Search results for: noise control
Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 4499

Search results for: noise control

4229 Process Capability Analysis by Using Statistical Process Control of Rice Polished Cylinder Turning Practice

Authors: S. Bangphan, P. Bangphan, T. Boonkang

Abstract:

Quality control helps industries in improvements of its product quality and productivity. Statistical Process Control (SPC) is one of the tools to control the quality of products that turning practice in bringing a department of industrial engineering process under control. In this research, the process control of a turning manufactured at workshops machines. The varying measurements have been recorded for a number of samples of a rice polished cylinder obtained from a number of trials with the turning practice. SPC technique has been adopted by the process is finally brought under control and process capability is improved.

Keywords: Rice polished cylinder, statistical process control, control charts, process capability.

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4228 Comparison of Frequency Estimation Methods for Reflected Signals in Mobile Platforms

Authors: Kathrin Reinhold

Abstract:

Precise frequency estimation methods for pulseshaped echoes are a prerequisite to determine the relative velocity between sensor and reflector. Signal frequencies are analysed using three different methods: Fourier Transform, Chirp ZTransform and the MUSIC algorithm. Simulations of echoes are performed varying both the noise level and the number of reflecting points. The superposition of echoes with a random initial phase is found to influence the precision of frequency estimation severely for FFT and MUSIC. The standard deviation of the frequency using FFT is larger than for MUSIC. However, MUSIC is more noise-sensitive. The distorting effect of superpositions is less pronounced in experimental data.

Keywords: Frequency estimation, pulse-echo-method, superposition, echoes.

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4227 Model Predictive Control Using Thermal Inputs for Crystal Growth Dynamics

Authors: Takashi Shimizu, Tomoaki Hashimoto

Abstract:

Recently, crystal growth technologies have made progress by the requirement for the high quality of crystal materials. To control the crystal growth dynamics actively by external forces is useuful for reducing composition non-uniformity. In this study, a control method based on model predictive control using thermal inputs is proposed for crystal growth dynamics of semiconductor materials. The control system of crystal growth dynamics considered here is governed by the continuity, momentum, energy, and mass transport equations. To establish the control method for such thermal fluid systems, we adopt model predictive control known as a kind of optimal feedback control in which the control performance over a finite future is optimized with a performance index that has a moving initial time and terminal time. The objective of this study is to establish a model predictive control method for crystal growth dynamics of semiconductor materials.

Keywords: Model predictive control, optimal control, crystal growth, process control.

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4226 Individual Configuration of Production Control to Suit Requirements

Authors: Ben Muenzberg, Prof. Peter Nyhuis

Abstract:

The logistical requirements placed on industrial manufacturing companies are steadily increasing. In order to meet those requirements, a consistent and efficient concept is necessary for production control. Set up properly, production control offers considerable potential with respect to achieving the logistical targets. As experience with the many production control methods already in existence and their compatibility is, however, often inadequate, this article describes a systematic approach to the configuration of production control based on the Lödding model. This model enables production control to be set up individually to suit a company and the requirements. It therefore permits today-s demands regarding logistical performance to be met.

Keywords: Production, planning, control, configuration.

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4225 Effect Comparison of Speckle Noise Reduction Filters on 2D-Echocardigraphic Images

Authors: Faten A. Dawood, Rahmita W. Rahmat, Suhaini B. Kadiman, Lili N. Abdullah, Mohd D. Zamrin

Abstract:

Echocardiography imaging is one of the most common diagnostic tests that are widely used for assessing the abnormalities of the regional heart ventricle function. The main goal of the image enhancement task in 2D-echocardiography (2DE) is to solve two major anatomical structure problems; speckle noise and low quality. Therefore, speckle noise reduction is one of the important steps that used as a pre-processing to reduce the distortion effects in 2DE image segmentation. In this paper, we present the common filters that based on some form of low-pass spatial smoothing filters such as Mean, Gaussian, and Median. The Laplacian filter was used as a high-pass sharpening filter. A comparative analysis was presented to test the effectiveness of these filters after being applied to original 2DE images of 4-chamber and 2-chamber views. Three statistical quantity measures: root mean square error (RMSE), peak signal-to-ratio (PSNR) and signal-tonoise ratio (SNR) are used to evaluate the filter performance quantitatively on the output enhanced image.

