Numerical study of thermal control system for rapid heat cycle injection molding process

2014 ◽  
Vol 229 (4) ◽  
pp. 315-326 ◽  
Author(s):  
Moez Hammami ◽  
Fatma Kria ◽  
Mounir Baccar
Keyword(s):  
Control System ◽  
Injection Molding ◽  
Numerical Study ◽  
Thermal Control ◽  
Injection Molding Process ◽  
Molding Process ◽  
Heat Cycle ◽  
Thermal Control System

A Numerical Study on the Thermal Control of Lithium Batteries by Composite Phase Change Materials and Metal Foams

2021 ◽  
Author(s):  
Bernardo Buonomo ◽  
Oronzio Manca ◽  
Ferdinando Menale ◽  
Francesco Moriello ◽  
Simone Mancin
Keyword(s):  
Control System ◽  
Phase Change ◽  
Metal Foam ◽  
Numerical Study ◽  
Liquid Fraction ◽  
Convective Heat Transfer Coefficient ◽  
Thermal Control ◽  
Temperature Fields ◽  
Local Thermal Equilibrium ◽  
Thermal Control System

Abstract This study attempts to control the temperature peaks due to the operation of the battery itself by examining a two-dimensional model to numerically investigate the thermal control of a lithium battery of a commercial electric car. The battery has the dimensions of 8 cm × 31 cm × 67 cm and its capacity is equal to 232 Ah with 5.3 kWh. Thermal control is achieved by means of an internal layer of copper or aluminum foam and phase change material (paraffin), placed on the top of the battery and the external surfaces are cooled by a convective flow. The governing equations, written assuming the local thermal equilibrium for the metal foam, are solved with the finite volume method using the commercial code Ansys-Fluent. Different cases are simulated for different thicknesses of the thermal control system and external convective heat transfer coefficient. The results are given in terms of temperature fields, liquid fraction, surface temperature profiles as a function of time and temperature distributions along the outer surface of the battery for the different cases. In addition, some comparisons with pure PCM are provided to show the advantages of the composite thermal control system with PCM inside the metal foam.

scholarly journals Development of a mathematical model for the numerical study of a thermal control system fluid circuit

2019 ◽  
Vol 537 ◽  
pp. 022003
Author(s):  
F V Tanasienko ◽  
Yu N Shevshenko ◽  
M G Melkozerov ◽  
A A Kishkin ◽  
A V Delkov ◽  
...  
Keyword(s):  
Mathematical Model ◽  
Control System ◽  
Numerical Study ◽  
Thermal Control ◽  
Thermal Control System

Comprehensive Online Control Strategies for Plastic Injection Molding Process

2014 ◽  
Vol 136 (4) ◽  
Author(s):  
Jaho Seo ◽  
Amir Khajepour ◽  
Jan P. Huissoon
Keyword(s):  
Injection Molding ◽  
Injection Pressure ◽  
Thermal Control ◽  
Plastic Injection Molding ◽  
Injection Molding Process ◽  
Molding Process ◽  
Element Analysis ◽  
Thermal Dynamics ◽  
Uncertain Dynamics ◽  
Plastic Injection

This study proposes an effective thermal control for plastic injection molding (polymer: Santoprene 8211-45 with density of 790 kg/m3, injection pressure: 1400 psi (9,652,660 Pa)) in a laminated die. For this purpose, a comprehensive control strategy is provided to cover various themes. First, a new method for determining the optimal sensor locations as a prerequisite step for modeling and controller design is introduced. Second, system identification through offline and online training with finite element analysis and neural network techniques are used to develop an accurate model by incorporating uncertain dynamics of the laminated die. Third, an additive feedforward control by adding direct adaptive inverse control to self-adaptive PID is developed for temperature control of cavity wall (cavity size: 52.9 × 32.07 × 16.03 mm). A verification of designed controller's performance demonstrates that the proposed strategy provides accurate online temperature tracking and faster response under thermal dynamics with various cycle-times in the injection mold process.

