Extruder Melt Temperature Control with Fuzzy Logic

In polymer extrusion, the delivery of a melt which is homogenous in composition and temperature is paramount for achieving high quality extruded products. However, advancements in process control are required to reduce temperature variations across the melt flow which can result in poor product quality. The majority of thermal monitoring methods provide only low accuracy point/bulk melt temperature measurements and cause poor controller performance. Furthermore, the most common conventional proportional-integral-derivative controllers seem to be incapable of performing well over the nonlinear operating region. This paper presents a model-based fuzzy control approach to reduce the die melt temperature variations across the melt flow while achieving desired average die melt temperature. Simulation results confirm the efficacy of the proposed controller.

Energy monitoring and quality control of a single screw extruder

Polymer extrusion, in which a polymer is melted and conveyed to a mould or die, forms the basis of most polymer processing techniques. Extruders frequently run at non-optimised conditions and can account for 15–20% of overall process energy losses. In times of increasing energy efficiency such losses are a major concern for the industry. Product quality, which depends on the homogeneity and stability of the melt flow which in turn depends on melt temperature and screw speed, is also an issue of concern of processors. Gear pumps can be used to improve the stability of the production line, but the cost is usually high. Likewise it is possible to introduce energy meters but they also add to the capital cost of the machine. Advanced control incorporating soft sensing capabilities offers opportunities to this industry to improve both quality and energy efficiency. Due to strong correlations between the critical variables, such as the melt temperature and melt pressure, traditional decentralized PID (Proportional–Integral–Derivative) control is incapable of handling such processes if stricter product specifications are imposed or the material is changed from one batch to another. In this paper, new real-time energy monitoring methods have been introduced without the need to install power meters or develop data-driven models. The effects of process settings on energy efficiency and melt quality are then studied based on developed monitoring methods. Process variables include barrel heating temperature, water cooling temperature, and screw speed. Finally, a fuzzy logic controller is developed for a single screw extruder to achieve high melt quality. The resultant performance of the developed controller has shown it to be a satisfactory alternative to the expensive gear pump. Energy efficiency of the extruder can further be achieved by optimising the temperature settings. Experimental results from open-loop control and fuzzy control on a Killion 25 mm single screw extruder are presented to confirm the efficacy of the proposed approach.

Feedforward Control of Shape Memory Alloy Actuators Using Fuzzy-Based Inverse Preisach Model

This brief investigates a possible application of the inverse Preisach model in combination with the feedforward and feedback control strategies to control shape memory alloy actuators. In the feedforward control design, a fuzzy-based inverse Preisach model is used to compensate for the hysteresis nonlinearity effect. An extrema input history and a fuzzy inference is utilized to replace the inverse classical Preisach model. This work allows for a reduction in the number of experimental parameters and computation time for the inversion of the classical Preisach model. A proportional-integral-derivative (PID) controller is used as a feedback controller to regulate the error between the desired output and the system output. To demonstrate the effectiveness of the proposed controller, real-time control experiment results are presented.

Position control of shape memory alloy actuators using self tuning fuzzy PID controller

Shape Memory Alloy (SMA) actuators, which have the ability to return to a predetermined shape when heated, have many potential applications such as aeronautics, surgical tools, robotics and so on. Although the conventional PID controller can be used with slow response systems, there has been limited success in precise motion control of SMA actuators, since the systems are disturbed by unknown factors beside their inherent nonlinear hysteresis and changes in the surrounding environment of the systems. This paper presents a new development of a SMA position control system by using a self-tuning fuzzy PID controller. This control algorithm is used by tuning the parameters of the PID controller thereby integrating fuzzy inference and producing a fuzzy adaptive PID controller, which can then be used to improve the control performance of nonlinear systems. The experimental results of position control of SMA actuators using conventional and self-tuning fuzzy PID controllers are both included in this paper.

Internal model control for shape memory alloy actuators using fuzzy based Preisach model

This paper investigates a possible application of Preisach model to control shape memory alloy (SMA) actuators using an internal model control strategy. The developed strategy consists in including the Preisach hysteresis model of SMA actuator and the inverse Preisach model within the control structure. In this work, an extrema input hystory and a fuzzy inference is utilized to replace the classical Preisach model. This allows to reduce a large amount of experimental parameters and computation time of the classical Preisach model. To demonstrate the effectiveness of the proposed controller in improving control performance and hysteresis compensation of SMA actuators, experimental results from real time control are presented.

Trajectory Control of Electro Hydraulic Excavator using Fuzzy Self Tuning Algorithm with Neural Network

This paper presents the trajectory control of a 2DOF mini electro-hydraulic excavator by using fuzzy self tuning with neural network algorithm. First, the mathematical model is derived for the 2DOF mini electro-hydraulic excavator. The fuzzy PID and fuzzy self tuning with neural network are designed for circle trajectory following. Its two links are driven by an electric motor controlled pump system. The experimental results demonstrated that the proposed controllers have better control performance than the conventional controller.

Modelling and Control of Shape Memory Alloy Actuators by using Preisach Model, Genetic Algorithm and Fuzzy Logic

Shapememoryalloy (SMA) actuators, which have the ability to return to a predetermined shape when heated, have many potential applications in aeronautics, surgical tools, robotics and so on. Nonlinearity hysteresis effects existing in SMA actuators present a problem in the motion control of these smart actuators. This paper investigates the control problem of SMA actuators in both simulation and experiment. In the simulation, the numerical Preisachmodel with geometrical interpretation is used for hysteresis modeling of SMA actuators. This model is then incorporated in a closed loop PID control strategy. The optimal values of PID parameters are determined by using geneticalgorithm to minimize the mean squared error between desired output displacement and simulated output. However, the control performance is not good compared with the simulation results when these parameters are applied to the real SMA control since the system is disturbed by unknown factors and changes in the surrounding environment of the system. A further automated readjustment of the PID parameters using fuzzylogic is proposed for compensating the limitation. To demonstrate the effectiveness of the proposed controller, real time control experiment results are presented.