TPU Foam Process Automation for Real-Time Property Control
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Solution Overview
Problem
The challenge in controlling the extruded foaming thermoplastic polyurethane process is the time-consuming and costly adjustment of process variables when precursor changes occur, leading to deviations in foam production and potential waste, as existing methods rely heavily on human expertise and are not objective.
Innovation Solution
A computer-implemented method using a data-driven property determination model to predict material properties of polyurethane foam based on process data, allowing for rapid correction of deviations and optimizing production parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual adjustment of process variables based on expert experience is used, then the production process can be controlled, but the process is time-consuming and leads to production of waste foam before corrections are made
Solution Approach 1:
The property determination model is trained in advance on historical process data and foam properties. During production, the trained model immediately predicts foam properties from current process data without requiring manual measurement or expert analysis, enabling real-time detection and correction of deviations before waste is produced.
Solution Approach 2:
The patent replaces the mechanical/manual system of expert inspection and adjustment with an automated computer-implemented model that processes process data and generates control recommendations, eliminating the time delay inherent in manual expert intervention.
2Reliability
If manual adjustment of process variables is performed, then expert experience can guide corrections, but the adjustments are subjective and may not objectively optimize foam production
Solution Approach 1:
The property determination model objectively analyzes process data and autonomously generates control recommendations without relying on subjective expert judgment. The system serves itself by automatically detecting deviations and proposing corrections, ensuring consistent and objective process optimization that improves productivity.
3Adaptability or versatility
If process variables are fixed during commissioning according to design specifications, then the initial production can meet target specifications, but the system cannot adapt when precursor quality changes
Solution Approach 1:
The model is trained on historical process data encompassing variations in precursor quality and process parameters. When precursor quality changes, the model automatically adapts by analyzing new process data and predicting the resulting foam properties, then recommends parameter adjustments to maintain target specifications without requiring system redesign.
Data Source
AI summary
The invention refers to a method (200) for process automation of a production process referring to an extruded foaming thermoplastic polyurethane process for producing a polyurethane foam. The method (200) comprises providing (210) process data indicative of at least a part of the performed production process for producing the polyurethane foam. Further, a property determination model is utilized (220) to determine a material property of the produced polyurethane foam, wherein the material property is indicative of at least one characteristic of the produced polyurethane foam and wherein the property determination model is a data driven model adapted to determine the material property based on the process data. Control actions are generated (230) for controlling the production process of the polyurethane foam based on the determined material property. The method allows for an improved automatic control of the production process referring to an extruded foaming thermoplastic polyurethane process.