Extruder Simulation Condition Setting from Control and Sensor Data
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Solution Overview
Problem
Conventional simulation devices for extruders require manual setting of analysis conditions such as physical properties of resins, extrusion conditions, and screw construction, which is time-consuming and prone to errors.
Innovation Solution
A simulation device, method, and program that automatically acquire and set analysis conditions by collecting data from control devices, sensors, and imaging devices, using machine learning models to specify screw and cylinder constructions, and calculating physical properties based on acquired data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual setting of analysis conditions is used, then simulation accuracy can be maintained, but operation time and complexity increase significantly
Solution Approach 1:
The system automatically acquires analysis conditions from the control device and imaging devices without requiring manual input. The simulation device self-serves by extracting necessary parameters (screw construction, cylinder construction, operation conditions) directly from the industrial machine's control system and sensors, eliminating manual data entry while maintaining accuracy.
Solution Approach 2:
The analysis conditions are acquired and prepared in advance from the control device before the simulation is executed. The system preliminarily collects data on resin physical properties, extrusion conditions, and machine construction from sensors and control systems, so that when simulation is needed, the data is already ready for immediate processing.
2Reliability
If manual input of analysis conditions is required, then data accuracy can be controlled, but ease of operation deteriorates
Solution Approach 1:
The simulation device automatically retrieves analysis conditions from the control device and imaging devices without manual intervention. The system self-acquires data on screw construction, cylinder construction, and operation conditions directly from the industrial machine's embedded systems, eliminating manual input errors while maintaining data reliability.
Solution Approach 2:
The control device and imaging devices act as intermediaries between the industrial machine and the simulation device. These intermediaries automatically transmit construction data and operation conditions from the machine to the simulation system, ensuring accurate data transfer without manual involvement.
3Reliability
If comprehensive analysis conditions are manually set, then simulation reliability improves, but device complexity increases
Solution Approach 1:
The control device and imaging devices serve multiple functions: they control the industrial machine operation, monitor its state, and simultaneously provide analysis conditions for the simulation device. This multi-functionality eliminates the need for separate data collection systems, reducing overall system complexity while maintaining comprehensive simulation data.
Solution Approach 2:
The system merges the data acquisition function into the existing control device and imaging devices. Instead of requiring a separate manual data entry system, the simulation device integrates with the control system to automatically acquire all necessary analysis conditions, reducing the number of independent components and simplifying the overall system architecture.
Data Source
AI summary
A simulation device is a simulation device simulating a behavior of an extruder, comprises: an acquisition unit that acquires data related to a behavior of the extruder from a control device performing operation control of the extruder, a sensor provided on the extruder or an imaging device imaging a component constituting the extruder; and an arithmetic unit that calculates a physical property indicating a behavior of the extruder on the basis of acquired data.