Keywords: Gaussian operator, median filter, speckle texture, peak signal-to-ratio

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4224 Fuzzy Boundary Layer Solution to Nonlinear Hydraulic Position Control Problem

Authors: Mustafa Resa Becan

Abstract:

Sliding mode control with a fuzzy boundary layer is presented to hydraulic position control problem in this paper. A nonlinear hydraulic servomechanism which has an asymmetric cylinder is modeled and simulated first, then the proposed control scheme is applied to this model versus the conventional sliding mode control. Simulation results proved that the chattering free position control is achieved by tuning the fuzzy scaling factors properly.

Keywords: Hydraulic servomechanism, position control, sliding mode control, chattering, fuzzy boundary layer.

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4223 Dynamic Fault Diagnosis for Semi-Batch Reactor under Closed-Loop Control via Independent Radial Basis Function Neural Network

Authors: Abdelkarim M. Ertiame, D. W. Yu, D. L. Yu, J. B. Gomm

Abstract:

In this paper, a robust fault detection and isolation (FDI) scheme is developed to monitor a multivariable nonlinear chemical process called the Chylla-Haase polymerization reactor, when it is under the cascade PI control. The scheme employs a radial basis function neural network (RBFNN) in an independent mode to model the process dynamics, and using the weighted sum-squared prediction error as the residual. The Recursive Orthogonal Least Squares algorithm (ROLS) is employed to train the model to overcome the training difficulty of the independent mode of the network. Then, another RBFNN is used as a fault classifier to isolate faults from different features involved in the residual vector. Several actuator and sensor faults are simulated in a nonlinear simulation of the reactor in Simulink. The scheme is used to detect and isolate the faults on-line. The simulation results show the effectiveness of the scheme even the process is subjected to disturbances and uncertainties including significant changes in the monomer feed rate, fouling factor, impurity factor, ambient temperature, and measurement noise. The simulation results are presented to illustrate the effectiveness and robustness of the proposed method.

Keywords: Robust fault detection, cascade control, independent RBF model, RBF neural networks, Chylla-Haase reactor, FDI under closed-loop control.

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4222 Technique for Voltage Control in Distribution System

Authors: S. Thongkeaw, M. Boonthienthong

Abstract:

This paper presents the techniques for voltage control in distribution system. It is integrated in the distribution management system. Voltage is an important parameter for the control of electrical power systems. The distribution network operators have the responsibility to regulate the voltage supplied to consumer within statutory limits. Traditionally, the On-Load Tap Changer (OLTC) transformer equipped with automatic voltage control (AVC) relays is the most popular and effective voltage control device. A static synchronous compensator (STATCOM) may be equipped with several controllers to perform multiple control functions. Static Var Compensation (SVC) is regulation slopes and available margins for var dispatch. The voltage control in distribution networks is established as a centralized analytical function in this paper. 

Keywords: Voltage Control, Reactive Power, Distribution System.

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4221 Model Predictive Control of Turbocharged Diesel Engine with Exhaust Gas Recirculation

Authors: U. Yavas, M. Gokasan

Abstract:

Control of diesel engine’s air path has drawn a lot of attention due to its multi input-multi output, closed coupled, non-linear relation. Today, precise control of amount of air to be combusted is a must in order to meet with tight emission limits and performance targets. In this study, passenger car size diesel engine is modeled by AVL Boost RT, and then simulated with standard, industry level PID controllers. Finally, linear model predictive control is designed and simulated. This study shows the importance of modeling and control of diesel engines with flexible algorithm development in computer based systems.

Keywords: Predictive control, engine control, engine modeling, PID control, feedforward compensation.

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4220 Quality Fed-Batch Bioprocess Control A Case Study

Authors: Mihai Caramihai, Irina Severin

Abstract:

Bioprocesses are appreciated as difficult to control because their dynamic behavior is highly nonlinear and time varying, in particular, when they are operating in fed batch mode. The research objective of this study was to develop an appropriate control method for a complex bioprocess and to implement it on a laboratory plant. Hence, an intelligent control structure has been designed in order to produce biomass and to maximize the specific growth rate.

Keywords: Fed batch bioprocess, mass-balance model, fuzzy control

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4219 Coding Structures for Seated Row Simulation of an Active Controlled Vibration Isolation and Stabilization System for Astronaut’s Exercise Platform

Authors: Ziraguen O. Williams, Shield B. Lin, Fouad N. Matari, Leslie J. Quiocho

Abstract:

Simulation for seated row exercise was a continued task to assist NASA in analyzing a one-dimensional vibration isolation and stabilization system for astronaut’s exercise platform. Feedback delay and signal noise were added to the simulation model. Simulation runs for this study were conducted in two software simulation tools, Trick and MBDyn, software simulation environments developed at the NASA Johnson Space Center. The exciter force in the simulation was calculated from motion capture of an exerciser during a seated aerobic row exercise. The simulation runs include passive control, active control using a Proportional, Integral, Derivative (PID) controller, and active control using a Piecewise Linear Integral Derivative (PWLID) controller. Output parameters include displacements of the exercise platform, the exerciser, and the counterweight; transmitted force to the wall of spacecraft; and actuator force to the platform. The simulation results showed excellent force reduction in the active controlled system compared to the passive controlled system, which showed less force reduction.

