Nonlinear Control of Liquid Molding of Advanced Composites with Simulations and Sensor/Actuator Optimization

液体复合材料模塑(LCM)是一种用途广泛、具有吸引力的大批量、高性能、低成本的聚合物复合材料制造工艺，在制造业的几乎所有领域都得到了广泛的应用。目前，加工成本是惊人的，因为每一个新的应用或原型都需要多次试验和修正周期，才能制造出符合规格的成功部件。本项目的目标是：(1)开发LCM过程的真实仿真，并使用仿真工具开发控制策略和优化实时控制器的传感器位置；(2)制定能够考虑零件到零件的变化和其他敏感模型参数并导致成型过程优化的非线性控制策略；以及(3)通过实验验证先进复合材料制造的非线性控制。这项研究在理论和实验之间取得了平衡。这项研究的结果可能导致：(1)制造过程的数值模拟和智能计算工具，有助于优化传感器和执行器的位置，并针对给定的模具几何形状开发非线性控制策略；(2)先进复合材料制造的非线性控制理论；以及(3)能够演示对现实零件的复合材料制造的控制的液体成型设备。

Liquid Composite Molding (LCM) is a versatile and attractive process for high volume, high performance, and low cost manufacturing of polymer composites that is gaining prominence in almost all areas of the manufacturing industry. At present, the processing costs are staggering as every new application or prototype requires many trial and correction cycles before one can manufacture a successful part within specifications. The objectives of this project are: (1) developing a realistic simulation of the LCM process and using the simulation tool to develop control strategies and to optimize the sensor locations for the real time controller; (2) formulating non-linear control strategies that can account for part-to part variation and other sensitive model parameters and lead to optimal finishing of the molding process; and (3) Verifying the nonlinear controls for advanced composite manufacturing with experiments. The research has a balance between theory and experimentation. The outcome of this research may lead to: (1) numerical simulation of the manufacturing process and an intelligent computational tool that will help to optimize the sensor and actuator locations and develop nonlinear control strategies for a given mold geometry; (2) a nonlinear control theory for advanced composite manufacturing; and (3) a liquid molding facility that can demonstrate the control of the composite manufacturing of a realistic part.