Australia and Germany have jointly established the Composites 4.0 production line to gain a competitive advantage in the next-generation manufacturing and labor market. #outofautoclave#Trend#Special report
Swinburne University of Technology (Melbourne, Australia), in cooperation with the Australian National Bureau of Science and the Commonwealth Scientific and Industrial Research Organization (CSIRO), has established an Industry 4.0 test laboratory for composite additive manufacturing. Please refer to “Developing higher quality, more High-strength, lower-cost products”. Carbon fiber”). The facility is currently under construction at CSIRO’s Clayton site and will be completed in October 2020.
With the support of the Australian Federal Government, the composite industry 4.0 testing laboratory is one of the six laboratories in the Australian national network, similar to the Labs Network Industrie 4.0 in Germany. The Testlab is the first national agency in the state network, and its goal is to enable small and medium-sized enterprises (SMEs) to test new technologies and business models from industry 4.0 to testing, from design to economic feasibility, before competition. An environment with minimal technical and financial risks. Each Testlab has a distinctive product focus. For Swinburne, this is additive manufacturing of composite materials.
Bronwyn Fox, Vice-Chancellor of Research and Enterprise at Swinburne University, said: “Swinburne’s Industry 4.0 Composites Testing Laboratory will provide a pilot-scale process to improve Australia’s manufacturing capabilities.” Fox said Joined Swinburne in 2015, initially as the director of Factory of the Future, and then as the director of the University’s Manufacturing Futures Institute. Before joining Swinburne, she was Director of Research at Carbon Nexus at Deakin University.
“Swinburne’s Testlab will demonstrate the capabilities of digital composite production in an immersive environment,” Fox said. “From part design and optimization to the final product, the pilot scale process will be digitally controlled. We will also create a digital twin of the process and break the boundaries of virtual commissioning.”
The composite 4.0 hub will be installed in the new custom building. Dr. Marcus Zipper, Executive Director of CSIRO’s Future Industries Division, said: “CSIRO/Swinburne Testlab is jointly committed to the world’s first process of industrial-scale carbon fiber reinforced composite additive manufacturing.” “This places it in the Clayton Additive Manufacturing Zone. The location of the center is very suitable. At CSIRO, we are committed to creating opportunities for SMEs and the broader innovation ecosystem, and this Testlab is an example of this.”
The Industry 4.0 Composites Testing Laboratory has many key partners. Among them, Siemens Australia (Bayswater, Victoria) was one of the first partners. In 2017, the company awarded Swinburne a $135 million digital software grant. This provides a set of advanced functions for Composite 4.0 Testlab. Product lifecycle management (PLM) software and MindSphere, an open Internet of Things (IoT) platform based on Siemens Cloud.
According to Siemens Australia, as of August 2019, there are approximately 500 digital applications/products and 1.4 million interconnected devices and systems in MindSphere. Fox explained in ICCM22′s speech “Industry 4.0 Methods for Composite 3D Printing”: “MindSphere will enable devices from a wide range of manufacturers to communicate with each other.” This article describes how Swinburne Industry 4.0 Testlab will run:
“Sensors… will enable each stage of the production line to collect a large amount of process data. This information will be stored in a secure local cloud and will also be immediately used to feed forward and feed production data to other machines in the production line, thereby achieving Adaptive production process.
