System for monitoring resin flow

Abstract

A system for monitoring of the resin front during resin infusion into a fiber preform for the manufacturing of composites. Such monitoring is based on Optical Frequency Domain Reflectometry by emitting light pulses through optic fibers which forms a resin infusion mesh in a fiber preform.

Claims

1. A system for monitoring resin flow during resin infusion into a fiber preform for manufacturing of composites, the system comprising: an optical reflectometer device configured to emit timed light pulses through optic fibers and to measure light reflected backwards; and at least one optic fiber connected to the reflectometer and arranged on or within at least a portion of the fiber preform over a determined length, wherein the at least one optic fiber is distributed so as to form a resin infusion mesh on or within the at least a portion of the fiber preform; and wherein the reflectometer is further configured to: calibrate the timed light pulses with distance based on the determined length of the optic fiber arranged on or within the fiber preform; measure a variation in the light which is reflected backwards for each light pulse emitted; and correlate a distance at which the resin reaches the at least one optic fiber of the resin infusion mesh along its determined length as resin flow advances.

2. The system according to claim 1, wherein the optical reflectometer device is configured to measure backscattering light.

3. The system according to claim 1, wherein the at least one optic fiber comprises Bragg gratings written therein at least over the determined length, and the optical reflectometer device is configured to measure light reflected from the Bragg gratings.

4. The system according to claim 1, wherein at least one optic fiber meanders the fiber preform such that said at least one optic fiber covers the portion of the fiber preform over a plurality of determined lengths.

5. The system according to claim 1, wherein the system further comprises a controller configured to receive as inputs: a geometry of the fiber preform, distribution of the optic fibers on or within the fiber preform forming the resin infusion mesh at least one determined length, and from the reflectometer, the resin front as the distance where resin flow reaches the at least one optic fiber along each of the at least one determined length; wherein the controller is further configured to modify at least one resin infusion parameter based on the received inputs during a manufacturing process.

6. The system according to claim 5, wherein the controller is configured to modify the at least one resin infusion parameter based on a predictive algorithm which checks whether a determined estimator is within an established confidence interval.

7. The system according to claim 6, wherein the controller is further configured to receive an expected pathway of the resin front determined according to the geometry of the fiber preform and distribution of the fiber optic, so that the controller is configured to modify the resin infusion parameters when the determined estimator is out of the confidence interval such that the resin front follows such expected pathway.

8. A composite manufacturing tooling, the tooling comprising: either a two-part closed mold, or a single-sided mold closed by vacuum bagging; heating equipment; an impregnation driving means; and a system for monitoring resin flow during resin infusion into a fiber preform according to claim 1.

9. The composite manufacturing tooling according to claim 8, the tooling further comprising caul plates.

10. A method for monitoring resin flow during resin infusion into a fiber preform for manufacturing of composites, the method comprising the following steps: providing a system for monitoring resin flow according to claim 1; wherein the at least one optic fiber is arranged on or within at least a portion of a fiber preform forming a resin infusion mesh; emitting by the reflectometer light pulses through the at least one optic fiber and measuring light reflected backwards; calibrating by the reflectometer, the timed light pulses with distance based on the determined length of the optic fiber arranged on or within the fiber preform; upon resin infusion into the fiber preform, measuring the variation in that light pulse which is reflected backwards for each light pulse emitted; and correlating the distance at which the resin reaches the at least one optic fiber of the resin infusion mesh along its determined length as resin flow advances.

11. The method according to claim 10, wherein the system further comprises a controller configured to receive as inputs: a geometry of the fiber preform, distribution of the optic fibers on or within the fiber preform forming the resin infusion mesh at least one determined length, and from the reflectometer, the resin front as the distance where resin flow reaches the at least one optic fiber along each of the at least one determined length; wherein the controller is further configured to modify at least one resin infusion parameter based on the received inputs during the manufacturing process, the method further comprising the step of: modifying at least one resin infusion parameter based on the received inputs during the manufacturing process.

12. The method according to claim 11, wherein the controller is configured to modify the at least one resin infusion parameter based on a predictive algorithm which checks whether a determined estimator is within an established confidence interval, the method further comprising the steps of: checking, by the controller, whether a determined estimator is within an established confidence interval set by a predictive algorithm; and modifying the at least one resin infusion parameter accordingly.

