CIDAUT Develops an Accurate Mould Design Methodology for Composite Parts Through the Simulation of Process-Induced Distortions

Within the scope of the Cleansky Programme, CIDAUT leads a research project aimed at the manufacturing of composite rotorcraft blades with very tight tolerances that will incorporate an Active Gurney Flap mechanism. Active Gurney Flap (AGF) systems enable the rotorcraft to safely operate with reduced tip speeds whilst preserving high performances with reduced fuel consumption and noise; something that constitutes one of the most challenging research areas leaded by the Green Rotorcraft Consortium in the Cleansky Programme: the development of Active Rotor Technologies.

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Active Gurney Flap mechanisms scheme.

In the ACCUBLADE project, CIDAUT researches on the development of a robust and very accurate moulding process for the manufacturing of carbon fibre model blades that will be used for validation of the AGF systems through wind tunnel tests. Due to the small scale of the model blades, the dimensional requirements for the manufacturing are very tight, less than +/- 0,1mm on the aerodynamic profile. In order to fulfil the tight tolerances, not only the mould must be machined with high precision means, but also the cavity design must be defined with special consideration for minimizing any distortion during the process.

The analysis of potential process-induced distortions, such as warping or spring-in, has been carried out by means of process simulations based in accurate material parameters identified through laboratory material characterisation tests. The influence of different material and processing parameters including the weave pattern, ply stacking, mould interaction, curing temperature and pressure has been experimentally characterised and correlated with the simulation models. These have been developed for the prediction of the distortions that would appear during the processing of the model blades. Using this methodology, the design of the cavity can be defined to fulfil the required tolerances.

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Mould design optimization methodology by means of process simulations.

During the near to follow validation stage, CIDAUT will partake in the processing of the model blades and the non destructive and destructive inspection tests that will be carried out to demonstrate the functionality of the tools and to validate the design methodology.

In particular, the following outcomes from the ACCUBLADE project will stand out among the technological expected results:

  • An optimization methodology for tooling and moulds design based in accurate distortion simulations accounting for different thermal coefficients of the composite materials.
  • A reduction in current development costs and lead-times for aeronautic composite parts, that usually need expensive and long lasting trial and error procedures to be carried out before a suitable mould cavity design is experimentally determined.

 

Nemesis, paving the way to Aircraft Recycling

Since January 2013 CIDAUT has been working on the NEMESIS project, entitled  “New Trends and Market Survey for the End of Life of Aircrafts. Eco Design Guideline”. CIDAUT has led the consortium working with three other partners (University of Valladolid, ITRB Ltd and PBLH International Consulting), all under the supervision of Fraunhofer Institute for Chemical Technology.

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The dismantling of aircraft materials nowadays is not a real option; many planes lie abandoned around the world or have been sent to landfills.
To deal with this undesired situation, the NEMESIS project has designed a methodology which combines the expected market data with the current and expected future steps for a/c dismantling and recycling.
To achieve this ambitious goal, firstly a market survey was conducted (questionnaires and interviews) whre more than 1000 experts were surveyed. Afterwards, their responses were thouroughly analyzed and used to carry out a forecast study. To this end, years 2014 and 2024 were chosen as horizon basis, considering four different future scenarios.

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In the course of the project an analysis of the technologies involved in the recycling processes was also conducted, identifying their most important characteristics.

With all this data an automatic decision tree was implemented, and two different conditions were analyzed: the cheapest process or the best quality. Afterwards, a complete application example was carried out as a case study for demonstration purposes. On this regard the Belly Fairing for an Airbus plane was chosen and the computer application was developed in MS Excel. Therefore this application can easily be used for any other component of the aircraft in the future.

Finally an economic sustainability study was conducted, where several estimations of the future of recycled materials were performed. These estimations were compared with those of the experts (obtained via the Market Survey) and the recycling methodologies previously calculated from an economic viewpoint were analyzed. This allowed a complete validation of the developed methodology.

The project finished last June and the results have met all the expectations, showing mainly the evolution of materials and, therefore, the future of aircraft recycling.

Thanks to this project, and others working in the same direction, the aircraft recycling will become a reality in the future. Perhaps, in a few years it will be possible to adapt aeronautical regulations in a similar way to those existing for the automotive industry.

E-VECTOORC dissemination event at the Heritage Motor Centre, Gaydon (UK)

The last dissemination event of the E-VECTOORC project was hosted in the Heritage Motor Center at Gaydon.

Three years after its launch, the E-VECTOORC consortium has organized the second and last workshop for stakeholders. This dissemination event was hosted in the Heritage Motor Centre, Gaydon (United Kingdom) on the 28th of August, and was organized jointly by Jaguar/Land Rover, the Ilmenau University of Technology and the University of Surrey. More than 60 attendees had the opportunity to get in contact with the vehicle demonstrator and the range extender.

