Comparative study about heating systems for pultrusion process

Different heating systems have been used in pultrusion, where the most widely used heaters are planar resistances. The primary objective of this study was to develop an improved heating system and compare its performance with that of a system with planar resistances. In this study, thermography was used to better understand the temperature profile along the die. Finite element analysis was performed to determine the amount of energy consumed by the heating systems. Improvements were made to the die to test the new heating system, and it was found that the new system reduced the setup time and energy consumption by approximately 57%.

Saving energy in the GFRP pultrusion process

This study addresses to the optimization of pultrusion manufacturing process from the energy-consumption point of view. The die heating system of external platen heaters commonly used in the pultrusion machines is one of the components that contribute the most to the high consumption of energy of pultrusion process. Hence, instead of the conventional multi-planar heaters, a new internal die heating system that leads to minor heat losses is proposed. The effect of the number and relative position of the embedded heaters along the die is also analysed towards the setting up of the optimum arrangement that minimizes both the energy rate and consumption. Simulation and optimization processes were greatly supported by Finite Element Analysis (FEA) and calibrated with basis on the temperature profile computed through thermography imaging techniques. The main outputs of this study allow to conclude that the use of embedded cylindrical resistances instead of external planar heaters leads to drastic reductions of both the power consumption and the warm-up periods of the die heating system. For the analysed die tool and process, savings on energy consumption up to 60% and warm-up period stages less than an half hour were attained with the new internal heating system. The improvements achieved allow reducing the power requirements on pultrusion process, and thus minimize industrial costs and contribute to a more sustainable pultrusion manufacturing industry.

How to reduce energy consumption on pultrusion

The global warming due to high CO2 emission in the last years has made energy saving a global problem nowadays. However, manufacturing processes such as pultrusion necessarily needs heat for curing the resin. Then, the only option available is to apply all efforts to make the process even more efficient. Different heating systems have been used on pultrusion, however, the most widely used are the planar resistances. The main objective of this study is to develop another heating system and compares it with the former one. Thermography was used in spite of define the temperature profile along the die. FEA (finite element analysis) allows to understand how many energy is spend with the initial heating system. After this first approach, changes were done on the die in order to test the new heating system and to check possible quality problems on the product. Thus, this work allows to conclude that with the new heating system a significant reduction in the setup time is now possible and an energy reduction of about 57% was achieved.

Uso da termografia na deteção de avarias

A civilização contemporânea, pelas suas características, é muito exigente em tudo o que diz respeito ao conforto dos edifícios, para trabalho ou habitação, e à necessidade de economizar e racionalizar o uso de energia. A térmica dos edifícios assume, por isso, uma importância acrescida na atividade profissional e no ensino. Para se conduzir ao aperfeiçoamento de soluções na envolvente dos edifícios a este nível, o trabalho aqui realizado centrou-se no estudo do funcionamento da termografia de infravermelhos e da importância da sua utilização na inspeção térmica de edifícios. Descoberta no início do século XIX e desenvolvendo os primeiros sistemas operativos desde a 1ª Guerra Mundial, a fim de determinar heterogeneidades de temperatura superficial, esta técnica não destrutiva permite identificar anomalias que não são visualizadas a olho nu. Com a análise dessas variações de temperatura é possível conhecer os problemas e a localização de irregularidades. Este trabalho baseia-se substancialmente no estudo de edifícios. A análise realizada teve como finalidade executar inspeções termográficas – visuais, com duas abordagens. Por um lado, avaliar salas pertencentes a estabelecimentos de ensino secundário, reabilitadas e não reabilitadas, todas construídas entre as décadas de 60 e 90, com o intuito de diagnosticar patologias construtivas, recorrendo à termografia. Por outro, a análise de edifícios de habitação, com a intenção de avaliar a necessidade de um equipamento complementar às inspeções termográficas – o sistema de porta ventiladora. As inspeções foram regidas pelas diretrizes da norma europeia EN 13187. A termografia é uma técnica importante na realização de ensaios in situ que requerem rapidez de execução, aliada à vantagem de disponibilizar resultados em tempo real, permitindo assim uma primeira análise das leituras no local. A inspeção termográfica complementada com o sistema de porta ventiladora permitiu, também, revelar a importância da necessidade de meios auxiliares em certos casos. A conjugação destas diferentes técnicas permite reduzir a subjetividade da análise in situ e aumentar a fiabilidade do diagnóstico.