In this paper the modeling of a typical injection cycle for an injection-molding machine (IMM) is examined. Both the mold filling and mold packing phases of the cycle are examined along with a critical fill-to-pack transition. The novelty in this modeling work is that the nonlinear model considers both the machine hydraulic actuator and polymer flow characteristics in extensive detail. The simulation model is validated against experimental data and demonstrates the availability of a relatively accurate system model for full cycle control design of this electro-hydraulic system. The accurate process model is used in the design of a controller for the injection cycle including the fill-to-pack transition. The overall algorithm includes two Iterative Learning Controllers connected by a bumpless transfer scheme between them. The algorithm is successfully tested through model simulations and machine experiments. The simulation and experimental results presented demonstrate a significantly smoother control signal and pressure transient between the two learning controlled phases as well as overall tracking convergence for each phase.
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e-mail: dzheng@uiuc.edu
e-mail: alleyne@uiuc.edu
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February 2003
Technical Papers
Modeling and Control of an Electro-hydraulic Injection Molding Machine With Smoothed Fill-to-Pack Transition*
Danian Zheng,
e-mail: dzheng@uiuc.edu
Danian Zheng
Dept. of Mechanical and Industrial Engineering, University of Illinois, Urbana-Champaign, Urbana, IL 61801
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Andrew Alleyne
e-mail: alleyne@uiuc.edu
Andrew Alleyne
Dept. of Mechanical and Industrial Engineering, University of Illinois, Urbana-Champaign, Urbana, IL 61801
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Danian Zheng
Dept. of Mechanical and Industrial Engineering, University of Illinois, Urbana-Champaign, Urbana, IL 61801
e-mail: dzheng@uiuc.edu
Andrew Alleyne
Dept. of Mechanical and Industrial Engineering, University of Illinois, Urbana-Champaign, Urbana, IL 61801
e-mail: alleyne@uiuc.edu
Contributed by the Manufacturing Engineering Division for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received July 2000; Revised October 2001. Associate Editor: R. Furness.
J. Manuf. Sci. Eng. Feb 2003, 125(1): 154-163 (10 pages)
Published Online: March 4, 2003
Article history
Received:
July 1, 2000
Revised:
October 1, 2001
Online:
March 4, 2003
Citation
Zheng, D., and Alleyne, A. (March 4, 2003). "Modeling and Control of an Electro-hydraulic Injection Molding Machine With Smoothed Fill-to-Pack Transition." ASME. J. Manuf. Sci. Eng. February 2003; 125(1): 154–163. https://doi.org/10.1115/1.1540126
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