Keywords: Simulation, counterweight, exercise, vibration.

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4218 Coverage and Capacity Performance Degradation on a Co-Located Network Involving CDMA2000 and WCDMA @1.9GH

Authors: O. C. Nosiri, V. E. Idigo, C. O. Ohaneme, K. A. Akpado

Abstract:

Coverage and capacity performance in a cellular network determines the system potentials. If the coverage radius is limited, end users suffer poor service quality, if the system capacity reduces, fewer subscribers will be accommodated. This paper investigated the performance effects of the noise rise caused by the spurious emission from a co-located jammer involving downlink frequency of CDMA2000 and uplink frequency of WCDMA operating at 1.9GHz. Measurements were carried out to evaluate the impact on the coverage radius and the system capacity.

Keywords: Capacity, Co-location, Coverage, Noise rise.

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4217 On the Bootstrap P-Value Method in Identifying out of Control Signals in Multivariate Control Chart

Authors: O. Ikpotokin

Abstract:

In any production process, every product is aimed to attain a certain standard, but the presence of assignable cause of variability affects our process, thereby leading to low quality of product. The ability to identify and remove this type of variability reduces its overall effect, thereby improving the quality of the product. In case of a univariate control chart signal, it is easy to detect the problem and give a solution since it is related to a single quality characteristic. However, the problems involved in the use of multivariate control chart are the violation of multivariate normal assumption and the difficulty in identifying the quality characteristic(s) that resulted in the out of control signals. The purpose of this paper is to examine the use of non-parametric control chart (the bootstrap approach) for obtaining control limit to overcome the problem of multivariate distributional assumption and the p-value method for detecting out of control signals. Results from a performance study show that the proposed bootstrap method enables the setting of control limit that can enhance the detection of out of control signals when compared, while the p-value method also enhanced in identifying out of control variables.

Keywords: Bootstrap control limit, p-value method, out-of-control signals, p-value, quality characteristics.

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4216 Novel Ridge Orientation Based Approach for Fingerprint Identification Using Co-Occurrence Matrix

Authors: Mehran Yazdi, Zahra Adelpour, Batoul Bahraini, Yasaman Keshtkar Jahromi

Abstract:

In this paper we use the property of co-occurrence matrix in finding parallel lines in binary pictures for fingerprint identification. In our proposed algorithm, we reduce the noise by filtering the fingerprint images and then transfer the fingerprint images to binary images using a proper threshold. Next, we divide the binary images into some regions having parallel lines in the same direction. The lines in each region have a specific angle that can be used for comparison. This method is simple, performs the comparison step quickly and has a good resistance in the presence of the noise.

Keywords: Parallel lines detection, co-occurrence matrix, fingerprint identification.

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4215 Integrate Communication Modeling into the Design Modeling at Early Stages of the Design Flow Case Study: Unmanned Aerial Vehicle (UAV)

Authors: Ibrahim A. Aref, Tarek A. El-Mihoub

Abstract:

This paper shows how we can integrate communication modeling into the design modeling at early stages of the design flow. We consider effect of incorporating noise such as impulsive noise on system stability. We show that with change of the system model and investigate the system performance under the different communication effects. We modeled a unmanned aerial vehicle (UAV) as a demonstration using SystemC methodology. Moreover the system is modeled by joining the capabilities of UML and SystemC to operate at system level.

Keywords: Modelling, SoC, SystemC, UAV, Simulation, SoC.

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4214 Integration of Acceleration Feedback Control with Automatic Generation Control in Intelligent Load Frequency Control

Authors: H. Zainuddin, F. Hanafi, M. H. Hairi, A. Aman, M.H.N. Talib

Abstract:

This paper investigates the effects of knowledge-based acceleration feedback control integrated with Automatic Generation Control (AGC) to enhance the quality of frequency control of governing system. The Intelligent Acceleration Feedback Controller (IAFC) is proposed to counter the over and under frequency occurrences due to major load change in power system network. Therefore, generator tripping and load shedding operations can be reduced. Meanwhile, the integration of IAFC with AGC, a well known Load-Frequency Control (LFC) is essential to ensure the system frequency is restored to the nominal value. Computer simulations of frequency response of governing system are used to optimize the parameters of IAFC. As a result, there is substantial improvement on the LFC of governing system that employing the proposed control strategy.

