Tifkitsis, KonstantinosWinistoerfer, A.Skordos, Alexandros A.2023-01-232023-01-232023-02-03Tifkitsis KI, Winistoerfer A, Skordos AA. (2023) Online optimisation and active control of the cure process of thick composite laminates, Journal of Manufacturing Processes, Volume 87, February 2023, pp. 221-2301526-6125https://doi.org/10.1016/j.jmapro.2023.01.027https://dspace.lib.cranfield.ac.uk/handle/1826/19003This paper addresses the development of an active control tool for the in-situ optimisation of the cure process of thick composite parts. The methodology integrates a cure process model with real time monitoring data exploring potential temperature dwells that accelerate the curing while avoiding undesirable thermal gradients. The cure process simulation is based on a Finite Element (FE) model solution validated in the curing of a thick composite flat panel with an average absolute error of about 1.8 °C. The active control tool interacts PID controller of an oven setting a new cure temperature periodically. The implementation of active control tool during the curing of a thick carbon fibre/epoxy cable has the capability to determine in real time optimal solutions minimising process duration whilst also satisfying constraints in temperature overshoot. A process duration reduction of about 70 % can be achieved compared to a nominal cure cycle with a maximum temperature overshoot lower than 9 °C. The active control tool can replace off-line optimisation tools exploiting in situ with real time monitoring to drive the process and minimise the effects of uncertainty.221-230enAttribution-NonCommercial-NoDerivatives 4.0 Internationalhttp://creativecommons.org/licenses/by-nc-nd/4.0/CompositesProcess monitoringCureAutomationProcess optimisationArticle87