Analysis and optimization of the film cooling in industrial operating high performance blown film plants based on an integrative and calibrated process model

基于集成和校准的工艺模型对工业运营的高性能吹膜工厂中的薄膜冷却进行分析和优化

基本信息

批准号：
284379684
负责人：
Professor Dr.-Ing. Johannes Karl Wortberg
金额：
--
依托单位：
Lehrstuhl für Konstruktion und Kunststoffmaschinen
依托单位国家：
德国
项目类别：
Research Grants (Transfer Project)
财政年份：
2016
资助国家：
德国
起止时间：
2015-12-31 至 2018-12-31
项目状态：
已结题

来源：
https://gepris.dfg.de/gepris/projekt/284379684?language=en
关键词：
Analysis optimization film cooling industrial

项目摘要

Like for any other extrusion process, the blown film extrusion is decisively limited by the provided air cooling capacity. Achievable throughputs can be improved by the optimization of the cooling system to a large extent. The motivation of this research project can be seen in the transfer of results and scientific knowledge, based on two preceding DFG projects, in the computer-aided optimization of cooling systems for laboratory blown film lines to industrial production scale. Besides the improvement of the output, the focus is on the identification of potentials in enhancing the process stability. With regard to remarkable changes in the process boundary conditions, one must now adapt and transfer the developed modelling approaches. This includes on the one hand geometric and on the other hand process-related boundary conditions. Besides the prevailing mass flow rates, cooling air volume flows as well as the flow phenomena, additionally the realistic deformation processes inside the film and the geometrical changes of all active and passive involved cooling components have to be taken into consideration. This included the integration of an internal bubble cooling device inside the process environment. The numerical realization is to be done by using the successfully verified and validated Prozess- and Prognosemodell. The challenge is the realistic computation of the tube formation zone at varying process- and cooling conditions. For this purpose various experimental process conditions have to be recorded, to create the basis for the following calibration process and the examination of the capability in reproducing the process state. After finishing the model calibration and proving the reproducing capabilities, the main emphasis will be on the simulation based realization of system optimization potentials.for high capacity blown film lines with output rates of 1000kg/h and die diameter up to 800mm. Furthermore the available material spectrum has to be extended by new multilayer compounds (3-layers / 5-layers), which have to be taken into account concerning the modeling. In cooperation with the industrial partner, the virtual proven optimization potentials have to be experimentally tested and validated in the industrial production environment, to meet the shared goal of improving the output.

与其他任何挤压过程一样，吹膜的挤出受到提供的空气冷却能力的限制。通过在很大程度上优化冷却系统可以改善可实现的吞吐量。基于上一个DFG项目的结果和科学知识的转移，可以在计算机辅助优化的冷却系统中，用于实验室吹制膜线至工业生产规模的计算机辅助优化，可以看到该研究项目的动机。除了提高输出外，重点是确定增强过程稳定性的电势。关于过程边界条件的显着变化，现在必须适应和传输开发的建模方法。这包括一方面的几何形状，另一方面包括与过程相关的边界条件。除了盛行的质量流速，冷却空气体积流以及流动现象外，还必须考虑膜内部的现实变形过程以及所有涉及的所有活性和被动的冷却组件的几何变化。这包括将内部气泡冷却设备集成在过程环境中。数值实现是通过使用成功验证和经过验证的Prozess-和Prognosemodell来完成的。挑战是在不同的过程和冷却条件下对试管形成区的现实计算。为此，必须记录各种实验过程条件，以为以下校准过程和复制过程状态的能力的检查创造基础。在完成模型校准并证明了复制功能后，主要重点将是基于模拟的系统优化电位的实现。对于高容量吹动的膜线，输出速率为1000kg/h，直径为800mm。此外，必须通过新的多层化合物（3层 / 5层）扩展可用的材料光谱，这些化合物必须考虑到有关建模的。与工业合作伙伴合作，必须在工业生产环境中对虚拟验证的优化潜力进行实验测试和验证，以实现提高产出的共同目标。