Keywords: Knowledge-based Supplementary Control, Acceleration Feedback, Load Frequency Control, Automatic Generation Control.

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4213 Industrial Compressor Anti-Surge Computer Control

Authors: Ventzas Dimitrios, Petropoulos George

Abstract:

The paper presents a compressor anti-surge control system, that results in maximizing compressor throughput with pressure standard deviation reduction, increased safety margin between design point and surge limit line and avoiding possible machine surge. Alternative control strategies are presented.

Keywords: Anti-surge, control, compressor, PID control, safety, fault tolerance, start-up, ESD.

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4212 Application of Flexi-Wall in Noise Barriers Renewal

Authors: B. Daee, H. M. El Naggar

Abstract:

This paper presents an experimental study on structural performance of an innovative noise barrier consisting of poly-block, light polyurethane foam (LPF) and polyurea. This wall system (flexi-wall) is intended to be employed as a vertical extension to existing sound barriers in an accelerated construction method. To aid in the wall design, several mechanical tests were conducted on LPF specimens and two full-scale walls were then fabricated employing the same LPF material. The full-scale walls were subjected to lateral loading in order to establish their lateral resistance. A cyclic fatigue test was also performed on a full-scale flexi-wall in order to evaluate the performance of the wall under a repetitive loading condition. The result of the experiments indicated the suitability of flexi-wall in accelerated construction and confirmed that the structural performance of the wall system under lateral loading is satisfactory for the sound barrier application. The experimental results were discussed and a preliminary design procedure for application of flexi-wall in sound barrier applications was also developed.

Keywords: Noise barrier, Polyurethane Foam, Accelerated construction, Full-scale experiment.

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4211 Performance of Coded Multi-Line Copper Wire for G.fast Communications in the Presence of Impulsive Noise

Authors: Israa Al-Neami, Ali J. Al-Askery, Martin Johnston, Charalampos Tsimenidis

Abstract:

In this paper, we focus on the design of a multi-line copper wire (MLCW) communication system. First, we construct our proposed MLCW channel and verify its characteristics based on the Kolmogorov-Smirnov test. In addition, we apply Middleton class A impulsive noise (IN) to the copper channel for further investigation. Second, the MIMO G.fast system is adopted utilizing the proposed MLCW channel model and is compared to a single line G-fast system. Second, the performance of the coded system is obtained utilizing concatenated interleaved Reed-Solomon (RS) code with four-dimensional trellis-coded modulation (4D TCM), and compared to the single line G-fast system. Simulations are obtained for high quadrature amplitude modulation (QAM) constellations that are commonly used with G-fast communications, the results demonstrate that the bit error rate (BER) performance of the coded MLCW system shows an improvement compared to the single line G-fast systems.

Keywords: G.fast, Middleton Class A impulsive noise, mitigation techniques, copper channel Model.

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4210 Taguchi-Based Six Sigma Approach to Optimize Surface Roughness for Milling Processes

Authors: Sky Chou, Joseph C. Chen

Abstract:

This paper focuses on using Six Sigma methodologies to improve the surface roughness of a manufactured part produced by the CNC milling machine. It presents a case study where the surface roughness of milled aluminum is required to reduce or eliminate defects and to improve the process capability index Cp and Cpk for a CNC milling process. The six sigma methodology, DMAIC (design, measure, analyze, improve, and control) approach, was applied in this study to improve the process, reduce defects, and ultimately reduce costs. The Taguchi-based six sigma approach was applied to identify the optimized processing parameters that led to the targeted surface roughness specified by our customer. A L9 orthogonal array was applied in the Taguchi experimental design, with four controllable factors and one non-controllable/noise factor. The four controllable factors identified consist of feed rate, depth of cut, spindle speed, and surface roughness. The noise factor is the difference between the old cutting tool and the new cutting tool. The confirmation run with the optimal parameters confirmed that the new parameter settings are correct. The new settings also improved the process capability index. The purpose of this study is that the Taguchi–based six sigma approach can be efficiently used to phase out defects and improve the process capability index of the CNC milling process.

Keywords: CNC machining, Six Sigma, Surface roughness, Taguchi methodology.