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During the project a Land Rover Evoque was modified to build up a fully electric demonstrator equipped with torque vectoring controller. This vehicle has four individual electric motors (switched reluctance electric motors) in order to create a 4WD individual wheel driven car. Each motor is able to give 200 Nm of torque. Also, the trailer range extender equipped with a Diesel generator of 20 kW was brought from Jaguar Land Rover Headquarter.

The goal and the main developments carried out during the project were pointed out by the E-VECTOORC coordinator, Aldo Sorniotti (Surrey University). Following that, different speakers showed the activities carried out in their tasks within the project: Demonstrator vehicle construction, Safety and reliability aspects of fully electric vehicles, Direct yaw moment controllers and Vehicle longitudinal dynamics and control.

During the last part of the meeting, the attendees to the 2nd E-VECTOORC Dissemination Event could take a look to the project demonstrator and the range extender attending a live demonstration of the car driving under different conditions.

You can find more information about the project and the events carried out so far in our website http://www.e-vectoorc.eu/.

Wasis at the European Congress on Composite Materials

Wasis took part last 25th June in Seville to the internationally recognised 16th European Congress on Composite Materials known as the largest congress dedicated to composites materials in Europe. In this occasion more than 1.200 experts from the industry and academia joined the event coming from all areas of the world.

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In agreement with the ECCM16 technical committee in charge of organising this relevant event, a session dedicated to lattice structures was organised, in which Wasis and other international initiatives as well as EU funded research projects shown their work in this field.

Directly related to WASIS, there were 6 publications, summarised in the table below:

Title Authors Summary
FABRICATION OF COMPOSITE CYLINDERS WITH INTEGRATED LATTICE STRUCTURE USING FILAMENT WINDING J.CERQUEIRA, H.FARIA (INEGI), R.FUNCK In WASIS project, a wafer-like integrative concept was developed for an innovative aircraft fuselage. A fuselage section was manufactured through filament winding. Increasingly complex tools, process kinematics and control for accurate prototypes manufacturing were developed. Feasibility analysis is also addressed.
MANUFACTURING AND TESTING OF COMPOSITE WAFER COMPONENTS WITH DUAL-PURPOSE INTEGRATED SEMI-LOOP JOINTS S.KRYVENDA, F.GAGAUZ, M.SHEVTSOVA, L.SMOVZIUK (NATIONAL AEROSPACE UNIVERSITY “KHAI”), I.TARANENKO Combination of wafer reinforcement concept and hybrid metal-to-composite joints provides sufficient reduction of aircraft fuselage weight. Within this work manufacturing process for curved CFRP wafer panel with integrated dual-purpose semi-loop hybrid joints is presented along with panels testing results discussion.
TESTING AND ANALYSIS OF GRID-STIFFENED COMPOSITE STRUCTURAL PANELS A.HAJDAEI, S.GIANNIS (ELEMENT MATERIALS TECHNOLOGY), V.MATEJAK, A.TOULITSIS A composite fuselage structure has been developed in WASIS project based on the lattice stiffening concept. To understand the mechanical performance and validate the design methodology a testing programme involving structural parts of different levels of complexity was executed.
ON THE SAFETY ASSESSMENT AND DAMAGE TOLERANCE OF COMPOSITE LATTICE TYPE AEROSPACE STRUCTURES A.KOTZAKOLIOS (UNIVERSITY OF PATRAS), D.VLACHOS, K.ANTONIADIS, V.KOSTOPOULOS In this work, impact and damage response of composite wafer structures is numerically modelled. The damage created on the structure is identified and the reduction of the airworthiness of the structure is investigated. Comparisons are made with conventional composite structures.
PREPREG LAY-UP TECHNOLOGY FOR MANUFACTURING OF LATTICE STRUCTURE FUSELAGE SECTIONS J.MACK (INSTITUT FUER VERBUNDWERKSTOFFE GMBH), O.MCGERGOR, P.MITSCHANG The manufacturing of isogrid lattice structures for a fuselage section with the AFP process was evaluated. Different designs for rib crossing points are proposed and experimentally analyzed. Solutions for convex as well as concave tooling concepts were tested
LATTICE COMPOSITE STRUCTURE DEVELOPMENT FOR SMALL AIRCRAFT; WASIS R.CORDERO (CIDAUT), M.AVERSANO Development of a vibroacoustic model for prediction of the CFRP fuselage section is described, emphasising on experimental characterisation of largest project prototypes and parameters identified to feed finite element and statistical energy analysis models

Two project prototypes were shown at the congress, the 0.5m and 1m in diameter scaled down fuselage sections, which attracted the attention of many participants to the congress.

