Low-cost process monitoring for polymer extrusion - Essex, 2013
description
Transcript of Low-cost process monitoring for polymer extrusion - Essex, 2013
![Page 1: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/1.jpg)
energy, power & intelligent control
low cost process monitoring for polymer extrusion
1
Dr Jing DengEnergy, Power and Intelligent Control
School of Electronics, Electrical Engineering and Computer ScienceQueen's University Belfast
13/08/[email protected]
![Page 2: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/2.jpg)
energy, power & intelligent control
Content2
1. Background .
2. Thermal energy consumption monitoring.
3. Motor power consumption monitoring.
4. Viscosity monitoring through ‘soft-sensoring’.
5. Summary and future work.
![Page 3: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/3.jpg)
energy, power & intelligent control
1. Background
Melt pressure
Melt temperature
Feed rate
Barrel temperature
Screw speed
Viscosity
3
![Page 4: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/4.jpg)
energy, power & intelligent control4
Killion KTS-100 laboratory single-screw extruder
Geometrical screw parameters
DC motor power (kW) 2.24Screw diameter (mm) 25No. of barrel temperature zones 3Additional temperature zones connected
3
Operating speed range (rpm) 0-115
Extruder Specifications
2. Thermal energy monitoring - the extruder1. Background
![Page 5: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/5.jpg)
energy, power & intelligent control
2. Thermal energy monitoring - the heating and cooling
Zone 1, Heating band1.296kw
Zone 2, Heating band1.267kw
Zone 3, Heating band1.238kw
Clamp ring heating band0.4964kw
Adapter heating band0.106kw
Controller circuit0.0016kw
Other circuits0.06kw
Cooling fan0.04637kw
Heating and cooling elements of the single screw extruder
5
2. Thermo energy monitoring
![Page 6: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/6.jpg)
energy, power & intelligent control
6
L1 L2 NL3
L1:• Controller circuits• Zone 3 heating and cooling• Motor drive power supply
L2:• Zone 1 heating and cooling• Zone 4 heating
L3: • Zone 2 heating and cooling• Zone 5 heating
2. Thermal energy monitoring - power supply
2. Thermo energy monitoring
![Page 7: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/7.jpg)
energy, power & intelligent control
2. Thermal energy monitoring - the controller
7
2. Thermo energy monitoring
![Page 8: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/8.jpg)
energy, power & intelligent control
8
PIDController
Heating band
Cooling Fan ExtruderBarrel Zone
Temperature
SetTemperature
AFM215-303DURAKOOL Mercury displacement contactor
Time-proportional control
2. Thermal energy monitoring - the controller
2. Thermo energy monitoring
![Page 9: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/9.jpg)
energy, power & intelligent control
9
More close to the actual
power consumption
2. Thermo energy monitoring
![Page 10: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/10.jpg)
energy, power & intelligent control
10
Advantage: • Additional power consumption measurement• More accurate thermal energy monitoring• Expensive power meter is not required
Separate power supply
2. Thermal energy monitoring - the advantages
2. Thermo energy monitoring
![Page 11: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/11.jpg)
energy, power & intelligent control
11
Plot of energy consumption by different zones, screw speed at 10, cooling temperature at 25 degree Temperature settings 170-180-190, material: LDPE 2102TN32W, MFR:2.5g/10min at 190 °C and 2.16 kg
2. Thermal energy monitoring - monitor separate heating zones
2. Thermo energy monitoring
![Page 12: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/12.jpg)
energy, power & intelligent control
12
Extruder Killion KTS-100Material SABIC LDPE 2100TN00WCooling temperature setting: 25Temperature setting: 170-180-190Screw speed: 40 rpmData file: 20120720C
2. Thermal energy monitoring - monitor separate heating zones
2. Thermo energy monitoring
![Page 13: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/13.jpg)
energy, power & intelligent control
3. Motor power consumption monitoring - the controller
13
L1 N
![Page 14: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/14.jpg)
energy, power & intelligent control
14
3. Motor power consumption monitoring - the controller
Power in
Power out
![Page 15: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/15.jpg)
energy, power & intelligent control
15
Those rising edges contain high-frequency energy from harmonics of the PWM signal's frequency. Because a motor presents an inductive load to the inverter circuits, its inductance filters much of the high-frequency energy. The high frequencies do little to rotate the motor, but the energy in those frequencies must go somewhere, and the high-frequency energy dissipates as heat.