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4209 On the Quantizer Design for Base Station Cooperation Systems with SC-FDE Techniques

Authors: K. Firsanov, S. Gritsutenko, R. Dinis

Abstract:

By employing BS (Base Station) cooperation we can increase substantially the spectral efficiency and capacity of cellular systems. The signals received at each BS are sent to a central unit that performs the separation of the different MT (Mobile Terminal) using the same physical channel. However, we need accurate sampling and quantization of those signals so as to reduce the backhaul communication requirements. In this paper we consider the optimization of the quantizers for BS cooperation systems. Four different quantizer types are analyzed and optimized to allow better SQNR (Signal-to-Quantization Noise Ratio) and BER (Bit Error Rate) performance.

Keywords: Base Stations cooperation scheme, Bit Error Rate (BER), Quantizer, Signal to Quantization Noise Ratio (SQNR), SCFDE.

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4208 Control of a DC Servomotor Using Fuzzy Logic Sliding Mode Model Following Controller

Authors: Phongsak Phakamach

Abstract:

A DC servomotor position control system using a Fuzzy Logic Sliding mode Model Following Control or FLSMFC approach is presented. The FLSMFC structure consists of an integrator and variable structure system. The integral control is introduced into it in order to eliminated steady state error due to step and ramp command inputs and improve control precision, while the fuzzy control would maintain the insensitivity to parameter variation and disturbances. The FLSMFC strategy is implemented and applied to a position control of a DC servomotor drives. Experimental results indicated that FLSMFC system performance with respect to the sensitivity to parameter variations is greatly reduced. Also, excellent control effects and avoids the chattering phenomenon.

Keywords: Sliding mode model following control, fuzzy logic, DC servomotor.

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4207 Bioprocess Intelligent Control: A Case Study

Authors: Mihai Caramihai Ana A Chirvase, Irina Severin

Abstract:

Bioprocesses are appreciated as difficult to control because their dynamic behavior is highly nonlinear and time varying, in particular, when they are operating in fed batch mode. The research objective of this study was to develop an appropriate control method for a complex bioprocess and to implement it on a laboratory plant. Hence, an intelligent control structure has been designed in order to produce biomass and to maximize the specific growth rate.

Keywords: Fed batch bioprocess, mass-balance model, fuzzy control.

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4206 Fuzzy Logic Control for Flexible Joint Manipulator: An Experimental Implementation

Authors: Sophia Fry, Mahir Irtiza, Alexa Hoffman, Yousef Sardahi

Abstract:

This study presents an intelligent control algorithm for a flexible robotic arm. Fuzzy control is used to control the motion of the arm to maintain the arm tip at the desired position while reducing vibration and increasing the system speed of response. The Fuzzy controller (FC) is based on adding the tip angular position to the arm deflection angle and using their sum as a feedback signal to the control algorithm. This reduces the complexity of the FC in terms of the input variables, number of membership functions, fuzzy rules, and control structure. Also, the design of the fuzzy controller is model-free and uses only our knowledge about the system. To show the efficacy of the FC, the control algorithm is implemented on the flexible joint manipulator (FJM) developed by Quanser. The results show that the proposed control method is effective in terms of response time, overshoot, and vibration amplitude.

Keywords: Fuzzy logic control, model-free control, flexible joint manipulators, nonlinear control.

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4205 Analog Front End Low Noise Amplifier in 0.18-µm CMOS for Ultrasound Imaging Applications

Authors: Haridas Kuruveettil, Dongning Zhao, Cheong Jia Hao, Minkyu Je

Abstract:

We present the design of Analog front end (AFE) low noise pre-amplifier implemented in a high voltage 0.18-µm CMOS technology for  a three dimensional ultrasound  bio microscope (3D UBM) application. The fabricated chip has 4X16 pre-amplifiers implemented to interface   a 2-D array of    high frequency capacitive micro-machined ultrasound transducers (CMUT). Core AFE cell consists of a high-voltage pulser in the transmit path, and a low-noise transimpedance amplifier in the receive path. Proposed system offers a high image resolution by the use of high frequency CMUTs with associated high performance imaging electronics integrated together.  Performance requirements and the design methods of the high bandwidth transimpedance amplifier are described in the paper. A single cell of transimpedance (TIA) amplifier and the bias circuit occupies a silicon area of 250X380 µm2 and the full chip occupies a total silicon area of 10x6.8 mm².

Keywords: Ultrasound, analog front end, medical imaging, beam forming, biomicroscope, transimpedance gain.

