GOALI: Integrated Modeling and Statistical Hierarchical Optimization for Improved Filmbuild and Defect Reduction of Automotive Polymeric Topcoats

摘要：汽车涂装作业涉及到几层薄薄的涂料的应用。面漆，包括底漆和清漆，是最关键的耐久性和外观的车辆涂料。在操作中，应在整个车辆表面均匀地一层一层地涂上极薄的无缺陷面漆。在实际应用中，由于油漆喷涂、干燥和固化不当，漆膜均匀性往往较差，涂料中可能出现各种缺陷。目前尚不清楚油漆喷涂参数、喷涂室空调条件、油漆流变性能、烘箱辐射和对流参数与薄膜拓扑结构、溶剂蒸发、交联反应和缺陷产生的关系。过程控制实质上是对涂层质量的开环控制；而且，能源效率和涂料材料消耗往往高于预期。因此，这项研究是一个系统的方法的发展规划和控制油漆应用的这种系统。主要重点将放在(i)建立工艺和性能参数之间的因果关系，以及（ii）制定系统优化策略，以确定喷雾、干燥和固化参数的最佳设置，作为操作模式的功能。PI计划使用各种建模技术开发集成的全厂模型，并使用大系统理论开发两层分层优化策略。这项工作将与福特汽车公司和杜邦汽车公司合作完成。实验测试将在他们的模拟实验室进行，然后在福特工厂进行。最终产品应该是一个系统的方法和计算机辅助工具，用于过程分析和操作改进，可能适用于汽车涂层工艺以外的其他工艺。韦恩州立大学是美国所有非hbcu中少数族裔人口最多的大学。该项目将为其中一些学生提供有价值的培训，让他们接触到当地的行业，从而获得未来潜在的专业工作机会。

ABSTRACTPI: Yinlun Huang Institution: Wayne State UniversityProposal Number: 0091398Automotive coating operations involve paint applications of several thin layers. The topcoat, including basecoat and clearcoat, is most critical to the durability and appearance of vehicle coatings. In operation, very thin defect-free topcoats should be uniformly applied, layer by layer on the entire vehicle surface. In practice film uniformity is often poor and various defects may appear in the coatings, due to improper paint spray, drying and curing. It is unclear how paint spray parameters, spray booth air condition, paint rheological properties, and oven radiative and convective parameters are related to film topology, solvent evaporation, crosslinking reaction and defect generation. Process control is essentially open loop to coating quality; and, energy efficiency and paint material consumption are often higher than expected. This research is therefore the development of a systematic methodology for planning and controlling paint application for such systems.The main focus will be on (i) the establishment of cause/effect relationships between process and performance parameters, and (ii) the development of system optimization strategies that can determine the optimal settings of spray, drying and curing parameters as a function of operational mode. The PI plans to develop integrated, plant wide models using various modeling technologies, and a two-layered hierarchical optimization strategy using large-scale systems theory. The work will be done in collaboration with the Ford Motor Company and DuPont Automotive Company. The experimental tests will be performed in their simulation labs and then a Ford plant. The end product should be a systematic methodology and a computer-aided tool for process analysis and operation improvement that may be applicable to other than automotive-coating processes.Wayne State University has the largest minority population among all non-HBCU's in the U.S. This project will provide valuable training for some of these students with exposure to local industries and thus potential future professional job opportunities.