13. The method according to claim 12, wherein the controller is further configured to receive an expected pathway of the resin front determined according to the geometry of the fiber preform and distribution of the fiber optic, so that the controller is configured to modify the resin infusion parameters when the determined estimator is out of the confidence interval such that the resin front follows such expected pathway, the method further comprising the step of: modifying, by the controller, at least one resin infusion parameter when the determined estimator is out of the confidence interval in such a way that the resin front follows the expected pathway.

14. A method for manufacturing a composite, the method comprising the steps of: providing a composite manufacturing tooling according to claim 8; laying up at least one fiber preform onto the mold; arranging the at least one optic fiber on or within at least a portion of said fiber preform forming a resin infusion mesh; closing the mold by either a closing mold, or by vacuum bag; applying heat by the heating equipment; applying at least one of vacuum and pressure by the impregnation driving means; injecting or infuse the resin into the fiber preform; monitoring the resin flow during the resin infusion into a fiber preform by: emitting by the reflectometer light pulses through the at least one optic fiber and measuring light reflected backwards; calibrating by the reflectometer, the timed light pulses with distance based on the determined length of the optic fiber arranged on or within the fiber preform; upon resin infusion into the fiber preform, measuring the variation in that light pulse which is reflected backwards for each light pulse emitted; and correlating the distance at which the resin reaches the at least one optic fiber of the resin infusion mesh along its determined length as resin flow advances.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) These and other characteristics and advantages of the invention will become clearly understood in view of the detailed description of the invention which becomes apparent from a preferred embodiment of the invention, given just as an example and not being limited thereto, with reference to the drawings.

(2) FIG. 1 shows a schematic arrangement of an optic fiber on or within at least a portion of a fiber preform.

(3) FIG. 2a shows a particular embodiment of the variation measure in the reflected light for a light pulse emitted during the calibration step vs. the length of the optic fiber shown in FIG. 1.

(4) FIG. 2b shows a particular embodiment of the variation measure in the reflected light for each light pulse emitted vs. the length of the optic fiber shown in FIG. 1.

(5) FIG. 3 shows different pictures at different times recorded by a video camera with the progression of the resin front through the fiber preform shown in FIG. 1.

(6) FIG. 4 shows the results for each determined length of the optic fiber shown in FIG. 2, as well as results from the video camera plotted separately vs. time.

(7) FIG. 5 shows a plot of Darcy's Law with the advance of the resin front vs. the optic fiber length for a portion thereof.

(8) FIG. 6 shows a schematic illustration of an optic fiber within a fiber preform in a mold of the system of an embodiment of the present invention having a single-sided mold enclosed by a heater and vacuum bagging.

(9) FIG. 7 shows a schematic illustration of a side view of a two-part closed mold, with caul plates, in an embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(10) As it will be appreciated by one skilled in the art, aspects of the present description may be embodied as a system (10), a composite manufacturing tooling (11) or a method.

(11) As it was mentioned, the present invention provides a system (10) capable to identify anomalies in the resin front (2) and, as a consequence, the global production system—by the interfaces between production controls and this monitoring system (10)—may modify in situ the injection parameters to correct, offset or compensate the potential defects (such as porosity) in the finished parts.

(12) FIG. 1 depicts an example of schematic arrangement of an optic fiber (1) on or within at least a portion of a fiber preform (3). For illustrative purposes, only one optic fiber (1) is shown.

(13) The fiber preform (3) schematically shown in top view are five composite fabric layers (unidirectional fabric layers) with dimensions of 250×290 mm. Furthermore, the optic fiber (1) meanders such fiber preform (3) such that the at least one optic fiber covers the portion of the fiber preform over three determined lengths, named as (A), (B), and (C).

(14) These determined lengths (A, B, C) or segments of the optic fiber coming in and out the fiber preform cover:

(15) Determined length (A) from 0.7413 to 0.942 m. of the fiber optic (1),

(16) Determined length (B) from 1.4304-1.231 m. of the fiber optic (1), and

(17) Determined length (C) from 1.8327 to 2.050 m. of the fiber optic (1).

(18) For infusing the resin into the fiber preform (3) for the composite manufacturing, the composite manufacturing tooling (11) comprises a single-sided aluminum mold (plate) (12) closed by vacuum bagging (13). The vacuum bagging (13) allows seeing through, so a video camera (14) may record the resin front (2) throughout the resin infusion process as will be explained in FIG. 3 for comparative purposes.

