Smart-Factory: Optimization and Process Control of Composite Centrifuged Pipes

Process optimization strategies and intelligent control algorithms for an industrial centrifugal pipe production are presented. The chemo-rheological and thermo-kinetic features of the polymerization of unsaturated polyester based composites are analyzed by means of a mathematical model that uses the heat transfer and generation properties of polymerizable systems. The evolution of the system temperature, viscosity and degree of cure profiles in a composite centrifuged pipe wall have been identified and mathematically described. The temperature profiles were calculated according to an appropriate kinetic and heat transfer modeling and then the corresponding viscosity profiles were evaluated. The viscosity and kinetic parameters to use in the model were measured in calorimetric and rheological tests. A commercial polyester system, which is used for centrifugal forming, has been catalyzed with two different types of peroxide (Methyl-Ethyl-Ketone and Acetyl-Acetone peroxides) and characterized by Differential Scanning Calorimetry (DSC) and adiabatic peak temperature measurements (gel time tests). The problem of incomplete cure in sections of the pipe wall has been discussed with respect to the processing conditions and creep behavior. Experimentally verification of thermal theoretical modeling and creep tests have been carried out on a system catalyzed with AA peroxide and processed in two different ways. The thermo-kinetic process modeling and control adequately predicts the thermal behavior at the internal surface of pipes that has been used to optimize by simulation of two different centrifugal pipe processing thermal cycles.