NSF/DOE/APC Workshop - Future of Modeling in Composites Molding ProcessesJune 9 and 10, 2004

9 and 10 June 2004Glancey – SCA Group

Automation and Control For Liquid Injection Molding Systems

Progress and Future Challenges

James GlanceyUniversity of Delaware

NSF/DOE/APC Workshop Future of Modeling in Composites Molding Processes

Design and Optimization GroupJune 9-10, 2004

9 and 10 June 2004NSF/DOE/APC Workshop - Future of Modeling in Composites Molding ProcessesGlancey – SCA Group

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

9 and 10 June 2004NSF/DOE/APC Workshop - Future of Modeling in Composites Molding ProcessesGlancey – SCA Group

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”

9 and 10 June 2004NSF/DOE/APC Workshop - Future of Modeling in Composites Molding ProcessesGlancey – SCA Group

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

9 and 10 June 2004NSF/DOE/APC Workshop - Future of Modeling in Composites Molding ProcessesGlancey – SCA Group

Automated Manufacturing Benchmarks

3) Injection Molding Station1) Flexible Manufacturing

2) CNC Machining

9 and 10 June 2004NSF/DOE/APC Workshop - Future of Modeling in Composites Molding ProcessesGlancey – SCA Group

Automation of Processes

9 and 10 June 2004NSF/DOE/APC Workshop - Future of Modeling in Composites Molding ProcessesGlancey – SCA Group

General Characteristics of Production Methods

9 and 10 June 2004NSF/DOE/APC Workshop - Future of Modeling in Composites Molding ProcessesGlancey – SCA Group

Typical Annual Production

TABLE 38.2Type of production Number produced Typical productsExperimental or prototype 1–10 AllPiece or small batch 10–5000 Aircraft, special machinery, dies, jewelry, orthopedic

implants, missiles.Batch or high volume 5000–100,000 Trucks, agricultural machinery, jet engines, diesel engines;

computer components, sporting goods.Mass production 100,000 and over Automobiles, appliances, fasteners, food and beverage

containers.

9 and 10 June 2004NSF/DOE/APC Workshop - Future of Modeling in Composites Molding ProcessesGlancey – SCA Group

Example: Defect Reduction In Casting via Automation

Common Casting Defects

9 and 10 June 2004NSF/DOE/APC Workshop - Future of Modeling in Composites Molding ProcessesGlancey – SCA Group

Example of Automation in Composites-Pultrusion

• Highly Automated• High Production Rates• Consistent, High Quality Parts • Technically and Economically Viable

9 and 10 June 2004NSF/DOE/APC Workshop - Future of Modeling in Composites Molding ProcessesGlancey – SCA Group

Integrating Part Quality into the Manufacturing System

Automated and Semi-AutomatedQuality Assessments

On-Line Part Characterization and Statistical Quality Control

9 and 10 June 2004NSF/DOE/APC Workshop - Future of Modeling in Composites Molding ProcessesGlancey – SCA Group

Current Work In VARTM

0

1

2

3

4

5

6

0 1 2 3 4 5 6 7 8

0

1

2

3

4

5

6

0 1 2 3 4 5 6 7 8

No Control

Controlled w/Segmented Line

High PermeabilityRegion

High PermeabilityRegion

Controlling Resin Flow within the Mold

- Critical for Automation - Localized Heating- Segmented Injection Line- Flow Sensing- Real-Time Simulations- Closed-Loop Control

9 and 10 June 2004NSF/DOE/APC Workshop - Future of Modeling in Composites Molding ProcessesGlancey – SCA Group

Controller Design

PID Processr e u

y

Traditional Form:

Adaptive Form:

Process

ProcessModel

StateCalculation

StateController

y

u

r

e

9 and 10 June 2004NSF/DOE/APC Workshop - Future of Modeling in Composites Molding ProcessesGlancey – SCA Group

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