The proposed production line… aims to allow product inspections after each stage of the manufacturing process. The inspection data will also be stored in the local cloud. The analysis of large data sets stored in the cloud may lead to the discovery of new and unexpected associations between the state of the finished product and the parameters at different stages of the manufacturing process, which can then be used to optimize the product. ”
Pilot production line of Swinburne University’s Industry 4.0 Composite Additive Manufacturing Test Laboratory. Source | Swinburne University
Fox also pointed out that the Industry 4.0 composite material production line cannot be purchased directly. Therefore, Swinburne has established a network of suppliers and end users to inform its Composites 4.0 Testlab equipment and facility design and development. Partners that provide key components include:
FILL (Gurten, Austria) provides a multi-layer system that stacks precisely cut and oriented unidirectional fiber tapes into an approximate mesh with a size of 1.6 x 1.6 meters. The use of tape close to the final shape can reduce waste from more than 60% to less than 10%. The tape is placed on the turntable from the spool, and one layer is completed every 15 seconds. Fox pointed out that Fill’s Multilayer machine can lay thermosetting prepregs and tow prepregs, as well as tapes of dry fibers and low-melting thermoplastics such as polyamide (PA). High melting point thermoplastics are currently being developed, such as polyether ether ketone (PEEK) and polyether ketone ketone (PEKK). She added: “Multi-layer machines can also achieve mixing materials, such as mixing glass fiber and carbon fiber, and mixing with natural fibers.”
Quickstep (Sydney, Australia) is Australia’s largest independent aerospace-grade advanced composite material manufacturer, providing extensive expertise in autoclave curing and autoclave (OOA) composite materials. Quickstep’s patented OOA system Qure and its high-performance version AeroQure for aerospace applications is an advanced composite material manufacturing process that has significant advantages over traditional manufacturing techniques (such as autoclave curing), including :
Qure uses pressurized circulating heat transfer fluid (HTF) to support the mold and quickly heat and cool parts. Lower pressure treatment (vacuum up to 2.5 bar) is conducive to reducing mold costs. The rapid heating of molds and materials reduces process viscosity and improves air release and fiber wettability. The lower viscosity can improve the adhesion to the honeycomb core and the foam core, thereby increasing the peel strength and reducing the core fragmentation during curing. Even for thick laminates that are prone to exothermic reactions, HTF can still achieve excellent thermal control.
The Qure process uses a pressurized circulating heat transfer fluid (HTF) to support the mold and rapidly heat and cool parts. Source | Quick Steps
Langzauner (Lambrechten, Austria) is supplying a high-temperature, automated press with a clamping force of up to 300 tons that can perform a variety of processes-from resin transfer molding (RTM) to thermoforming. It will be able to inject resin into dry preforms and then perform curing or compression molding of thermosetting and thermoplastic prepregs.
The press achieves energy efficiency/savings through a servo hydraulic system, and can achieve the highest accuracy with single piston control even under asymmetric loads. The high-performance infrared (IR) oven can quickly heat the material to the required processing temperature, and a separate radiator control system is used to compensate for different thicknesses. The linear axis ensures that the preheated material is quickly transferred to the press station. The high-temperature platen heating system can mold parts at a temperature of at least 400°C to suit the processing of advanced thermoplastics such as polyether ether ketone (PEEK).
The printer also has the function of a double diaphragm frame (see the blog about double diaphragm forming in 2020). Flexible, powerful and user-friendly software ensures the highest degree of digitization and monitoring.
NETZSCH (Selb, Germany) will provide in-mold curing monitoring technology, which will be able to control the manufacturing of composite materials based on material properties.
Plataine (Israel) provides digitization, optimization and digital twin software for composite manufacturing, which can track tools, parts and raw materials, create digital twins and analyze machine sensor data to optimize part production. Plataine has established extensive partnerships with leaders and suppliers in the composite materials industry, including Siemens.
The CIKONI DrapeWatch detection system for Swinburne’s Industry 4.0 Testlab is used for composite product automation. Source | Sicconi
CIKONI (Stuttgart, Germany) has provided the DrapeWatch system for online inspection and digitization of preforms and merged parts. This robot-based 3D analysis system can identify gaps, misalignments and irregularities. It combines a vision sensor for detailed surface inspection and an EddyCurrent sensor for internal defects and in-depth material analysis. The system’s artificial intelligence algorithm analyzes the data to provide early detection of defects, thereby avoiding costly re-runs. The finite element analysis (FEA) interface can export the fiber angle results to the simulation model to evaluate the effect of defects on the performance of the part. The modular system can also be expanded by integrating thermal imaging, ultrasound or laser scanning equipment.