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Besides presentations from complementary projects like ALASKA and MAXIMUS were given.
During the lattice structures session, experts exchanged their experience in design and manufacturing, sharing information in open debates and questions sessions after each presentation. It was very interesting to compare the achievements of different initiatives in the aeronautical and aerospace sectors, obtained in European and Asian initiatives.
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For more information and Wasis publications, please visit: http://www.wasis.eu/

New Jersey project ongoing work

NewJersey

Jersey project (http://www.lifeproject-newjersey.com/) is a Life+ project which main objective is to demonstrate and validate a new generation of eco-friendly safety barriers with improved impact absorption performance made of recycled rubber, recycled plastics and concrete, by means of developing, designing and manufacturing the barriers and later on testing, demonstrating and validating them in a real road stretch.

Every day 3,6 people die at Spanish roads, as announced by the Dirección General de Tráfico. Though this figure is considerably lower than the 2000 average, there is still a long way to go to reach our complete safety. A good alternative to mitigate accidents and injuries is the improvement of the dampening properties of safety barriers, decreasing their stiffness and increasing the energy absorption. Moreover, if recycled rubber in form of end of life tires (ELT’s) and secondary plastics are part of the equation, then you have a safer and eco friendly barrier, which is exactly New Jersey’s main goal.

New Jersey project Consortium consists of: the Dirección General de Carreteras de la Comunidad de Madrid, Acciona Infraestructuras, Signus Ecovalor, Cidaut and the European Union Road Federation (ERF). Together, New Jersey partners have undertaken the study of the amount of rubber that can be added in the barrier, and how to include it; and the development of a elastic cover for the used rubber. Two prototypes were designed in the project and scale models of the two types of barriers have been designed, and manufactured.

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Prototype 1 consists of a New Jersey Barrier with a coating of ELTs, plastics and Resins. For this prototype a material analysis was performed. Different designs were proposed and evaluated and then real scale prototypes were manufactured. Finally, EN 1317 crash test ended on July 2013.

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For this prototype a material analysis was performed as well, and then a barrier was designed and produced. A summary of the results of the tests can be found on the project website (http://www.lifeproject-newjersey.com/activities.php).

Ongoing work currently focuses on prototype 2 (mixed concrete with ELTs). Prior to evaluating Prototype 2 behaviour on full scale vehicle crash test, according to EN 1317, during the month of May, several pendulum dynamic tests have been performed to evaluate impact behaviour of selected mixed concrete with ELTs formulation. (http://www.lifeproject-newjersey.com/images/ACTION32.pdf)

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Cidaut was exhibiting at the European Automotive Testing Expo in Stuttgart

One more year, Cidaut was exhibiting at the European Automotive Testing Expo, which took place in Stuttgart (Germany) from June 24th to June 26th.

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The Automotive Testing Expo is the global exhibition for every aspect of vehicle, motorcycle and components testing, validation, reliability assessment, quality evaluation and related data capture and analysis. It is the only event of its type taking place globally, and the essential environment for every vehicle and motorcycle test and validation system, with around 300 exhibiting parties. The latest technologies and new iterations of existing technologies are shown. This is an event that you should visit every year if you are involved in any area of vehicle, motorcycle and components testing, evaluation, quality engineering and validation.

This year, three departments from Cidaut were involved in the exhibition, namely Acoustics & Vibrations, Mechanical Testing and Vehicle Safety. We showed our visitors how partnering with CIDAUT can help them to speed up their developments thanks to our concurrent engineering basis where a full range of testing facilities, numerical modelling and engineering services with multidisciplinary experts are combined together on the same place.

 

 

 

 

 

 

 

 

 

 

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The first urban road restraint system, designed for protecting pedestrians and cyclists is installed

With the aim of mitigating consequences of a possible run-off accident of a motor vehicle and protect the vulnerable users (pedestrians and cyclists), CIDAUT-CIDRO has developed the first road restraint system (RRS) to contain impacts of passenger cars, coaches and buses.

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Run-off accidents in urban areas mean an important road safety problem, specially for pedestrians and cyclists, due to the fact that current RRS installed between the urban road (platform) and the pedestrian pavement or the cycling pathwhen they do not meet safety requirements indicated in the european standard (EN-1317-2 “Road Restraint Systems – Safety Barriers”).

With the aim of mitigating consequences of a possible run-off accident of a motor vehicle and protect vulnerable users like pedestrians and cyclist, CIDAUT-CIDRO has developed the first RRS ready to be safe (to contain) against impacts of passenger cars at 80Km/h (although urban speed limit is lower) and coaches and buses at 50Km/h: https://www.youtube.com/watch?v=rXUixw1azK8. The impact parameters (based on EN-1317-2) measured during these crash tests will ensure mitigation of severity associated to this kind of accidents.

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Last May, this innovative solution was applied in the Spanish city of Lucena, urban road belonging to the Spanish Road Administration of “Junta de Andalucía”.

Join us in Brussels next September 18th for a demonstration on EV interoperability!

