical systems offer great potential for integration in composite structures. This turns ordinary structures into smart ones and offers a new approach to monitor and investigate the influence of external loads on real parts. By embedding an off-the-shelf three-axis acceleration sensor with an on board temperature sensor into fiber-reinforced plastic specimens, it is possible to generate further additional digital value over the product life cycle. This work presents the sensor network, the injection process and discusses the investigated approach for flow front detection as part of an inline monitoring system. A printed circuit board, carrying three MEMS, was designed to be positioned within a heated resin transfer molding tool. Using a microcontroller, the sensor data is read and transferred to an SD card via serial communication. By analyzing the acceleration data it is possible to determine the time of impact of the resin flow front on the embedded sensors. Comparing the data of multiple sensors enables the calculation of the flow direction. By analyzing the strength of the impact and the temperature change irregularities in the textile’s positioning within the mold can be detected. Furthermore, the paper proceeds to present live data out of the consolidated structure to show the system’s potential for structure monitoring purposes.