INTELLIGENT PROCESSING OF POLYMER SHEETS FOR CALENDERING

The Intelligent Processing of Materials (IMP) concept has been applied to the calendering process with the goal of improving shape quality and process efficiency. All four basic features of the IPM, including modeling, data processing, sensing, and controlling, are considered. In the process modeling, bending and thermal models are developed. With these models, the relationship between the process parameters and quality of the calendered sheets has been established. A material data bank has been established to couple with the process modeling and real-time sensing data. In sensing, ultrasonic and temperature sensors have been implemented to measure critical quality and process parameters in situ. The sensing data have been used not only to verify the modeling prediction but also to establish information needed to diagnose the causes of the layflat problem. Based on the model prediction as well as sensing information, a better control system to alleviate layflatness problems has been developed. Finally, a control strategy for future improvement of the calendering system is proposed. (C) 1993 John Wiley & Sons, Inc.