Dokumentation Composite Heizvorgang

2 Clicks for creating a composite curing report

How long does it take to document a composite curing process?

The documentation of the heating process is an important proof in wind energy and aviation that the composite repair was carried out properly and according to the manufacturer’s specifications. And thus it stands for quality and reliability.

Nowadays, a detailed report on the curing process is required by many customers. However, the documentation also serves quality purposes for the service providers and composite manufacturers themselves. Curing under certain temperature conditions often takes ten hours or more.

Due to detailed process documentation, the conditions under which the curing process took place can be retraced.

Automated temperature documentation by using easyHeat software

easyHeat Bedienung der Heizregler, Composite Repair

Automatically generated reports

For documentation purposes, the heating controllers and hot bonders from msquare offer a convenient solution for service providers or manufacturers of composite components. The temperature data is automatically recorded during the entire heating process.

After the cooling phase or after the heating process is finished, the detailed data log of the composite curing can be downloaded by pressing a button in the easyHeat software. A data log contains temperature data ranging from a few hours up to several days curing process.

Report generation by 2 buttons

By pressing another button the log file is imported into the msquare evaluation tool. A full curing report is then created automatically. This report not only contains all project-relevant information, but also the heating ramp graph. At a glance, it is possible to see to which temperature conditions the component was exposed during the entire heating and curing phase.

If several temperature elements were applied to the composite component during the heating process they will be  evaluated as well and their deviation will be indicated. The report is generated as PDF file and thus can be easily sent by email or filed in the QM system.

And now for the best part: It took no more than two buttons to create this important proof of quality! A real efficiency gain! So you can focus on your actual job and we are happy to make your work easier.

Example of repair report generated by RedZero heat controller

Reparaturbericht-RedZero-Heizregler

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Vakuum-Heizmatte für Composite

Composite repair under vacuum conditions - How a heating blanket eliminates the need for vacuum build-up

What difference does it make whether composites are repaired under vacuum?

Almost all manufacturers’ repair manuals specify the use of vacuum for composite repairs. However, in this respect I remember a conversation with an experienced composite technician who has specialized in the repair of composite components for several decades and who firmly argues against the need for vacuum. “You can achieve a perfect repair result even without vacuum” – so his statement.

The fact is, anyone who has ever done a vacuum buildup knows that it sounds much easier than it actually is – because at the end of the day, it’s all about airtight sealing of the area to be repaired.

I already had the chance to assist a CFRP repair. But, as you would expect, as a complete beginner I had to struggle even more with the pitfalls of vacuum bagging and was surprised how the air finds its way through the most tiniest folds in the vacuum bag.

With these experiences in mind I show greatest respect for those who are handling vacuum build ups every day, applying the tape and sealing the bag with perfected dexterity. I was amazed how technicians master this. Thank you for these insights into your work.

Technicians creating a typical vacuum setup

Rotorblattreparatur Vakuum

msquare heating blankets supersede the conventional vacuum bagging

Shouldn’t it be possible to repair composites without the time-consuming vacuum build-up? The vacuum heating blankets from msquare have been exactly developed for this purpose: They allow for repairing or curing composite under vacuum conditions without creating a separate vacuum setup.

How does it work? Channels are incorporated into the border of the silicone heating blanket and the surface of the heating blanket also has a structure similar to a breather. A vacuum pump removes the air below the blanket whilst the edges of the heating blanket form an airtight seal and the pressure ensures that the materials are well pressed together. The repair takes place under vacuum conditions without creating a separate vacuum build-up in the conventional sense. This not only saves valuable time but also consumables and, above all, it is so easy to handle.

Due to the remarkable flexibility of the msquare heating blankets, even strongly curved composite structures which are often found in aviation or wind energy can be treated in this way. The heating blankets with vacuum function are available from a size of 30 x 30 cm – heated surface.

Heating blanket with vacuum functionality

Heizmatte mit Vakuumfunktion

Successful use of vacuum heating blankets in extreme applications

The vacuum heating blankets have already proven themselves in many extreme applications. A user from the wind energy sector reports that the heating blankets with vacuum function were the only option – thanks to their easy handling – that made rotor blade repairs under extreme wind and weather conditions possible.

The vacuum heating blankets can also be used without hesitation for overnight repairs. A built-in temperature sensor ensures that any temperature fluctuations on the surface of the blanket are reliably compensated and a constant temperature is ensured during the whole repair process. The heating blanket is operated conveniently from a smartphone, tablet or PC using the easyHeat app.

Sounds interesting? We’d be happy to make your life easier, too – heating blanket and heating controller can be tested without obligation.

Vacuum heating blanket used in rotor blade repair

Vakuum-Heizmatte Rotorblatt

easyHeat digitaler Heizregler für Composite

The digital transformation of heating - Optimal control of heating processes with the smart heating controllers from msquare.

Heating controllers operated via smartphone, tablet or PC

With the smart heating controllers and hot bonders from msquare, the digital transformation is taking place in the area of composite tempering and repair. Where analog rotary controls were previously used to set the temperature of the heating blanket, the msquare app “easyHeat” now facilitates the specific curing process when repairing fiber reinforced structures and offers significantly more options for precisely regulating the heating process, e.g. by entering a heating ramp and other functions.

Via an internal WLAN connection with a range of up to 120 m, the operating parameters for the tempering process are conveniently set remotely via smartphone, tablet or PC and monitored via live tracking. The long range of remote operation is particularly advantageous for the rotor blade repair of wind turbines.

The heating controllers are operated remotely via Smartphone, Tablet or PC

easyHeat for remote operation the heating controller

Live monitoring of the heating process and data logging

In addition to the target temperature, the heating rate in °C/min and the dwell time can be entered in  the RedZero and Red300 digital heating controllers via the easyHeat software to allow for a controlled heating of the heating blanket. By precisely defining this heating ramp, the specific conditions of the individual repair site are optimally taken into account, which always requires a different, individual heating process depending on the material and resin used.

Last but not least, this ensures compliance to the manufacturer’s repair specifications. And as a matter of fact this can be easily documented because digital heating of composites also offers the advantage that the entire data of the heating process (temperature, time and maximum deviation) is continuously logged and, if necessary, transferred to an automated repair protocol.

In this way, it is possible to trace which temperatures have affected the composite component during the heat cycle – a documentation that takes precautions and significantly reduces the effort required for manually created reports.

A heat ramp can be set for each heating cycle for optimum repair results

Heizrampe - easyHeat

Defining heating ramps and controlling temperature

Once defined, the heating ramp can be stored in the system and recalled or repeatedly performed at any time. In addition, the Hot Bonder Red300 offers the possibility of connecting multiple temperature sensors in parallel. The easyHeat software can then be used to define which thermocouple shall be used to control the heating process; an average across all sensors can also be used as the basis for control.

Nevertheless, the temperature of all sensors is always evaluated and graphically displayed. If a software update is pending, it can of course be downloaded “over the air” to the heating controller or the Hot Bonder. In case of special requirements an adaptation of the software to the needs of the respective application is possible.

Contact us or simply test our heating controllers and the easyHeat software yourself.