Advanced Modelling and Optimization of Infared Oven in Injection Stretch Blow-moulding for Energy Saving

In the production process of polyethylene terephthalate (PET) bottles, the initial temperature of preforms plays a central role on the final thickness, intensity and other structural properties of the bottles. Also, the difference between inside and outside temperature profiles could make a significant impact on the final product quality. The preforms are preheated by infrared heating oven system which is often an open loop system and relies heavily on trial and error approach to adjust the lamp power settings. In this paper, a radial basis function (RBF) neural network model, optimized by a two-stage selection (TSS) algorithm combined with partial swarm optimization (PSO), is developed to model the nonlinear relations between the lamp power settings and the output temperature profile of PET bottles. Then an improved PSO method for lamp setting adjustment using the above model is presented. Simulation results based on experimental data confirm the effectiveness of the modelling and optimization method.

Process efficiency in polymer extrusion: Correlation between the energy demand and melt thermal stability

Thermal stability is of major importance in polymer extrusion, where product quality is dependent upon the level of melt homogeneity achieved by the extruder screw. Extrusion is an energy intensive process and optimisation of process energy usage while maintaining melt stability is necessary in order to produce good quality product at low unit cost. Optimisation of process energy usage is timely as world energy prices have increased rapidly over the last few years. In the first part of this study, a general discussion was made on the efficiency of an extruder. Then, an attempt was made to explore correlations between melt thermal stability and energy demand in polymer extrusion under different process settings and screw geometries. A commodity grade of polystyrene was extruded using a highly instrumented single screw extruder, equipped with energy consumption and melt temperature field measurement. Moreover, the melt viscosity of the experimental material was observed by using an off-line rheometer. Results showed that specific energy demand of the extruder (i.e. energy for processing of unit mass of polymer) decreased with increasing throughput whilst fluctuation in energy demand also reduced. However, the relationship between melt temperature and extruder throughput was found to be complex, with temperature varying with radial position across the melt flow. Moreover, the melt thermal stability deteriorated as throughput was increased, meaning that a greater efficiency was achieved at the detriment of melt consistency. Extruder screw design also had a significant effect on the relationship between energy consumption and melt consistency. Overall, the relationship between the process energy demand and thermal stability seemed to be negatively correlated and also it was shown to be highly complex in nature. Moreover, the level of process understanding achieved here can help to inform selection of equipment and setting of operating conditions to optimise both energy and thermal efficiencies in parallel. 

A Soft Sensor for Viscosity Control of Polymer Extrusion

Viscosity represents a key indicator of product quality in polymer extrusion but has traditionally been difficult to measure in-process in real-time. An innovative, yet simple, solution to this problem is proposed by a Prediction-Feedback observer mechanism. A `Prediction' model based on the operating conditions generates an open-loop estimate of the melt viscosity; this estimate is used as an input to a second, `Feedback' model to predict the pressure of the system. The pressure value is compared to the actual measured melt pressure and the error used to correct the viscosity estimate. The Prediction model captures the relationship between the operating conditions and the resulting melt viscosity and as such describes the specific material behavior. The Feedback model on the other hand describes the fundamental physical relationship between viscosity and extruder pressure and is a function of the machine geometry. The resulting system yields viscosity estimates within 1% error, shows excellent disturbance rejection properties and can be directly applied to model-based control. This is of major significance to achieving higher quality and reducing waste and set-up times in the polymer extrusion industry.

Hydroprocessing of waste cooking oil over a dispersed nano catalyst: Kinetics study and temperature effect

The kinetics of hydrodeoxygenation of waste cooking oil (WCO) is investigated with unsupported CoMoS catalysts. A kinetic model is established and a comprehensive analysis of each reaction pathway is carried out. The results show that hydrodecarbonylation/decarboxylation (HDC) routes are the predominant reaction pathways in the elimination of oxygen, with the rate constant three times as high as that of hydrodeoxygenation (HDO). However, the HDC activity of the CoMoS catalyst deactivates due to gradual loss of sulfur from the catalyst. HDO process is insensitive to the sulfur deficiency. The kinetic modeling shows that direct hydrodecarbonylation of fatty acids dominates the HDC routes and, in the HDO route, fatty acids are transferred to aldehydes/alcohols and then to C-18 hydrocarbons, a final product, and the reduction of acids is the rate limiting step. The HDO route via alcohols is dominant over aldehydes due to a significantly higher reaction rate constant. The difference of C-18/C-17 ratio in unsupported and supported catalysts show that a support with Lewis acid sites may play an important role in the selectivity for the hydrodeoxygenation pathways and promoting the final product quality

