Data Collection and Analysis for the Creation of a Digital Shadow During the Production of Thermoplastic Composite Layers in Unbonded Flexible Pipes

Abstract

Unbonded flexible pipes present a mature technology for the efficient recovery and transport of hydrocarbons offshore. The substitution of metallic reinforcement layers in the multi-layered structure by thermoplastic fiber-reinforced polymer (FRP) presents a solution for self-weight issues of especially long pipes, as FRP materials display high specific strength and modulus while being resistant to external pressure and corrosion. The production of these layers is automated by the laser-assisted tape winding process without the need of additional curing steps. During the manufacturing process, several data like process temperature and consolidation pressure are continuously monitored by non-contact sensors to ensure process stability without interfering in the consolidation process. To gain additional information about the temperature distribution within the multi-layered laminate, contact temperature sensors were introduced in the tape winding process. By this method the temperature of subjacent tapes can be assessed during the continued winding process. Additionally, this paper features a new approach of utilizing winding path data for relating the time-dependent sensor data to the exact position on the produced part. The visualization of path-dependent sensor data opens up possibilities of linking quality monitoring results to manufacturing insufficiencies and potential part defects.

A Survey on AI-Driven Digital Twins in Industry 4.0: Smart Manufacturing and Advanced Robotics

“…AI-driven digital process twins are envisioned to learn and interpret implicit correlations between manufacturing processes and material/process/environmental parameters from an aggregation of (heterogeneous) data with the objective of optimizing process development, production ramp-up, and quality assurance cycle. From an engineering implementation perspective, we have noted that despite the significance of algorithms and models, novel sensor technologies [167,[213][214][215][216][217] and networked digital process chains [218][219][220][221][222] should not be neglected, as they are essential pillars for constructing DTs and can considerably influence the effectiveness and efficiency of their development and deployment in practice. Figure 5 shows an example of a DT dynamically mapping the manufacturing process of an aerospace part and the data sources involved from the contextualized CAD-CAM-CNC-CAQ process chain.…”

On the temperature evolution during continuous laser-assisted tape winding of multiple C/PEEK layers: The effect of roller deformation

“…The ATW technique is highly automated and used to manufacture tubular-like structures such as flywheel rotors [21,38], tanks for energy storage, pipes for oil and gas industry [29,44], tubes for bikes, etc. The heating source can be a hot gas torch [12,13,22], infrared lamp [4,16,18], near-infrared (NIR) diode lasers [5,10,11,31], and recently LED heating [25].…”

Temperature variation during continuous laser-assisted adjacent hoop winding of type-IV pressure vessels: An experimental analysis

“…Several efforts have therefore been made towards analyzing the temperature distributions on the substrate and incoming tape to define the nip-point temperature, e.g. Del Castillo et al 17 used fiber-Bragg grating (FBG) sensors and a thermocouple, Stokes-Griffin et al and Scha¨kel et al [18][19][20] used thermocouples and Perez et al 21 used an infrared thermographic camera. In Weiler et al 22 , carbon fiber-reinforced PA12 composites were employed for the LATP process on flat surfaces.…”