EQUIPMENT, CONTROLS AND ACCESSORIES FOR LIGHT RTM/INFUSION

APPLICATIONS
Presenter: Ms. Joan Tracy, Vice-President of International Sales, Magnum Venus Plastech

Composites manufacturers have been experiencing the same quality control issues for years,
including porosity, pre-release, gelcoat cracking and more. As pumping technology improved
over the years to address things like lowering styrene emissions, the root problem behind the
quality control issues was not directly addressed. That problem imprecise metering. Seeing a
growing trend with Composites manufacturers moving to closed mould processes where
pumping system performance and precise metering would become critical, the next generation of
Composites Pumping System was developed.
Design Criteria:
Work as efficiently in the small-to-mid size shop as it would in a fully automated operation.
Ability to handle multiple flow rates and varying materials to meet the demand for efficient
modularity.
Be constructed of rugged materials able to withstand increased production runs.
Greatly reduce the flow-rate variations to improve the precision in production.
Through extensive testing it has been shown that most standard pumping systems available on
the market today have variations in their resin flow rates as high as 25%, and the catalyst to resin
variance ratios were as high as 30%.
It became clear that as more manufacturers move into closed mould production, pumping system
performance would be even more critical to an efficient operation.
With a high precise metering system, many of the quality issues that currently face composites
manufacturers can be dramatically reduced. Those issues include:
Porosity
Pre-Release
Post Curing
Gelcoat Cracking
Alligatoring
Inconsistent Thickness
And more
While there are other factors that can contribute to these quality issues, an improved performance
in the meter/mix system can result in a significant reduction of these problems.

Alligatoring Porosity

Cracking
Why Is Precision in the Metering System Important?
The quality of the pumping system itself is another variable that will become more important as
the industry moves forward. In an increasing effort to find new ways of lowering production
costs, customers will begin demanding systems that will run and last longer and will deliver a
higher level of precise metering.


Catalyst Slide
Encoded Shaft for
Monitoring
Balanced Powerhead
Capture &
Control Weep
Point
Unique Self-
Healing Seal
Soft Stop
Inlet Valve
Floating
Slave Reduces
Wear
Ultra-Efficient
2-inch Stroke
Powerslide
Valve
Deep Induction Heat
Hardened Displacement Rod
Unique Self-Healing Seal
Guided Inlet Reduces
Pressure Loss
WHAT MAKES THE SYSTEM DIFFERENT?
Fluid Section
The displacement rod is deep induction heat hardened, and then coated with a thick hard chrome
layer to increase the wear characteristics of the system, allowing it to run for longer periods.
A unique self-healing seal with the lowest coefficients of friction available today is also a
component of what makes the system better. This seal, in both the resin and catalyst pumps,
does not require packing adjustments, and greatly reduces the problems associated with heat
build-up and wear.
Catalyst Pump
The Catalyst Pump is designed to be more efficient and durable. In addition to the new self-
healing seal, the Catalyst Pump features a new soft stop inlet valve which allows for a positive
seating surface with a stop feature to maintain consistent flow and reduce inlet ball wear, no
packing adjustments are necessary, the seals are pre-loaded, and is fully passivated to increase
durability.
Powerhead
Designed to meet market demand to reliably deliver smooth power at low pressures, the
Powerhead is available in three diameters:
3.25 Powerhead
5 Powerhead
7 Powerhead
With these sizes, the system is able to fit virtually any application process, and has been
engineered with interchangeable parts for easy ratio changes. In addition, the shaft in the
Powerhead has been encoded for easy adaptation when monitoring is required.
The technology engineered into the Powerhead includes:
- a pilot valve operated by line pressure
- allows for quick response shifting
- modular components
- Rapid Access Design (R.A.D.) for quick disassembly and reassembly
PUMP EFFICIENCY IN CLOSED MOULDING
How Does Precision Improve LRTM?
The extremely low variance rate offered by this new technology makes this system ideal not only
for typical chop and spray operations, but also for closed molding processes such as LRTM.
The closed molding process requires a higher level of precision with every cycle, and testing has
shown that it delivers the most efficient and consistent level of precision for the closed mold
process. If the injection system is inconsistent, the quality of the product will be inconsistent.
Testing Proves Efficiency
In the course of developing this system extensive testing was conducted, comparing it with two
existing standard pumping systems. The results were remarkable.
Flow variations, like the ones seen in the first set of graphs, were recorded during typical
application methods. The extreme fluctuations in pressure/flow can become real problems when
used in composites processing. Porosity, mil-build consistency, runs, sags, cracking and
emissions spikes are just a few of the problems that can occur with inconsistent material flow.












