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

摘要：Yinlun Huang机构：韦恩州立大学提案编号：0091398汽车涂层操作涉及几个薄层的油漆应用。 面漆，包括底漆和清漆，对车辆涂层的耐久性和外观至关重要。 在操作中，应将非常薄的无缺陷面漆均匀地逐层涂敷在整个车辆表面上。 在实际生产中，由于喷涂、干燥和固化不当，漆膜均匀性往往较差，涂层中可能出现各种缺陷。 目前尚不清楚喷漆参数、喷漆室空气条件、油漆流变性能以及烘箱辐射和对流参数与膜拓扑结构、溶剂蒸发、交联反应和缺陷产生的关系。 过程控制本质上是涂层质量的开环控制;而且，能源效率和涂料消耗往往高于预期。 因此，这项研究是一个系统的方法，规划和控制涂料应用程序的发展，这样的systems.The主要重点将是（i）的过程和性能参数之间的因果关系的建立，和（ii）系统优化策略的发展，可以确定最佳设置的喷涂，干燥和固化参数作为一个功能的操作模式。 PI计划使用各种建模技术开发集成的工厂范围模型，并使用大规模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和福特工厂进行。 最终产品应该是一个系统的方法和计算机辅助工具的过程分析和操作改进，可能适用于其他比汽车涂装工艺。韦恩州立大学有最大的少数民族人口在所有非HBCU的在美国这个项目将提供宝贵的培训，为这些学生接触到当地行业，从而潜在的未来的专业工作机会。

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.