Sustainability & Industry 4.0

The replacement of metallic reinforcement layers in the multilayer structure with thermoplastic FRP offers a viable solution to address sustainability concerns. Enhancing the longevity of a LATW/LATP product necessitates improved production quality, particularly in terms of bond strength achieved through precise control of the nip-point temperature. To mitigate the costs associated with trial and error, the implementation of a simulation tool becomes indispensable. This can only be achieved by employing a physics-based model, representing a sustainable development in the production cycle aimed at regulating this process. The comprehensive automation procedure serves as the ultimate output solution derived from the LATW/LATP simulation model, propelling LATW/LATP production to the forefront of sustainability. As a result, this approach minimizes waste and enhances the overall quality of the final product, thereby benefiting society, the economy, and natural resources. It fosters a harmonious relationship with nature and contributes to a prosperous existence.

Adaptive nip-point tracking with the thermal camera

Controlling the nip-point temperature only helps if it is measured in the right place. On a moving laser head the nip point shifts from frame to frame, so a probe fixed at one position in the thermal image soon reports the tape or the substrate instead of the bond line. In one and the same IR frame, probes placed on the tape, on the nip-point and on the substrate can differ by tens of degrees — which is exactly the uncertainty that leads to repeated trials.

OTOM therefore tracks the nip point adaptively. Feature tracking follows the geometry through the recorded thermal frames so that the probes travel with the nip point instead of standing still, learning frames are used to keep the trace stable, and the simulated nip point from the physics-based model is overlaid on the measurement for direct comparison. The resulting temperature trace can be exported frame by frame and used with confidence for process settings and feedback control.

This is a sustainability gain as much as a quality one. A nip-point temperature that is measured where it actually occurs removes a large part of the trial-and-error lay-ups, and with them the scrapped tape, the machine hours and the energy those trials consume — while a correctly consolidated bond line extends the service life of the LATW/LATP product itself.

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