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4204 A WIP Control Based On an Intelligent Controller

Authors: Chih-Hui Chiu, Chun-Hsien Lin

Abstract:

In this study, a robust intelligent backstepping tracking control (RIBTC) system combined with adaptive output recurrent cerebellar model articulation control (AORCMAC) and H∞ control technique is proposed for wheeled inverted pendulums (WIPs) real-time control with exact system dynamics unknown. Moreover, a robust H∞ controller is designed to attenuate the effect of the residual approximation errors and external disturbances with desired attenuation level. The experimental results indicate that the WIPs can stand upright stably when using the proposed RIBTC.

Keywords: Wheeled inverted pendulum, backsteppingtracking control, H∞ control, adaptive output recurrentcerebellar model articulation control.

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4203 Model Reference Adaptive Control and LQR Control for Quadrotor with Parametric Uncertainties

Authors: Alia Abdul Ghaffar, Tom Richardson

Abstract:

A model reference adaptive control and a fixed gain LQR control were implemented in the height controller of a quadrotor that has parametric uncertainties due to the act of picking up an object of unknown dimension and mass. It is shown that an adaptive controller, unlike the fixed gain controller, is capable of ensuring a stable tracking performance under such condition, although adaptive control suffers from several limitations. The combination of both adaptive and fixed gain control in the controller architecture can result in an enhanced tracking performance in the presence parametric uncertainties.

Keywords: UAV, quadrotor, model reference adaptive control, LQR control.

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4202 The Exploitation of Balancing an Inverted Pendulum System Using Sliding Mode Control

Authors: Sheren H. Salah, Ahmed Y. Ben Sasi

Abstract:

The inverted pendulum system is a classic control problem that is used in universities around the world. It is a suitable process to test prototype controllers due to its high non-linearities and lack of stability. The inverted pendulum represents a challenging control problem, which continually moves toward an uncontrolled state. This paper presents the possibility of balancing an inverted pendulum system using sliding mode control (SMC). The goal is to determine which control strategy delivers better performance with respect to pendulum’s angle and cart's position. Therefore, proportional-integral-derivative (PID) is used for comparison. Results have proven SMC control produced better response compared to PID control in both normal and noisy systems.

Keywords: Inverted pendulum (IP) proportional-integralderivative (PID), sliding mode control (SMC).

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4201 Blind Channel Estimation Based on URV Decomposition Technique for Uplink of MC-CDMA

Authors: Pradya Pornnimitkul, Suwich Kunaruttanapruk, Bamrung Tau Sieskul, Somchai Jitapunkul

Abstract:

In this paper, we investigate a blind channel estimation method for Multi-carrier CDMA systems that use a subspace decomposition technique. This technique exploits the orthogonality property between the noise subspace and the received user codes to obtain channel of each user. In the past we used Singular Value Decomposition (SVD) technique but SVD have most computational complexity so in this paper use a new algorithm called URV Decomposition, which serve as an intermediary between the QR decomposition and SVD, replaced in SVD technique to track the noise space of the received data. Because of the URV decomposition has almost the same estimation performance as the SVD, but has less computational complexity.

Keywords: Channel estimation, MC-CDMA, SVD, URV.

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4200 Six Sigma-Based Optimization of Shrinkage Accuracy in Injection Molding Processes

Authors: Sky Chou, Joseph C. Chen

Abstract:

This paper focuses on using six sigma methodologies to reach the desired shrinkage of a manufactured high-density polyurethane (HDPE) part produced by the injection molding machine. It presents a case study where the correct shrinkage is required to reduce or eliminate defects and to improve the process capability index Cp and Cpk for an injection molding process. To improve this process and keep the product within specifications, the six sigma methodology, design, measure, analyze, improve, and control (DMAIC) approach, was implemented in this study. The six sigma approach was paired with the Taguchi methodology to identify the optimized processing parameters that keep the shrinkage rate within the specifications by our customer. An L9 orthogonal array was applied in the Taguchi experimental design, with four controllable factors and one non-controllable/noise factor. The four controllable factors identified consist of the cooling time, melt temperature, holding time, and metering stroke. The noise factor is the difference between material brand 1 and material brand 2. After the confirmation run was completed, measurements verify that the new parameter settings are optimal. With the new settings, the process capability index has improved dramatically. The purpose of this study is to show that the six sigma and Taguchi methodology can be efficiently used to determine important factors that will improve the process capability index of the injection molding process.

Keywords: Injection molding, shrinkage, six sigma, Taguchi parameter design.

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