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Automation and Control For Liquid Injection Molding Systems Progress and Future Challenges

Automation and Control For Liquid Injection Molding Systems Progress and Future Challenges. James Glancey University of Delaware NSF/DOE/APC Workshop Future of Modeling in Composites Molding Processes Design and Optimization Group June 9-10, 2004. Presentation Overview.

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Automation and Control For Liquid Injection Molding Systems Progress and Future Challenges

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  1. Automation and Control For Liquid Injection Molding SystemsProgress and Future Challenges James Glancey University of Delaware NSF/DOE/APC Workshop Future of Modeling in Composites Molding Processes Design and Optimization Group June 9-10, 2004

  2. Presentation Overview • Potential Benefits of Automation and Control for LCM Systems • Benchmarks for Automation and Controls in Other Industries • Examples of Recent Developments • Localized Heating • Smart Injection Line and Real Time Adaptive Control Developments • Short and Long Term Automation Strategies for LCM

  3. Key Issues to being Addressed in LCM Manufacturing • Quality • Need exists to continue to improve individual part quality • Dry spots/voids, especially with complex geometries • Cost • Abundant injection lines • Extended injection times • Trial and error approach for making parts • Overcoming “Manual Manufacturing Processes”

  4. Potential Benefits of Automation • Improve controllability as a means to automate • Reduce manual operations • Improve part quality, reduce resin waste, and decrease injection for VARTM • Requirements: • Versatile • Simple • Low cost • System Integration • Value

  5. Automated Manufacturing Benchmarks 2) CNC Machining 1) Flexible Manufacturing 3) Injection Molding Station

  6. Automation of Processes

  7. General Characteristics of Production Methods

  8. Typical Annual Production

  9. Example: Defect Reduction In Casting via Automation Common Casting Defects

  10. Example of Automation in Composites-Pultrusion • Highly Automated • High Production Rates • Consistent, High Quality Parts • Technically and Economically Viable

  11. Integrating Part Quality into the Manufacturing System On-Line Part Characterization and Statistical Quality Control Automated and Semi-Automated Quality Assessments

  12. Current Work In VARTM • Controlling Resin Flow • within the Mold • Critical for Automation • Localized Heating • Segmented Injection Line • Flow Sensing • Real-Time Simulations • Closed-Loop Control High Permeability Region No Control High Permeability Region Controlled w/Segmented Line

  13. Controller Design Traditional Form: r e u y PID Process Adaptive Form: y State Controller u Process Process Model e r State Calculation

  14. Potential Strategies for LCM Automation • Short-term – Resin Flow Control • Continue to develop actuation methods (Smart Injection Line, Localized Heating, etc) • Develop Other Techniques • Work towards true closed-loop control of the flow • Long-Term – True System Automation • Integrate, Exploit and Adapt Existing Science and Technology • Computer Controls, Sensors, • Modern Control Theory - In Particular Stochastic Methods • System Integration • Integration of Quality Control into the Manufacturing Process

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