(19) FIGS. 2a and 2b depict the actual variation in the reflected light measured for each light pulse emitted by the reflectometer (18) vs. the length of the optic fiber detailed in FIG. 1. Particularly in these figures, the backscattered light measured by the optical reflectometer device (18) is depicted. Light reflected backwards may come from the scattering over the length of the fiber optic or from the light reflection from Bragg gratings (28) written previously in the optical fiber (1).

(20) The backscattering of the optic fiber vs. distance before injection enables the calibration of the timed light pulses with distance based on the three determined lengths (A, B, C) of the optic fiber (1) arranged with the fiber preform. That is, without resin infused yet, the backscatter peaks (16) shown in the graph of FIG. 2a correspond to the edges (3.1) of the fiber preform (3) where the meandering optic fiber (1) comes in or out. In another particular embodiment, the at least one optic fiber (1) comprises Bragg gratings (28) written therein at least over the determined length and the optical reflectometer device (18) is configured to measure light reflected from the Bragg gratings.

(21) Comparison between the initial situation (FIG. 2a) and over the time (FIG. 2b) provides the precise location of the resin flow front (2).

(22) FIG. 2b shows the amplitude of the intensity in reflected light signal for the different fiber determined lengths. As it may be seen, the three determined lengths of FIG. 1 (identified as (A), (B) and (C)) correspond to each of the ‘wells’ in FIG. 2b.

(23) Upon injection/infusion starts, as the resin front (2) advances, it gradually reaches the optic fiber (1)—of the resin infusion mesh—along its determined lengths (A, B, C), the optical backscattering of the optic fiber is progressively modified and the measurement of the backscattering variation allows the following of the evolution of the resin flow front (2) inside the mold.

(24) The evolution of the optical backscattering response over the injection time can be seen separately for each determined length (A), (B) and (C). Therefore, for this example where uniform resin front (2) is expected, if resin position in each determined length is seen unbalanced, it may entail race tracking.

(25) The measurements of FIG. 2b show a baseline (15) from which respective peaks (16) project. These peaks (16) may be associated to edges (3.1) of the fiber preform (3) or ends of the determined distances in FIG. 2a, as well as the resin front (2) in FIG. 2b. As it can be seen, the evolution of the optical backscattering response is a displacement of the peaks (16) shown in FIG. 2b, while the baseline (15) is an indicator of the temperature inside the mold.

(26) The coincidence or intersecting points between the baseline (15) and the peaks (16) once the injection has begun inside the mold determines the subsequent positions of the resin front (2). Therefore, by detecting the intersecting points of all the peaks (16) of each of the graphs with the baseline (15), the resin front (2) advancement is monitored. This resin front (2) evolution (inferred by the peaks (16)) is represented in FIG. 2b.

(27) As the resin front (2) advances, these peaks (16) may distort and become difficult to identify the exact point where the resin front locates as the peaks (16) are less abrupt or do not distinguishably intersect the baseline (15). A relation between intersection point with the baseline (15) and inclination of the peak (16) will be described in the following for the correct identification of the resin front.

(28) The resin flow front flow (2) has been monitored not only by variation of the optic fiber (1) backscattering, but also by a video camera (14) for correlating the results. FIG. 3 shows a set of instant pictures at different times recorded by the video camera (14) with the progression of the resin front (2) through the fiber preform (3).

(29) The dark area corresponds to the portion of the fiber preform (3) where resin has impregnated, while the lighter area is still dry fabric. It can be further seen that there is a uniform resin front (2), so no race tracking has taken place.

(30) In FIG. 4, the measurements of both technologies (the reference video camera, and the system (10) according to the invention) have been plotted together. It is shown that the backscattering measurements from optic fiber (1) reproduces the logarithmic expression that usually defines resin advancement (2). Results for each determined length of the optic fiber shown in FIG. 2 have been plotted separately.

(31) The light pulses emitted by the reflectometer (18) and video camera recording have been time synchronized and switch-on simultaneously. Thus, the reliability of the distributed fiber data is demonstrated. In particular, the reference position of determined length B has been taken for the video camera recording in the present experiment, in other words, it has been taken how resin front advances along the middle point of the fiber preform.

(32) As it was mentioned, the system (10) of the present invention may further comprise a control unit (20) configured to receive inputs about the fiber preform geometry and optic fiber(s) distribution as well as the resin front from the reflectometer (18). Based on these received inputs, the control unit (20) modifies at least one resin infusion parameter during the manufacturing process.

(33) The control unit (20) functioning is based on a predictive algorithm checking whether a determined estimator calculated by the results of FIG. 2b is within an established confidence interval.

