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首页> 外文学位 >Studies in process modeling, design, monitoring, and control, with applications to polymer composites manufacturing.
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Studies in process modeling, design, monitoring, and control, with applications to polymer composites manufacturing.

机译：研究过程建模，设计，监控和控制，并将其应用于聚合物复合材料的制造。

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High material and manufacturing costs have hindered the introduction of advanced polymer composite materials into mainstream civilian applications such as automotive. Even though high-fidelity models for several polymer composite manufacturing processes have become available over the past several years and offer significant benefits in manufacturing cost reduction, concerns about their inflexibility and maintenance has adversely affected their widespread usage. This research seeks to advance process modeling and design in polymer composites manufacturing to address these concerns. Other more general issues in measurement validation and distributed control are also addressed.; Using a rigorous 3-D model of the injected pultrusion (IP) process validated recently, an algorithm was developed for process and equipment design with integrated economic, operability and environmental considerations. The optimum design promised enhanced throughput as well as reduction in the time and expenses of the current purely experimental approaches. Scale-up issues in IP were analyzed, and refinements to overcome some drawbacks in the model were suggested. The process model was then extended to simulate the co-injection resin transfer molding (CIRTM) process used for manufacture of foam-core sandwich composites. A 1-D isothermal model for real-time control was also developed. Process optimization using these models and experimental parametric studies increased the debond fracture toughness of sandwiches by 78% over current technology. To ensure the availability of validated measurements from process instrumentation, a novel in-situ sensor modeling approach to sensor validation was proposed. Both active and passive, time and frequency domain techniques were developed, and experimentally verified using temperature and flow sensors. A model-based dynamic estimator to predict the true measurement online was also validated. The effect of network communication delay on stability and control of processes has been studied theoretically and experimentally for the first time. An application protocol was developed for safe remote access of laboratory-scale heat-exchanger and mixing tank processes, and used to characterize network delays. A new model predictive control algorithm based on time-stamps and buffering was developed and experimentally validated.; This research will help reduce manufacturing costs by providing methods in process development and optimization. The methodology and algorithms developed are easily extensible to a variety of processes.
机译：高昂的材料和制造成本阻碍了将先进的聚合物复合材料引入主流民用应用，例如汽车。尽管在过去的几年中已经可以使用几种聚合物复合材料制造工艺的高保真度模型，并且在降低制造成本方面具有显着的优势，但由于其灵活性和维护性的担忧，已经严重影响了其广泛使用。这项研究旨在推进聚合物复合材料制造中的过程建模和设计，以解决这些问题。还讨论了测量验证和分布式控制中的其他更普遍的问题。使用最近验证的注射拉挤成型（IP）过程的严格3-D模型，开发了一种用于过程和设备设计的算法，并综合了经济，可操作性和环境方面的考虑。最佳设计有望提高吞吐量，并减少当前纯实验方法的时间和费用。分析了IP中的放大问题，并提出了改进措施以克服该模型中的某些缺点。然后扩展了工艺模型，以模拟用于制造泡沫芯三明治复合材料的共注射树脂传递模塑（CIRTM）工艺。还开发了用于实时控制的一维等温模型。与现有技术相比，使用这些模型和实验参数研究进行的过程优化使三明治的脱粘断裂韧性提高了78％。为了确保从过程仪表获得经过验证的测量结果的可用性，提出了一种新颖的用于传感器验证的原位传感器建模方法。主动和被动，时域和频域技术都得到了发展，并使用温度和流量传感器进行了实验验证。还验证了基于模型的动态估计器，以在线预测真实的测量结果。首次在理论和实验上研究了网络通信延迟对过程稳定性和过程控制的影响。开发了一种应用协议，用于安全地远程访问实验室规模的热交换器和混合罐工艺，并用于表征网络延迟。开发了一种基于时间戳和缓冲的模型预测控制算法，并进行了实验验证。这项研究将通过提供过程开发和优化方法来帮助降低制造成本。所开发的方法和算法很容易扩展到各种过程。

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