Dynamic modelling of die melt temperature profile in polymer extrusion: Effects of process settings, screw geometry and material

Extrusion is one of the major methods for processing polymeric materials and the thermal homogeneity of the process output is a major concern for manufacture of high quality extruded products. Therefore, accurate process thermal monitoring and control are important for product quality control. However, most industrial extruders use single point thermocouples for the temperature monitoring/control although their measurements are highly affected by the barrel metal wall temperature. Currently, no industrially established thermal profile measurement technique is available. Furthermore, it has been shown that the melt temperature changes considerably with the die radial position and hence point/bulk measurements are not sufficient for monitoring and control of the temperature across the melt flow. The majority of process thermal control methods are based on linear models which are not capable of dealing with process nonlinearities. In this work, the die melt temperature profile of a single screw extruder was monitored by a thermocouple mesh technique. The data obtained was used to develop a novel approach of modelling the extruder die melt temperature profile under dynamic conditions (i.e. for predicting the die melt temperature profile in real-time). These newly proposed models were in good agreement with the measured unseen data. They were then used to explore the effects of process settings, material and screw geometry on the die melt temperature profile. The results showed that the process thermal homogeneity was affected in a complex manner by changing the process settings, screw geometry and material.

Investigation of the temperature homogeneity of die melt flows in polymer extrusion

Polymer extrusion is fundamental to the processing of polymeric materials and melt flow temperature homogeneity is a major factor which influences product quality. Undesirable thermal conditions can cause problems such as melt degradation, dimensional instability, weaknesses in mechanical/optical/geometrical properties, and so forth. It has been revealed that melt temperature varies with time and with radial position across the die. However, the majority of polymer processes use only single-point techniques whose thermal measurements are limited to the single point at which they are fixed. Therefore, it is impossible for such techniques to determine thermal homogeneity across the melt flow. In this work, an extensive investigation was carried out into melt flow thermal behavior of the output of a single extruder with different polymers and screw geometries over a wide range of processing conditions. Melt temperature profiles of the process output were observed using a thermocouple mesh placed in the flow and results confirmed that the melt flow thermal behavior is different at different radial positions. The uniformity of temperature across the melt flow deteriorated considerably with increase in screw rotational speed while it was also shown to be dependent on process settings, screw geometry, and material properties. Moreover, it appears that the effects of the material, machine, and process settings on the quantity and quality of the process output are heavily coupled with each other and this may cause the process to be difficult to predict and variable in nature

Design of a Virtual Reality Framework for Maintainability and assemblability test of complex systems

This paper presents a unique environment whose features are able to satisfy requirements for both virtual maintenance and virtual manufacturing through the conception of original virtual reality (VR) architecture. Virtual Reality for the Maintainability and Assemblability Tests (VR_MATE) encompasses VR hardware and software and a simulation manager which allows customisation of the architecture itself as well as interfacing with a wide range of devices employed in the simulations. Two case studies are presented to illustrate VR_MATE's unique ability to allow for both maintainability tests and assembly analysis of an aircraft carriage and a railway coach cooling system respectively. The key impact of this research is the demonstration of the potentialities of using VR techniques in industry and its multiple applications despite the subjective character within the simulation. VR_MATE has been presented as a framework to support the strategic and operative objectives of companies to reduce product development time and costs whilst maintaining product quality for applications which would be too expensive to simulate and evaluate in the real world.

Estudo da substituição parcial do cloreto de sódio por cloreto de potássio em presunto

Dissertação para obtenção do grau de mestre em Sistemas de Prevenção e Controlo Alimentar, Escola Superior Agrária do Instituto Politécnico de Santarém, 2011

Manutenção preditiva e pró-activa: filosofias alternativas ou complementares: estudo de caso

Trabalho Final de Mestrado para obtenção do grau de Mestre em Engenharia Mecânica Ramo Manutenção e Produção

Equipamentos de congelação industrial de produtos alimentares perecíveis: análise comparada de apoio à decisão

Trabalho Final de Mestrado para obtenção do grau de Mestre em Engenharia Mecânica

Projeto de uma instalação frigorífica

Trabalho Final de Mestrado para obtenção do grau de Mestre em Engenharia Mecânica

