Abstract
Process optimization strategies and intelligent control algorithms for an industrial centrifugal pipe production are presented. The chemo-rheological and thermo-kinetic features of the polymerization of unsaturated polyester based composites are analyzed by means of a mathematical model that uses the heat transfer and generation properties of polymerizable systems. The evolution of the system temperature, viscosity and degree of cure profiles in a composite centrifuged pipe wall have been identified and mathematically described. The temperature profiles were calculated according to an appropriate kinetic and heat transfer modeling and then the corresponding viscosity profiles were evaluated. The viscosity and kinetic parameters to use in the model were measured in calorimetric and rheological tests. A commercial polyester system, which is used for centrifugal forming, has been catalyzed with two different types of peroxide (Methyl-Ethyl-Ketone and Acetyl-Acetone peroxides) and characterized by Differential Scanning Calorimetry (DSC) and adiabatic peak temperature measurements (gel time tests). The problem of incomplete cure in sections of the pipe wall has been discussed with respect to the processing conditions and creep behavior. Experimentally verification of thermal theoretical modeling and creep tests have been carried out on a system catalyzed with AA peroxide and processed in two different ways. The thermo-kinetic process modeling and control adequately predicts the thermal behavior at the internal surface of pipes that has been used to optimize by simulation of two different centrifugal pipe processing thermal cycles.
Highlights
We are standing on the edge of a fourth industrial revolution; one which, while enabling us to mate the worlds of production and the “Internet of Things”, is making “Industry 4.0” a reality that could connect embedded system production technologies and smart production processes.The development of the new technological age of the “Smart factory” will radically transform the industrial production value chains and business models
The present paper presents an experimental verification of the application of an intelligent process strategy choice and control for the fabrication of Glass Reinforced Polymeric (GRP) centrifuged pipes
Flexible GRP pipes are designed to act as soil-pipe interaction system and, as such, the external loadings resulting from the soil pressure, assembly, accidental loads and impacts must be evaluated for this type of design system to perform properly
Summary
The development of the new technological age of the “Smart factory” will radically transform the industrial production value chains and business models. “Smart production” is becoming the standard in a world where ICT intelligent machines, networks and systems are capable of independently exchange and respond to information to manage an industrial production processes (Hwang et al, 2016). The present paper presents an experimental verification of the application of an intelligent process strategy choice and control for the fabrication of Glass Reinforced Polymeric (GRP) centrifuged pipes. The manufactured product must maintain, from a quality control and design point of view, a constant and adequate smooth wall thickness and profile. Any variance from the theoretical thickness or not homogeneous profile alters the pipe stiffness values leading to:
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