GOALI: A Framework For Integrated Product Design and Control in Polymer Nanocomposites

0652172 Ogunnaike本研究的主要目标是开发和验证一个框架，用于将产品设计与所需的适当控制策略相结合，以在制造的产品中始终实现设计目标的最终用途特性。新的建模和控制技术将在与杜邦公司的持续合作中开发和实验验证。由于其当前和未来的重要性，以及它们如何完美地满足产品设计和随之而来的性能控制挑战，这项工作将专门针对聚合物纳米复合材料进行。然而，拟议研究的最终结果将普遍适用于其他产品类别。需要回答的具体问题如下：在制造为特定最终用途设计的产品（如聚合物纳米复合材料）时，需要采取什么策略来有效控制产品特性并确保可接受的最终用途性能？具体任务如下：任务1：开发和测试控制产品最终用途属性的新框架。PI将开发实现有效最终用途属性控制的理论框架，并与杜邦公司合作，在聚丙烯/蒙脱土纳米复合材料产品的生产过程中对其进行测试。任务2：扩展任务1中开发的框架，以纳入客户对实际产品性能的反馈：客户对最终用途实际性能的反馈是产品目标实现的最终衡量标准。 PI将开发一个控制策略，利用这些信息，将其纳入框架，并分析所产生的整体方案的理论属性。任务3：测试和验证的整体框架上的实验过程中使用的任务1，并概括的原则。 PI将在半商业过程中实施已开发的框架，将客户反馈纳入实际最终使用性能;我们将推广适用于其他产品的概念。知识价值化学工业的系统性变化要求快速开发尽可能精确满足客户需求的新产品。传统的化学工程侧重于过程设计，而重要的是，现在必须纳入“产品设计”。即便如此，要将“产品设计”的结果转化为现实，产品仍然必须被制造出来--并且以这样一种方式制造出来的产品将满足最终使用的客户要求。因此，产品设计必须与高水平的产品特性控制直接集成，以实现成功的“产品工程”。目前，没有系统的控制范例来确保在制造过程中将最终用途属性控制到规范（而不仅仅是事后进行“测试”以确定其状态）。这项研究将建立一个系统的范例，产品特性控制及其与产品设计的整合，“提供新的解决方案，以解决与交付给客户有关的问题，产品是精确地制造到设计规格，并直接纳入控制方案，客户对实际最终使用性能的反馈。研究结果也将对制造设计产品的工业实践产生直接影响，因为实验部分是拟议研究的一个组成部分，将完全在工业研究环境中进行，在半商业规模的过程中。研究成果也将被纳入产品设计和过程动力学和控制的教学，并通过出版物和演示文稿广泛传播给教育工作者和其他研究人员，包括学术和工业。

0652172OgunnaikeThe primary goal of this research is to develop and validate a framework for integrating product design with the appropriate control strategies required for consistently achieving, in the manufactured product, the design target end-use characteristics. Novel modeling and control techniques will be developed and validated experimentally in a continuing collaboration with DuPont. Because of their current and future importance and because of how they perfectly exemplify product design and the accompanying property control challenges, the work will be carried out specifically for polymer nanocomposites. However, the end result of the proposed research will be applicable in general to other product classes.The specific question to be answered may be stated as follows:In manufacturing products (such as polymer nanocomposites) designed for specific end-use applications, what strategy is required for effective control of product properties and assuring acceptable end-use performance?The specific tasks to be performed are:Task 1: Develop and test a novel framework for controlling product end-use attributes.The PIs will develop a theoretical framework for achieving effective end-use attribute control and, in collaboration with DuPont, test it on a process for manufacturing a Polypropylene/Montmorillonite clay nanocomposite product.Task 2: Extend the framework developed in Task 1 to incorporate customer feedback on actual product performance: Feedback from customers on actual performance in end-use is the ultimate measure of product target attainment. The PIs will develop a control strategy for utilizing this information, incorporate it into the framework, and analyze the theoretical properties of the resulting overall scheme.Task 3: Test and validate the overall framework on the experimental process used in Task 1 and generalize the principles. The PIs will implement the developed framework on the semi-commercial process incorporating customer feedback in actual end-use performance; we will generalize the concepts to be applicable to other products.Intellectual Merit Systemic changes in the chemical industry have created a need for the rapid development of new products that meet customer needs as precisely as possible. The traditional chemical engineering focus on process design, while important, must now incorporate "product design". Even so, to translate the result of "product design" into reality, the product must still be manufactured--and in such a way that the resulting product will meet the customer requirements in end-use. Product design must therefore be integrated directly with high level product characteristic control for successful "product engineering". Currently, there are no systematic control paradigms for ensuring that end-use attributes are controlled to specification during the manufacturing process (and not merely "tested" afterwards to ascertain their status). This research will establish a systematic paradigm for product characteristic control and its integration with product design "providing novel solutions to the problems associated with delivering to customers, products that are manufactured precisely to design specifications, and directly incorporating into the control scheme, customer feedback on actual end-use performance.Broader Impact: The outcomes of the research will also have a direct impact on the industrial practice of manufacturing designed products because the experimental component, an integral part of the proposed research, is to be carried out entirely within an industrial research environment, on a semi-commercial scale process. The research results will also be incorporated into the teaching of product design and process dynamics and control, and widely disseminated through publications and presentations to educators and other researchers both academic and industrial.