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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

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

presentation overview
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
key issues to being addressed in lcm manufacturing
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”
potential benefits of automation
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
automated manufacturing benchmarks
Automated Manufacturing Benchmarks

2) CNC Machining

1) Flexible Manufacturing

3) Injection Molding Station

example of automation in composites pultrusion
Example of Automation in Composites-Pultrusion
  • Highly Automated
  • High Production Rates
  • Consistent, High Quality Parts
  • Technically and Economically Viable
integrating part quality into the manufacturing system
Integrating Part Quality into the Manufacturing System

On-Line Part Characterization and Statistical Quality Control

Automated and Semi-Automated

Quality Assessments

current work in vartm
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

controller design
Controller Design

Traditional Form:

r

e

u

y

PID

Process

Adaptive Form:

y

State

Controller

u

Process

Process

Model

e

r

State

Calculation

potential strategies for lcm automation
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