无模型自适应迭代学习控制在注塑过程测量扰动抑制的应用

Application of Model-free Adaptive Iterative Learning Control for Measurement Disturbance Suppression during the Injection Molding Process

  • 摘要: 注塑成型是高分子加工行业中最重要且应用最广泛的制造技术之一. 在注塑成型过程中,注射速度对塑料制品的品质起着决定性作用. 然而在实际的注塑过程中,注塑机可能会受到外部测量扰动影响,从而使注射速度无法跟踪期望速度,最终影响产品质量. 因此,设计一套控制方案以削弱外部非重复性扰动对系统性能的影响至关重要. 基于此,本文提出一种融合衰减因子的无模型自适应迭代学习控制(Model free adaptive iterative learning control, MFAILC)方案. 首先,本文阐述了注塑成型的过程,并针对注塑成型过程的注射段建立了非线性状态空间模型. 由于该模型具有较强的非线性与不确定性,采用传统控制策略难以实现控制器的有效设计,因此本文构建了具有迭代特性的紧格式动态线性化(Compact form dynamic linearization, CFDL)模型,并设计了注塑速度控制策略以及迭代轴上伪偏导数(Pseudo partial derivative, PPD)学习律,并引入PPD重置条件以避免其出现学习发散问题. 为了抑制外部扰动对注射速度的影响,本文在所提MFAILC策略的基础上引入衰减因子. 随后从期望意义层面完成了严格的收敛性推导,证明了MFAILC算法的收敛性. 最后在MATLAB中利用一个仿真实例验证本文所设计控制策略的可行性.

     

    Abstract: Injection molding is among the most important and widely adopted manufacturing technologies in the polymer processing industry, in which the speed of injection plays a decisive role in the quality of plastic products. However, in the actual molding process, the injection molding machinery may be subjected to external disturbance, such that the desired injection speed is not efficiently maintained, ultimately affecting product quality and increasing production waste. It is thus essential to design a control scheme that contributes to mitigating the effects of external non-repetitive disturbance on system performance. In this study, we developed a model-free adaptive iterative learning control (MFAILC) scheme that is combined with a fading factor. We initially describe the injection molding process in detail, which covers mold closing, melt injection, pressure holding and plasticization stages. After that, we established a non-linear state-space model for the injection section of the molding process. Given that this model has strong non-linearity and uncertainty, it is difficult to design a controller using traditional strategies. Thus, to address this problem, we developed a compact-form dynamic linearization (CFDL) model with iterative characteristics, which contains a pseudo-partial derivative (PPD) that incorporates all of the non-linearities of the injection system and reflects the relationship between the variations in system input and output. Having established this model, we then designed a speed control strategy and a PPD learning law based on the iterative axis by minimizing an optimal quadratic index function that balances tracking accuracy and the smoothness of control input. To prevent the PPD from learning divergence, a resetting algorithm of the PPD is then introduced. These three elements thus form an integrated MFAILC scheme. To mitigate the adverse effects of external measurement disturbance, a fading factor was subsequently integrated into the proposed MFAILC scheme, which adaptively reduces the weight of historical disturbance-related errors in subsequent iterations. Rigorous convergence analysis is conducted in the sense of expectation, proving that both the mean value and variance of the output tracking error of the MFAILC algorithm converge to zero as the number of iterations increases, thereby verifying the robustness of the algorithm from the perspectives of both deterministic convergence and statistical characteristics. Finally, using actual injection molding process parameters, we conducted a series of simulation experiments based on the MATLAB platform. The results obtained revealed that the proposed MFAILC strategy with a fading factor achieves full convergence of the injection speed trajectory with the desired curve after fifty times iteration, with a maximum tracking error of only 0.00039. Comparative experiments, in which we used MFAILC without a fading factor (maximum error of 0.0008) and P-type ILC with a fading factor, indicated that the proposed method outperforms the contrast schemes with respect to both convergence speed and disturbance suppression capacity. Collectively, the procedures developed in this study provide a reliable data-driven control solution for the regulation of high-precision injection speed and will facilitate the deployment of the MFAILC strategy in practical industrial procedures.

     

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