A careful analysis of the data showed how close the pressure/flow of both the resin and catalyst
were throughout the cycle of the pump. Again, the results clearly show that the resin to catalyst
ratios in the two standard systems vary dramatically, while the new precision metering system
remained consistent throughout the cycle. Key issues such as post curing, pre-release,
Precision Metering System Flow Variation 1.6%
Standard Metering System-1 Flow Variation 29% Standard Metering System-2 Flow Variation 22%
yellowing, and varying levels of Barcol development can easily be attributed to inconsistent
metering of catalyst.













Accurate catalyst-to-resin ratios are vital in achieving top quality in the end product when
processing todays materials.
CLOSED MOULDING CONTROLS
Process controls allow for a higher level of consistency during the injection/infusion process.
These controls can monitor and control the injection cycle, mould pressure and catalyst flow.
Currently, most manufacturers using LRTM/infusion use an electronic version of these controls.
However, it is not always best to put delicate electronics and associated power supplies on the
mould. New controls and monitors that are powered strictly by pneumatics, making them
safer and more rugged than electronic models, are now being developed and sold.
Utilizing Sensors for Improved Injection Control
A closed mould held together with vacuum is basically held with atmospheric pressure, so any
injected resin exceeding this pressure will warp the mould open. To avoid this, the mould
designer has two options, either build the mould much stronger, or simply provide the machine
with a control system so that the internal mould pressure never exceeds atmospheric clamping
pressure.
Precision Metering System Ratio Drift
Standard System 1 Ratio Drift
Standard System 2 Ratio Drift
Many injection machine suppliers attempt to do this at the machine nozzle, but as many have
come to realise this is not accurate enough. A pressure sensing device located INSIDE the
mould cavity, providing the machine with a signal to reduce speed as the pressure builds, is the
only accurate way to guard against over pressure inside the mould.
Pneumatic Pressure/Vacuum Sensor (PPVS) and Automatic Flow Shut-Off Valve Sensors
For several years this requirement has been addressed with electronic Pressure/Vacuum Sensors;
a small, inexpensive electronic sensor linked to the machine flow control circuit. However, even
though it operates the pneumatic machine control at low 12VDC supply, the ideal answer is to
avoid any electrical power altogether and maintain pure pneumatics on the whole system.
Developing a new pneumatic version of this technology was a challenge, especially in view that
a pressure change of only 30 -40 mb (0.75 psi) has to be sensed for these applications.
What was designed is the new ALL Pneumatic Pressure/Vacuum Sensor (PPVS). Embodied in a
neat PTFE sensor housing of remarkable sensitivity for a pneumatic device, and designed to fit in
a Universal mould insert system, it gives exactly the same precision control of the machine flow
and pressure that the earlier electronic version does. An added advantage is a significantly lower
cost than the earlier electronic version and, being pneumatic, it is considerably more robust for
the workshop environment.
In operation the Pneumatic Pressure/Vacuum Sensor system needs only one air supply which is
conveniently available, when injection starts, from the mould mounted automatic injection sprue
injection valve. The output is a single 6mm signal line which plugs into any injection system
with the proper signal.