Numerical Study on the Melt Flow Length of the Composite Materials in the Injection Molding Process

2019 ◽  
Vol 971 ◽  
pp. 15-20
Author(s):  
The Nhan Phan ◽  
Trung Do Thanh ◽  
Son Minh Pham
Keyword(s):  
Composite Materials ◽  
Injection Molding ◽  
Numerical Study ◽  
Mold Temperature ◽  
Injection Molding Process ◽  
Melt Flow ◽  
Molding Process ◽  
Flow Length ◽  
Part Thickness ◽  
Good Agreement

Improving the melt flow length by increasing the mold temperature has been an issue encountered in the injection molding processes for composite products. In this study, an injection molding process was applied to a melt flow length model having a part thickness of 1.0 mm. The mold temperature varied from 30 °C to 110 °C. Six types of composite materials of polycaprolactam 6 (PA6) and glass fiber (GF) were selected to study the influence of mold temperature on the material filling in the injection molding process. The simulation results denoted that the mold temperature considerably influenced the flowability during the injection molding process, especially using 30% GF; further, the melt flow length was increased by 25.5% when the mold temperature was increased from 30 °C to 110 °C. In accordance with the simulation, our experiments demonstrated that we could achieve a mold temperature of 110 °C using all types of composite materials. Therefore, in this study, we denoted that both the simulation and experimental results of the melt flow length were comparable, thereby indicating a good agreement.

scholarly journals Study of an Online Monitoring Adaptive System for an Injection Molding Process Based on a Nozzle Pressure Curve

Polymers ◽  
2021 ◽  
Vol 13 (4) ◽  
pp. 555
Author(s):  
Jia-Chen Fan-Jiang ◽  
Chi-Wei Su ◽  
Guan-Yan Liou ◽  
Sheng-Jye Hwang ◽  
Huei-Huang Lee ◽  
...  
Keyword(s):  
Control System ◽  
Injection Molding ◽  
Peak Pressure ◽  
Viscosity Index ◽  
Injection Molding Process ◽  
Pressure Curve ◽  
Molding Process ◽  
Injection Speed ◽  
Nozzle Pressure ◽  
Product Weight

Injection molding is a popular process for the mass production of polymer products, but due to the characteristics of the injection process, there are many factors that will affect the product quality during the long fabrication processes. In this study, an adaptive adjustment system was developed by C++ programming to adjust the V/P switchover point and injection speed during the injection molding process in order to minimize the variation of the product weight. Based on a series of preliminary experiments, it was found that the viscosity index and peak pressure had a strong correlation with the weight of the injection-molded parts. Therefore, the viscosity index and peak pressure are used to guide the adjustment in the presented control system, and only one nozzle pressure sensor is used in the system. The results of the preliminary experiments indicate that the reduction of the packing time and setting enough clamping force can decrease the variation of the injected weight without turning on the adaptive control system; meanwhile, the master pressure curve obtained from the preliminary experiment was used as the control target of the system. With this system, the variation of the product weight and coefficient of variation (CV) of the product weight can be decreased to 0.21 and 0.05%, respectively.

Towards Controllability of Injection Molding

1999 ◽  
Author(s):  
David Kazmer ◽  
David Hatch
Keyword(s):  
Injection Molding ◽  
System Design ◽  
Polymer Melt ◽  
Thermal Control ◽  
Polymer Processing ◽  
Injection Molding Process ◽  
Molding Process ◽  
Thermal Dynamics ◽  
Design Changes ◽  
Novel Processing

Abstract Process control has been recognized as an important means of improving the performance and consistency of thermoplastic parts. However, no single control strategy or system design has been universally accepted, and molding systems continue to produce defective components during production. The capability of the injection molding process is limited by the thermal and flow dynamics of the heated polymer melt. This paper discusses some of the difficulties posed by complex and distributed nature of the injection molding process. The flow and thermal dynamics of the process are analyzed with respect to transport and rheology. Then, two novel processing methods are described to enable in-cycle flow, pressure, and thermal control. Simulation and experimental results demonstrate effectiveness of these innovations to increase the consistency and flexibility in polymer processing. Such system design changes simplify the requisite control structures while improving the process robustness and productivity.

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