高分子產品品質如機械、光學、電學的性質及均質性等，可藉由控制製程中的溫度、壓力或黏度在一個狹窄範圍內變動來達到。早期有關加工品質及品質控制如溫度控制、壓力控制及黏度控制的研究文獻很多，其中黏度控制策略相信是品質控制最有效的方法，因為黏度與高分子的組成、分子量分布及材料特性有密切的關係。
在黏度控制策略中，黏度為一應變數，可由 (1) 流量及線上黏度量測儀量測之壓力降，或 (2) 溫度、轉速(或壓力)、加工機幾何尺寸及加工材料常數(不需線上量測儀)來獲得，前一個方法會影響產量，後者則不會。
為利用”黏度量測裝置”做為感測器來控制產品品質，我們發展一個經驗黏度模式，以推導出加工黏度模式，該方式可以不需要線上黏度量測儀來獲得黏度。經驗黏度模式經證實比以前被提出的黏度模式如WLF及Andrade方程式等更能契合實驗資料。為證實加工黏度模式的有效性，我們利用聚丙烯(PP)來做測試，經比較加工黏度模式與線上黏度量測儀的黏度計算值，發現兩者之黏度特性相當脗合，兩者皆可用來當做量測黏度的方法。
本文旨在利用發展的加工黏度模式，配合數種先行加工實驗數據，以及樣板規則庫設計出高分子加工製程的多輸入/輸出閉迴路模糊控制器。該控制器可以消除加工過程之變異, 使產品品質保持穩定。模糊控制器因為可克服發生在加工過程中如非線性、時間變異性及量測訊號品質不良等優點，適合用來做高分子加工的控制，因此被用來做多變數閉迴路控制器的設計。先行加工實驗包括：(1)調查高分子熔体溫度與與設定溫度的關係 (2)調查熔体壓力與與設定轉速的關係 (3)建立線上黏度儀之黏度值與熔体溫度及轉速之間的關係式等。
為印證所設計之模糊控制器是否有效，我們利用發展之離線程式做測試，及實際在加工機器上做閉回路實驗，結果證明該多變數模糊控制器確實可以有效的控制產品品質。

In the polymer extrusion process the product quality like mechanical, optical, electrical properties and homogeneity etc. can be achieved by controlling the melt temperature, melt pressure or viscosity within a narrow fluctuation range. In the earlier studies there are many literatures in connection with the extrusion quality and related quality controls; i.e. temperature control, pressure control and viscosity control. In each of the control strategies, it is believed that the most effective to maintain product quality utilising viscosity control, because a polymer viscosity closely correlates with its composition and molecular distribution, and hence the characteristic of the material.
In the viscosity control strategy, viscosity is an induced variable calculated from either the (1) flow rate and pressure drop with in-line rheometer or (2) melt temperature, screw speed (or pressure), geometrical dimensions of extruder, and extrusion material constants without in-line rheometer; the former method may interfere the output rate while the latter one does not.
On the demand of using viscosity-measuring instruments as sensors to control the quality of the products, we developed an empirical off-line viscosity model, which is used to derive the extrusion viscosity models in the control process without in-line rheometer. The off-line viscosity model is proved more accuracy than other previous suggested models, such as WLF and Andrade’s equations, to fit the experimental data. Polypropylene (PP) was used in this study to test the effectiveness of the extrusion viscosity models. Comparing the calculated results, it was found that the viscosity characteristics obtained by the extrusion viscosity models are in agreement with those obtained by using an in-line rheometer. Both methods can be used to obtain the viscosity in the polymer extrusion process.
The objective of this study is to develop extrusion viscosity models together with collected data from several experimental tests and template rule-base to build a Multi-Input Multi-Output (MIMO) fuzzy logic closed-loop controller for the plastics extrusion control. The objective of this controller is to eliminate process variations and to produce the polymer of consistent quality. The fuzzy logic is provided for designing the MIMO closed-loop controller because it is suitable for applying to the polymer extrusion process control with such advantages as handling complex problems like non-linear, time varying behaviour and poor quality measurements happened in the extrusion process, etc. The experimental pre-tests include (1) investigation of the relationship between melt temperature and barrel setting temperatures (2) investigation of the relationship between melt pressure and screw speed and (3) building the relation equation between measured viscosity, melt temperature and speed for the in-line rheometer, etc.
In order to test the effectiveness of the MIMO FLC, an off-line simulation program is developed, and the closed-loop tests are performed on the extruder. The test results prove that the designed MIMO FLC can effectively control the quality of products.

誌謝
Contents
List of figures
List of tables
Nomenclature
Abstract
Chapter 1. Introduction
1.1 Background
1.2 Extrudate quality
1.3 Polymer quality control strategies
1.4 A brief review of polymer extrusion control literatures
1.5 MIMO Fuzzy Logic closed-loop control system
1.6 Objectives
1.7 Outline of the present work
Chapter 2. Polymer extrusion control literature reviews
2.1 Quality and disturbance studies
2.2 Modeling studies
2.2.1 Physical modeling studies
2.2.2 Mathematical modeling studies
2.2.2.1 Deterministic identification studies
2.2.2.2 Stochastic identification studies
2.2.3 Conceptual modeling studies
2.3 Control strategy studies
2.3.1 Temperature control
2.3.2 Pressure control
2.3.3 Viscosity control
2.4 Discussion
Chapter 3. Polymer rheological properties in extrusion process
3.1 Polymer
3.2 Polymer rheological properties
3.2.1 Basic definitions
3.2.2 Power law
3.2.3 Effect of temperature on viscosity
3.3 Polymer extrusion
3.3.1 Phenomenological description of extrusion process
3.3.2 The shear rate of polymer melt in the screw extruder
3.4 Discussion
Chapter 4. Model development
4.1 Empirical viscosity model
4.2 Polymer extrusion viscosity model
4.3 Viscosity control method
4.4 Discussion
4.5 Experimental equipment
4.6 Summary
Chapter 5. Some results of polymer extrusion tests
5.1 Empirical viscosity model tests
5.1.1 Model verification for the empirical viscosity models
5.1.2 Models comparison
5.2 Polymer extrusion viscosity test
5.2.1 Test results
5.2.2 Models comparison
5.3 Extrusion temperature tests
5.4 Extrusion pressure tests
5.5 Discussion
5.6 Conclusion
Chapter 6. Fuzzy logic control
6.1 Fuzzy sets
6.2 Membership functions and fuzzification
6.3 Fuzzy logic operations and linguistic variables
6.4 Fuzzy relations and their compositions
6.5 Fuzzy implication
6.6 Fuzzy inference and composition
6.7 Fuzzy algorithm
6.8 Fuzzy logic controllers
6.9 Polymer extrusion fuzzy logic controller
Chapter 7. The design of MIMO fuzzy logic controller
7.1 Closed-loop fuzzy logic control system
7.2 MIMO fuzzy logic controller design
7.3 Controller tests
7.3.1 No load simulation test
7.3.2 On line load test
7.4 Conclusion
Chapter 8. Conclusions
References
Appendix A
Appendix B
Appendix C

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