Lean management: aplicação a uma pequena empresa de construção civil

Trabalho Final de Mestrado para obtenção do grau de Mestre em Engenharia Civil Especialização em Edificações

Multilayer Perceptron Neural Networks Training Through Charged System Search and its Application for Non-Technical Losses Detection

The non-technical loss is not a problem with trivial solution or regional character and its minimization represents the guarantee of investments in product quality and maintenance of power systems, introduced by a competitive environment after the period of privatization in the national scene. In this paper, we show how to improve the training phase of a neural network-based classifier using a recently proposed meta-heuristic technique called Charged System Search, which is based on the interactions between electrically charged particles. The experiments were carried out in the context of non-technical loss in power distribution systems in a dataset obtained from a Brazilian electrical power company, and have demonstrated the robustness of the proposed technique against with several others natureinspired optimization techniques for training neural networks. Thus, it is possible to improve some applications on Smart Grids.

Desenvolvimento de sistema de apoio dinâmico da chapa no corte em guilhotina

Guilhotinas são máquinas robustas, de corte rectilíneo, normalmente associadas a equipamentos de baixo custo, devido à pequena quantidade de dispositivos tecnológicos incorporados. No entanto, esta situação pode ser alterada através da criatividade dos projetistas deste tipo de equipamento. Analisando algumas operações específicas, pode-se observar que algumas ferramentas, quando associadas ao equipamento, podem aumentar substancialmente a produtividade do processo de corte e a qualidade do produto final. Em relação ao processo de corte de chapas finas de metal, pode-se observar que na fase final de corte, o peso do material a cortar é suspenso por uma pequena porção de material que ainda não foi sujeita ao corte. Este facto leva a uma deformação plástica nesta última zona, causando problemas de qualidade no produto final, que não ficará completamente plano. Este trabalho foi desenvolvido em torno deste problema, estudando a melhor solução para desenvolver uma nova ferramenta, capaz de evitar a falta de nivelamento da placa, após corte. Um novo equipamento foi concebido, capaz de ser facilmente incorporado na guilhotina, permitindo o acompanhamento da inclinação da lâmina durante a operação de corte. O sistema é totalmente automatizado, sendo operado por uma única instrução de corte dada pelo operador da máquina. Este sistema permite à empresa fabricante aumentar o valor agregado de cada máquina, oferecendo aos clientes soluções avançadas, contribuindo desta forma para a sustentabilidade do negócio da empresa.

Melhoria de linha de produção na indústria automóvel

No âmbito da unidade curricular Dissertação do 2ºano do Mestrado em Engenharia mecânica – Ramo de Gestão Industrial do Instituto Superior de Engenharia do Porto, o presente trabalho de dissertação foi enquadrado num projeto industrial para a racionalização de uma linha de produção. O projeto foi desenvolvido numa empresa de produção de componentes por alumínio injetado e seguidamente processos de maquinação, para mercados a nível mundial destinados à indústria automóvel. A realização deste projeto teve como objetivo a melhoria de uma linha de produção na empresa TESCO Componentes para automóveis, Lda. recorrendo a métodos e ferramentas utilizadas pela Gestão Industrial tais como, Lean, 5’S, PDCA assim como ferramentas específicas de balanceamento e otimização de linhas. Os métodos e ferramentas utilizados permitiram a seleção da linha, a definição e caraterização do modelo em produção e posto de trabalho, isto com o objetivo reduzir os custos, aumentar a produtividade e conduzir a melhorias ao nível de qualidade. Através de análises realizadas aos dados de produção foi possível a avaliação do indicador de eficiência operacional do equipamento, através dos OEE’s, o que possibilitou uma análise mais compreensiva da capacidade e cadência da linha de produção. Com a aplicação dos métodos ligados à filosofia de produção em Lean, foi possível atingir-se os objetivos inicialmente definidos, e em alguns casos foi possível ultrapassá-los. Em função da abordagem integrada que foi seguida, conseguiu-se uma redução de um posto de trabalho, traduzindo-se na redução do custo de fabrico não deixando de referir que também houve melhorias a nível de qualidade do produto. Reduzindo a possibilidade de falhas com as especificações estabelecidas pelos clientes. Como efeito positivo deste projeto pode-se apontar o fato de que a empresa Tesco Componentes para Automóveis, Lda. aumentou a sua competitividade com a oportunidade de redução do preço final do produto e também com o aumento da qualidade do mesmo.