Adaptive control of the filling velocity of thermoplastics injection molding

Injection velocity, a key variable in injection molding, was controlled via an adaptive controller using a self-tuning regulator (STR) scheme. The pole-placement design was employed first, together with the performance enhancement techniques of anti-windup estimation, feed-forward control, and cycle-to-cycle adaptation. The pole-placement design with the enhancement techniques was found experimentally to work very well over different molding conditions. However, this design was also found to be sensitive to the model mismatch. To overcome this problem, a new adaptive controller based on a generalized predictive control (GPC) principle was designed to make the controller more robust. Experiments have shown that the adaptive GPC control of injection velocity has inherently good set-point tracking performance and excellent tolerance to model structure mismatch. (C) 2000 Elsevier Science Ltd. AII rights reserved.