The Green eMotion project is part of the European Green Cars Initiative (EGCI) that was launched within the context of the European Recovery Plan. It supports the achievement of the EU’s ambitious climate goals, such as the reduction of CO2 emissions by 60 percent by the year 2050. EGCI supports the research and development of road transport solutions that have the potential to achieve sustainable as well as groundbreaking results in the use of renewable and non-polluting energy sources. The project is working to prepare the foundation for the mass deployment of Europe-wide electromobility.

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Green eMotion demonstration sites, the locations from which EV will reach Brussels include Dublin, Strasburg, Berlin and Copenhagen among others.

As part of the Green eMotion project events, EV interoperability will be shown next September 18th in Brussels during the EC mobility week. Several partners in the project will drive different EV from their countries to the Belgium capital; the different charging events necessary to reach Brussels will be managed using the Green eMotion market place. The idea is to demonstrate that EV charging is feasible between different companies managing these charging points, as well as between different countries in a similar way to the mobile phone roaming. This rally to Brussels will be complemented on the morning of September 18th with a live demonstration of the EV interoperability. The EV driven to Brussels will be connected to different charging points, the identification of those vehicles, as well as the authorization for the charging of their batteries will be shown validating the Green eMotion marketplace, which is the tool developed within the project.

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This Green eMotion project event will be held in Hotel Courtyard Brussels, Avenue des Olympiades 6, Brussels 1140 and it will include a demonstration of charging, using different vehicles, charging points and charging RFID cards. Afterwards, a series of conferences will be held, to present the main achievements of the project on the charging infrastructure, ICT tools and standards among others. The demonstration of the charging event and the marketplace will take place on the morning, while the conferences will take place from 13.00 to 17.00.

You will find more information on the following number of our newsletter, as well as on the Green eMotion project public web site http://www.greenemotion-project.eu/

 

Cidersol Tecnología Solar: Good prospects for a new solar heating generation

 

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Have you ever felt the sun heat coming on your body while having a shower? Can you swim in an open pool at 28 degrees in winter? Are you aware of the savings that a solar network of district heating provides to its users?

Solar prospective markets are on the move and most European countries have been seeing some of their smart technology companies leaving off to America to start up business in the last few years. Now the falling prices of systems are driving the growth of the solar market in Eastern Europe, while main markets such as South and Western Europe are losing their importance when compared internationally. In addition, the players of the international sector are in the meantime looking towards the Asia-Pacific region leaving behind a struggling European economy.

Is there a true effort to explore all chances within an activity area or are companies just getting used to the limits of the current market?

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Cidersol Tecnología Solar is a new generation of solar concept. Having a free shower may have never been easier for ALL. Our systems are aimed at the savings of the final customer, while retaining the highest comfort, confidence and promoting green feeling through a conscious use of renewable energies, and not simply heating the house.
Whether you live in a farm or a flat you are always welcome to explore ways of “adapting the sun to you”, thinking of biomass as a perfect companion when we are committed to fulfill the needs of the application.

Hundreds of families are already enjoying Cidersol solar benefits guaranteed for three years by the installers. After such a time of coping with a solar system, most individuals can be perfectly aware of their savings, efficiency, cleansing and goodness, and would create to their new generations a positive feeling that here comes the future… and WORKS.

Cidersol Tecnología Solar has been on the market since 2011. Our manufacturing site has been conceived in Cidaut as a spin-off devoted to provide high-efficient products to the renewable energy sector in Spain and the vast Globe. Our strong motivation is doing our best “in the right way, in the right market, in the right position” and exploring all possibilities on how YOU, who are reading, could take advantage of that of which there is millions of watts available in the nature for use… and for FREE.
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Cidersol solar thermal collectors have an excellent performance/price/weight ratio. With an innovative construction based on an auto insulated frame of hybrid material and an absorber with a unique design to improve the thermal transmission between the absorber surface and the fluid conduits.
Main features:
• Collector glazing: 4mm low iron coating tempered glass.
• Aluminum harp constructed absorber specially designed for a balanced flow and an optimal thermal transfer.
• High selective vacuum coating (absorption 95%, emission 5%).
• Metal-plastic hybrid frame with the best insulation/weight/toughness ratio.
• High performance thermal insulation.
• Ready to use Cidersol quick connections.
• Several anodized and lacquered finishing available.

For the first time a manufacturer can provide a whole long-life primary circuit in aluminum, avoiding high costs of copper.

We use a highly automated manufacturing process in a compact production cell with state of the art technology to deliver consistently the highest levels of quality in our products.

Custom made research and development for each specific manufacturing process ensure continuous improvement of our products.

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Become part of our team, and receive specialized technical support and preferential treatment, which will provide the edge of technology needed our days to satisfy our customers.

Contact us in info@cidersol.es.
Find further references in: http://www.cidersol.es/en_index.html

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