(34) This predictive algorithm utilizes a multiple regression model and calculation by least squares of the estimators. The estimators are the slope of the peaks (16) and the intersection with the baseline (15), and are calculated by matrix operations.

(35) Therefore, these points that identify the resin front position for each light pulse emitted by the reflectometer (18) are expected to be within a confidence interval established in the predictive model. If so, i.e., if the next measurement corresponding to the next light pulse emitted by the reflectometer (18), particularly the point intersecting the baseline for each determined length of the optic fiber, is within the confidence interval (i.e., with α=0.05), the same adjustment is used for next point. However, if the next detected point is not within the confidence interval, two possible options may be followed: i. either modifying the infusion parameters from the ports so that the resin front follows the adjustment of the previous behavior; or ii. selecting this point as the new valid point and then estimating the following point according to the new curves that include this point.

(36) For N observations (where the ‘observations’ are the group of points for each of the curves of FIG. 2b, that is, each light pulse), the regression straight line has n+1 estimating parameters as follows:
y=X.Math.β+u

(37) Where ‘y’ is the response vector, ‘X’ the matrix of experimental variables, ‘β’ the parameter vector containing each of the estimators belonging to each of the variables or the observations, and ‘u’ is an error vector associated with the adjustment.

(38) In addition, the vector of estimator parameters is as follows
{circumflex over (β)}=(X.sup.TX).sup.−1X.sup.T.Math.y

(39) If the adjustment is given, the response vector (‘y’) for ‘X’ observations is estimated as follows:
ŷ=X.Math.{circumflex over (β)}

(40) Wherein symbol ‘{circumflex over ( )}’ denotes ‘estimated’. Moreover, by having a point (x, y), the deviation from the value predicted by our linear regression adjustment can be determined.

(41) This deviation or distance being defined as:
e=y−ŷ

(42) Wherein ‘y’ is the experimental value and ‘ŷ’ is the estimated value.

(43) By analyzing the variance with the new estimated point, and further using the statistical hypothesis set by p-value, the significance of the model may be determined within a determined level of significance alpha (particularly, α=0.05). This calculation not only validates the model but also corroborates the high correlation of the variables that participate in the inference process (x.sub.i, y.sub.i).

(44) On the other hand, by calculating the confidence interval of a new estimated point with the former significant model, it can be determined which points are to be within that confidence interval and thus, in case the point of intersection is not clear for instance due to signal smearing, estimating it within the confidence interval.

(45) This prediction assist in knowing which parameters need to be controlled (speed, pressure, temperature, etc.) in case the new experimental point within the predictor model is not known.

(46) All these estimations are repeated for each of the experimental points detected allowing those fuzzy (due to the experimental deficiencies discussed above) to be further studied. Therefore, the advancement of the resin front (2) is accurately defined and reducing the error in the points of intersection with the baseline (15).

(47) The advance of the resin front by the points of intersection in the first determined length (A) of FIG. 2b is represented by the curve shown in FIG. 5. It corresponds to a potential adjustment or Darcy's Law accounting the advance of the resin front.

(48) As from the intersecting points shown in FIG. 5, the advance of the fluid front may be estimated in case such points of intersection are not totally clear. In this scenario, for the adjustment, a non-linear statistical inference (Xn type, with n approximately 0.5 if the advance is deemed correct) may be performed.

(49) It should be noted that the final part of the resin front is where the fuzziest points may be seen, and therefore the adjustment needed, particularly for the final 20% of the resin front through the fiber preform. In that portion, new points and their errors should be estimated deciding whether to act in order to correct the resin front advance. Similarly, in the event that none of the curves intersect, the previous optimization method may be used to determine the proper intersection and therefore calculate the point of the advance of the resin front in that area of the fiber preform.

(50) It is furthermore noted that a high correlation in how the resin front advances along the different determined lengths of the optic fiber (1) entails a more homogeneous resin front.

(51) In a second inventive aspect, the invention provides a composite manufacturing tooling (11), the tooling comprising either a two-part closed mold (30)(FIG. 7), or a single-sided mold (12) (FIG. 6) closed by vacuum bagging (13); optionally, caul plates (32); heating equipment (24); an impregnation driving means (26); and a system (10) for monitoring resin flow during resin infusion into a fiber preform according to any of the embodiments of the first inventive aspect.

(52) While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms “comprise” or “comprising” do not exclude other elements or steps, the terms “a” or “one” do not exclude a plural number, and the term “or” means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority.