Mathematical modeling and simulation of heat flow through pultrusion die assembly system for thermoset composites

Pultrusion is an industrial process used to produce glass fibers reinforced polymers profiles. These materials are worldwide used when performing characteristics, such as great electrical and magnetic insulation, high strength to weight ratio, corrosion and weather resistance, long service life and minimal maintenance are required. In this study, we present the results of the modelling and simulation of heat flow through a pultrusion die by means of Finite Element Analysis (FEA). The numerical simulation was calibrated based on temperature profiles computed from thermographic measurements carried out during pultrusion manufacturing process. Obtained results have shown a maximum deviation of 7%, which is considered to be acceptable for this type of analysis, and is below to the 10% value, previously specified as maximum deviation. © 2011, Advanced Engineering Solutions.

CADDS: an automated die design system for sheet-metal blanking

This article reports on the design and implementation of a Computer-Aided Die Design System (CADDS) for sheet-metal blanks. The system is designed by considering several factors, such as the complexity of blank geometry, reduction in scrap material, production requirements, availability of press equipment and standard parts, punch profile complexity, and tool elements manufacturing method. The interaction among these parameters and how they affect designers' decision patterns is described. The system is implemented by interfacing AutoCAD with the higher level languages FORTRAN 77 and AutoLISP. A database of standard die elements is created by parametric programming, which is an enhanced feature of AutoCAD. The greatest advantage achieved by the system is the rapid generation of the most efficient strip and die layouts, including information about the tool configuration.

Effectiveness of a Differential Temperature Controller on a Solar Water Heating System: An Experimental Study

A differential temperature controller is incorporated in a solar water heating system to study the influence of its set points on system performance. The effectiveness of the controller set points DeltaT ON and DeltaT OFF on the pump cycling and energy collection has been studied experimentally and the results are presented in this paper.

Implementation of microprocessor based self-tuning control on a heating system

This paper describes the implementation, using a microprocessor, of a self-tuning control algorithm on a heating system. The algorithm is based on recursive least squares parameter estimation with a state-space, pole placement design criterion and shows how the controller behaves when applied to an actual system.

Rapport från/Report from IEA Task-14 mötet/meeting on solar heating system, Hameln Tyskland/Germany August 1992

Participation as observer at the meeting of Task 14 of IEA's Solar Heating and Cooling Projects held in Hameln, Germany has led to greater understanding of interesting developments underway in several countries. This will be of use during the development of small scale systems suitable for Swedish conditions. A summary of the work carried out by the working groups within Task 14 is given, with emphasis on the Domestic Hot Water group. Experiences of low-flow systems from several countries are related, and the conclusion is drawn that the maximum theoretical possible increase in performance of 20% has not been achieved due to poor heat exchangers and poor stratification in the storage tanks. Positive developments in connecting tubes and pumps is noted. Further participation as observer in Task 14 meetings is desired, and is looked on favourably by the members of the group. Another conclusion is that SERC should carry on with work on Swedish storage tanks, with emphasis on better stratification and heat exchangers, and possible modelling of system components. Finally a German Do-it-Vourself kit is described and judged in comparison with prefabricated models and Swedish Do-it-Yourself kits.

Monitoring results of combined pellet and solar heating system

In this study the monitoring results of prototype installation of a recently developed solar combisystem have been evaluated. The system, that uses a water jacketed pellet stove as auxiliary heater, was installed in a single family house in Borlänge/Sweden. In order to allow an evaluation under realistic conditions the system has been monitored for a time period of one year. From the measurements of the system it could be seen that it is important that the pellet stove has a sufficient buffer store volume to minimize cycling. The measurements showed also that the stove gives a lower share of the produced heat to the water loop than measured under stationary conditions. The solar system works as expected and covers the heat demand during the summer and a part of the heat demand during spring and autumn. Potential for optimization exists for the parasitic electricity demand. The system consumes 680 kWh per year for pumps, valves and controllers which is more than 4% of the total primary heating energy demand.

Comparison of advanced waste heat recovery systems with a novel oil heating system

Latest trends in waste heat recovery include systems like Thermo Electric Generation (TEG), Rankine cycle, and active warm up systems. The advantages and disadvantages of different approaches are critically discussed and compared with a novel and effective oil heating system that can deliver between 7% and 12% reductions of CO2 emissions and fuel consumption. The comparison includes the expected CO2 and fuel saving potential related to the legal drive cycle as well as real world driving, effects on regulated exhaust emissions, utilisation of resources, maintenance and service, vehicle performance, comfort, noise, and durability.

Comparison of advanced waste heat recovery systems with a novel oil heating system

Latest trends in waste heat recovery include systems like Thermo Electric Generation (TEG), Rankine cycle, and active warm up systems. The advantages and disadvantages of different approaches are critically discussed and compared with a novel and effective oil heating system that can deliver between 7% and 12% reductions of CO2 emissions and fuel consumption. The comparison includes the expected CO2 and fuel saving potential related to the legal drive cycle as well as real world driving, effects on regulated exhaust emissions, utilisation of resources, maintenance and service, vehicle performance, comfort, noise, and durability.

THEODORE, a two-step heating system for the EC/OC determination of radiocarbon (14C) in the environment

Measurements of 14C in the organic carbon (OC) and elemental carbon (EC) fractions, respectively, of fine aerosol particles bear the potential to apportion anthropogenic and biogenic emission sources. For this purpose, the system THEODORE (two-step heating system for the EC/OC determination of radiocarbon in the environment) was developed. In this device, OC and EC are transformed into carbon dioxide in a stream of oxygen at 340 and 650 �C, respectively, and reduced to filamentous carbon. This is the target material for subsequent accelerator mass spectrometry (AMS) 14C measurements, which were performed on sub-milligram carbon samples at the PSI/ETH compact 500 kV AMS system. Quality assurance measurements of SRM 1649a, Urban Dust, yielded a fraction of modern fM in total carbon (TC) of 0.522 ±0.018 (n ¼ 5, 95% confidence level) in agreement with reported values. The results for OC and EC are 0.70± 0.05 (n ¼ 3) and 0.066 ± 0.020 (n ¼ 4), respectively.

Evaluation of a heating system using a heat pump and heat store

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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.

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%.

Finite Element Analysis (FEA) applied to heat transfer optimization process of pultrusion die systems

The aim of this study is to optimize the heat flow through the pultrusion die assembly system on the manufacturing process of a specific glass-fiber reinforced polymer (GFRP) pultrusion profile. The control of heat flow and its distribution through whole die assembly system is of vital importance in optimizing the actual GFRP pultrusion process. Through mathematical modeling of heating-die process, by means of Finite Element Analysis (FEA) program, an optimum heater selection, die position and temperature control was achieved. The thermal environment within the die was critically modeled relative not only to the applied heat sources, but also to the conductive and convective losses, as well as the thermal contribution arising from the exothermic reaction of resin matrix as it cures or polymerizes from the liquid to solid condition. Numerical simulation was validated with basis on thermographic measurements carried out on key points along the die during pultrusion process.