Fill and Langzauner’s equipment will be installed in mid-2020. “Phil has been doing experiments for us,” Fox pointed out. “We have sent people to Austria for training on specific parts and digital training. Once all the process equipment is debugged, we will use Plataine’s RFID (Radio Frequency Identification) technology and It is extended to its latest edge computing platform PlataineEdge, which will support real-time analysis and communication between machines.”
Another part of Swinburne’s Composites 4.0 Testlab vision is to enable flexible manufacturing to adapt very quickly to changing industry needs:
“In a typical production line, product changes or modifications require a lot of equipment modifications and manual intervention. Therefore, in order to make this product change profitable, a minimum batch of new products is required. In contrast, in the vision of Industry 4.0 , Smart factory allows personalized customer needs, even one-time production of goods can be profitable. Such a factory can easily respond to the final changes on behalf of customers and suppliers. Therefore, one of the main goals of the proposed production line is to make it Able to produce different products with minimal or no manual intervention.” — Fox and Subic, “Industry 4.0 Composite Material 3D Printing Method”
In addition to providing a digital physical composite material 4.0 factory, Swinburne will also train the next generation of labor. The latter is achieved through the Australian Global Innovation Link Program providing 1 million Australian dollars in grants every four years. The main partner of the program is ARENA2036, an industry-based on-campus research and development program at the University of Stuttgart, which claims to be “a highly flexible future mobility and production research platform.” With the support of the Federal Ministry of Education and Research (Bonn, Germany, BMBF), ARENA2036, as a registered association, is composed of 38 members from the scientific and industrial circles, with “STARTUP AUTOBAHN” and a building of 10,000 square meters, of which 4,700 square meters Mi is an open production workshop with a 16-meter high ceiling and a 10-ton industrial crane. Swinburne joined ARENA2036 as a member in 2018.
ARENA2036 is an important partner of Swinburne’s Industry 4.0 Composite Material Testing Laboratory. It has an open production workshop of 4700 square meters with a 16-meter high ceiling and a 10-ton industrial crane. Swinburne joined the list of 38 members in 2018. ARENA2036
Swinburne’s Composites 4.0 Testlab and ARENA2036 are collaborating through an A$3.6 million program under the Australian Government’s Global Innovation Linkage Program (GIL), which involves the manufacturing of high-volume lightweight composite materials for Industry 4.0, with a focus on Through a flexible tool system and digital twin technology. It will include:
The partnership also envisages joint R&D projects with the Fraunhofer Institute for Manufacturing Engineering and Automation and the Institute for Industrial Engineering (Fraunhofer IPA and IAO, Stuttgart), including at the University of Stuttgart’s School of Aircraft Design ( IFB) PhD student internship. Industry 4.0 field. Professor Peter Middendorf, Director of IFB, said: “The GIL project is an important milestone for the advanced composite process and the cooperation between SUT, the University of Stuttgart and ARENA2036.” “We are honored to be the partner of the project itself and announced the support of the German government. Two other collaborative research projects directly related to GIL.”
“We will train a new group of digital joint doctoral students between Swinburne and the University of Stuttgart,” Fox said. “We will not only further develop the Composite 4.0 process, but also consolidate global partnerships and develop new products that can be exported from Australia, especially in new travel markets. Through these international cooperation, Swinburne’s Industry 4.0 Testlab will actively promote Australian SMEs are connected to global value chains. We have demonstrated this with our partner, Imagine Intelligent Materials, and we look forward to expanding it to more Australian innovators.”
Fox said: “In the fast-developing digital manufacturing in the future, international competition will be very fierce.” “This is why we are now developing this composite material 4.0 function and labor force is so important.”
Swinburne University’s Industry 4.0 Testlab for composite additive manufacturing will be launched in December 2020. Stay tuned to CW for future updates, and read the July 2020 feature “Composite Materials 4.0: Digital Transformation, Adaptive Production, New Paradigm” and its five online versions. Sidebar:
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Post time: Mar-27-2021