Measure PWM motor efficiency
3. Motor power consumption monitoring - the controller
![Page 16: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/16.jpg)
energy, power & intelligent control
16
Motor Apparent power consumption
Power factor
Active power
Screw speed
Voltage
current
current
Screw speed
3. Motor power consumption monitoring - Apparent power consumption
![Page 17: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/17.jpg)
energy, power & intelligent control
17
V_a = R_a * I + K_v * w
R_a = 12.4222;K_v = 0.0038
V_a = 12.4222 * I + 0.0038 * N
3. Motor power consumption monitoring - the controller
![Page 18: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/18.jpg)
energy, power & intelligent control
18
4. Viscosity monitoring
Viscosity measurement
On-line rheometer In-line rheometer Off-line rheometer
![Page 19: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/19.jpg)
energy, power & intelligent control
2. Viscosity monitoring
3/09/2012 Queen's University Belfast
19
Viscosity calculation
𝜏=𝐻2 (∆ 𝑃𝐿 ) �̇�=
2𝑛+13𝑛 ( 6𝑄𝑊 𝐻 2 )
4. Viscosity monitoring
![Page 20: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/20.jpg)
energy, power & intelligent control
2. Viscosity monitoring
3/09/2012 Queen's University Belfast
20
Viscosity calculation
By substituting typical values
4. Viscosity monitoring
![Page 21: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/21.jpg)
energy, power & intelligent control
21
4. Viscosity monitoring
![Page 22: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/22.jpg)
energy, power & intelligent control
Table 1: The comparison of forward and backward selection
Advantage Disadvantage
Forward Fast/less computing Constrained minimization
Backward Slow/much computing Unconstrained minimization
• Forward selection method (constrained minimisation)y
X1X1 θ1
e = y – X1 θ1
y
X1X1
= y – X1 θ1-X2 θ2
X2
X2 θ2
e
θ 1
4. Viscosity monitoring
![Page 23: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/23.jpg)
energy, power & intelligent control
1 2 k n
j
Selected termsStage 1: Forward model selection
Stage 2: Backward model refinement - Loop 1 …….. - Loop 2 …….. - Loop 3 …….. ………
Candidate terms pool
Two-stage selection
• Remains efficient and effective from FRA• Eliminates optimization constraint in FRA• Reduces the training error without increasing model size
4. Viscosity monitoring
![Page 24: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/24.jpg)
energy, power & intelligent control
24
4. Viscosity monitoring
Consider a general nonlinear model
Write in a matrix form
![Page 25: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/25.jpg)
energy, power & intelligent control
25
4. Viscosity monitoring
A optimal design criterion
where is known as the design matrix
The new cost function becomes
![Page 26: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/26.jpg)
energy, power & intelligent control
26
4. Viscosity monitoring
define
Some properties of R
![Page 27: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/27.jpg)
energy, power & intelligent control
27
4. Viscosity monitoring
Also define some auxiliary matrices
![Page 28: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/28.jpg)
energy, power & intelligent control
28
4. Viscosity monitoring
![Page 29: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/29.jpg)
energy, power & intelligent control
29
4. Viscosity monitoring
Recursive updating
Net contribution of a new term to the cost function
![Page 30: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/30.jpg)
energy, power & intelligent control
30
4. Viscosity monitoring
Employing Branch and Bound
![Page 31: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/31.jpg)
energy, power & intelligent control
31
4. Viscosity monitoring
The net contribution of a new term to the cost function
where
![Page 32: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/32.jpg)
energy, power & intelligent control
32
4. Viscosity monitoring
![Page 33: Low-cost process monitoring for polymer extrusion - Essex, 2013](https://reader036.fdocuments.us/reader036/viewer/2022062511/54c234e74a79596d658b4652/html5/thumbnails/33.jpg)
energy, power & intelligent control
33
5. Summary and future work
• Low cost process monitoring techniques have been developed for polymer extrusion, including thermo energy monitoring, motor power consumption monitoring, and viscosity monitoring.
• A-optimal design criterion and branch and bound can be employed into subset selection algorithm to further improve model compactness and computational effort.
• Current and future work mainly focus on commercialisation of research outputs through an PoC project.