Machine output flow (red) decreases as in-mould pressure builds (yellow)
The Pneumatic Pressure/Vacuum Sensor has been developed further in that its remarkable
sensitivity also allows for sensing the presence of resin at any point in the mould. Users normally
fill closed moulds with a certain amount of resin determined by the mould fill capacity. Most
modern day machines now incorporate a shot size pre-determined counter. This provides a
volumetric count of the machines output, and when the pre-determined shot count is reached the
machine is made to stop automatically. This method of mould fill is, at best, based on a degree of
guesswork as variations in fibre density and atmospheric conditions along with temperature
variations effecting resin viscosity all have an effect upon the exact amount of resin needed per
same mould fill. The consequence of these slight variations is that a higher mould fill shot count
is normally set to ensure the mould is never under filled.

This problem is addressed with the new Pneumatic Automatic Flow Shut-Off Valve, based upon
the same precision resin sensing technology of the PPVS described above. The Pneumatic
Automatic Flow Shut-Off Valve signals the machine to stop injecting in response to real
knowledge of when the mould is filled; meaning that the Automatic Flow Shut-Off Valve sensor,
strategically positioned near the final point of fill, will only stop the machine when the resin
actually arrives thus saving unnecessary overfill.









This simple, but highly effective, pneumatic sensor system eliminates the need for any form of
machine mould fill programming whether it be provided by a pre-determined shot counter or
more costly PLC controlled menu driven RFID system. As an alternative, the Pneumatic
Automatic Flow Shut-Off Valve now offers a significant cost savings, and provides safer and
more robust automatic control of the injection.
The new Pneumatic sensors have also been shown to be valuable tools in infusion moulds.
Positioned on the film using a PTFE flange insert they provide sufficient sensitivity to
automatically control the speed of incoming resin. Once infusion flow starts, especially into a
deep draw shape like a boat hull, the vacuum under the film will decrease in proportion to the fill
of resin. At a point determined by the experienced operator, the sensor is set to signal resin flow
to reduce or cease to guard against lifting the film. This sensor output signal is then directly fed
to a new low cost inline flow control valve to throttle down the resin thus providing a stand alone
automatic safe fill. Multiple pins of control can be set up in this manner so that no operator
intervention on infusion fill is needed. The low cost sensor and new in line throttle valve are all
non-sacrificial.
After infusion the various primary resin feed lines can be sealed below the valve, and then these
lines and valves can be flushed clean for further use.
Pure pneumatics provides precision injection pressure control and brings new safety to mould
filling.

ACCESSORIES FROM TOOLING TO INJECTION
There are a broad range of accessories available for LRTM/infusion, used in the mould tooling
process as well as in the injection/infusion process itself. In mould tooling there are a variety of
seals, inserts and more that are necessary to ensure a solid vacuum. During the injection/infusion
process there are tools such as the Universal Insert that allow for several of the process
accessories to attach to the mould using a single insert. Those accessories include the Automatic
Injection Valve, Vacuum Catchpot, Air Ejector, Pressure/Vacuum Sensor and more.

Automatic Injection Valve: The Automatic Injection Valve locks into the production mould
cavity and is controlled by the injection machine. The valve is connected to the machine nozzle
(via quick connect) and upon start of the injection, it opens, allowing mixed resin to pass into the
mould cavity. On completion of injection, the Automatic Injection Valve closes, isolating itself
from the mould cavity. It is then flushed at the mix-head.

Air Ejector: An Air Ejector is attached to one or more ports in a mould to assist with de-
moulding the finished part. It works by forcing air through it which provides a gentle ejection of
the part from the mould face. The precision engineering of the Air Ejector moves back from the
moulded part by only 0.5mm to allow air release between the mould and part faces.

Universal Insert: The Universal Insert standardizes all Light RTM mould fittings. Any
attachment to the mould is now possible using one industrial standard insert. This includes the
mould injection pipe or Automatic Injection Valve (Turbo Autosprue), flange vacuum, catchpot,
air ejector and mould pressure sensor.

Seals: Seals are a vital part of any mould as they allow a vacuum to be preserved during the
mould sealing and injection of the part. They are offered in a variety of types and styles to fit the
needs of most mould tooling.