Abstract
Injection molding, a polymer processing technique that converts thermoplastics into a variety of plastic products, is a complicated nonlinear dynamic process that interacts with a different group of variables, including the machine, the mold, the material, and the process parameters. As injection molding process operates sequentially in phases, we treat it as a batch process. The review paper discusses the batch nature of injection molding and identifies the three main objectives for future development of injection molding: higher efficiency, greater profitability, and longer sustainability. From the perspective of system engineering, our discussion centers on the primary challenges for the batch operation of injection molding systems: 1) Model development in face of product changes, 2) Control strategies in face of dynamic changes, 3) Data analysis and process monitoring, and 4) Safety assurance and quality improvement, and the current progress that has been made in addressing these challenges. In light of the advancement of new information technologies, this paper provides several opportunities and encourages further research that may break existing capability limits and develop the next generation of automation solutions to bring about a revolution in this area.
Article PDF
Similar content being viewed by others
Explore related subjects
Discover the latest articles, news and stories from top researchers in related subjects.Avoid common mistakes on your manuscript.
References
Z. Chen and L.-S. Turng, Adv. Polym. Technol., 24, 165 (2005).
J. A. Brydson, Plastics materials, Elsevier, Netherlands (1999).
M. Betsche, US Patent, 8,229,591 (2012).
Y. Yang, K. Yao and F. Gao, Adv. Polym. Technol., 27, 217 (2008).
M. Moayyedian, Intelligent optimization of mold design and process parameters in injection molding, Springer, New York (2018).
Y. Yang, X. Chen, N. Lu and F. Gao, Injection molding process control, monitoring, and optimization, Hanser Publications, Cincinnati, Ohio, USA (2016).
F. Gao, Y. Yang and C. Shao, Chem. Eng. Sci., 56, 7025 (2001).
H. Yoo, H. E. Byun, D. Han and J. H. Lee, Annu. Rev. Control, 52, 108 (2021).
Q. Jiang, S. Yan, X. Yan, H. Yi and F. Gao, IEEE Trans. Ind. Inform., 16, 2839 (2019).
Z. Lou, Y. Wang, Y. Si and S. Lu, Automatica, 138, 110148 (2022).
Y. Zhou, K. Gao, D. Li, Z. Xu and F. Gao, Ind. Eng. Chem. Res., 60, 15658 (2021).
D. Bonvin, B. Srinivasan and D. Hunkeler, IEEE Control Syst. Mag., 26, 34 (2006).
J. Lu, Z. Cao and F. Gao, Acta Autom. Sin., 43, 933 (2017).
H. Havlicsek and A. Alleyne, IEEE-ASME T. Mech., 4, 312 (1999).
Y. Wang, D. Zhou and F. Gao, J. Process Control, 18, 543 (2008).
Y. Zhou, K. Gao, X. Tang, H. Hu, D. Li and F. Gao, IEEE T. Cybern., 1 (2022).
J. Liu, Z. Xu, J. Zhao and Z. Shao, Chem. Eng. Res. Des., 181, 278 (2022).
H. Zhou, Computer modeling for injection molding Simulation, optimization, and control, John Wiley & Sons (2012).
B. Chen, J. Wan, L. Shu, P. Li, M. Mukherjee and B. Yin, IEEE Access, 6, 6505 (2017).
J. Zhu, Z. Ge, Z. Song and F. Gao, Annu. Rev. Control, 46, 107 (2018).
Y. Zhou and F. Gao, IFACPapersOnLine, 55, 774 (2022).
T. Liu and F. Gao, Industrial process identification and control Design: Step-test and relay-experiment-based methods, Springer Science & Business Media (2011).
A. K. Tangirala, Principles of system identification: Theory and practice, CRC Press (2018).
J. Chen, B. Huang, F. Ding and Y. Gu, Automatica, 94, 194 (2018).
J. Shi, F. Gao and T.-J. Wu, AIChE J., 52, 2171 (2006).
J. Lu, Y. Yao and F. Gao, Ind. Eng. Chem. Res., 48, 9603 (2009).
J. Lu and F. Gao, Ind. Eng. Chem. Res., 47, 9508 (2008).
J. Lu, K. Yao and F. Gao, AIChE J., 55, 2318 (2009).
W. Yan, S. Hu, Y. Yang, F. Gao and T. Chen, Chem. Eng. J., 166, 1095 (2011).
L. Luo, Y. Yao and F. Gao, Ind. Eng. Chem. Res., 54, 5736 (2015).
D. E. Seborg, T. F. Edgar, D. A. Mellichamp and F. J. Doyle III, Process dynamics and control, John Wiley & Sons, Hoboken, NJ (2016).
B. Kim, J. K. Huusom and J. H. Lee, Ind. Eng. Chem. Res., 58, 13 664 (2019).
Y. Wang, F. Gao and F. J. Doyle III, J. Process Control, 19, 1589 (2009).
J. Shi, F. Gao and T.-J. Wu, J. Process Control, 15, 907 (2005).
Y. Wang, H. Zhang, S. Wei, D. Zhou and B. Huang, IEEE Trans. Syst. Man Cybern. -Syst., 48, 1493 (2017).
D. H. Jeong and J. M. Lee, Comput. Chem. Eng., 139, 106875 (2020).
D. A. Bristow, M. Tharayil and A. G. Alleyne, IEEE Control Syst. Mag., 26, 96 (2006).
J. H. Lee and K. S. Lee, Control Eng. Practice, 15, 1306 (2007).
H.-S. Ahn, K. L. Moore and Y. Chen, Iterative learning control: robustness and monotonic convergence for interval systems, Springer Science & Business Media, Berlin, Germany (2007).
T. D. Son, H.-S. Ahn and K. L. Moore, Automatica, 49, 1465 (2013).
J. Shi, F. Gao and T.-J. Wu, Ind. Eng. Chem. Res., 44, 8095 (2005).
J. Shi, F. Gao and T.-J. Wu, J. Process Control, 17, 715 (2007).
Y. Zhou, D. Li and F. Gao, IEEE Trans. Ind. Inform., 18, 3095 (2022).
S.-K. Oh and J. M. Lee, J. Process Control, 36, 64 (2015).
J. Lu, Z. Cao, C. Zhao and F. Gao, Ind. Eng. Chem. Res., 58, 17164 (2019).
L. Wang, J. Yu, R. Zhang, P. Li and F. Gao, IEEE Trans. Syst. Man Cybern. -Syst., 51, 2536 (2019).
Y. Zhou, D. Li, J. Lu, Y. Xi and L. Cen, IET Contr. Theory Appl., 12, 504 (2018).
Y. Zhou, D. Li, Y. Xi and Z. Gan, Int. J. Robust Nonlinear Control, 29, 43 (2019).
J.-X. Xu and X. Jin, IEEE Trans. Autom. Control, 58, 1322 (2012).
S. Mishra, U. Topcu and M. Tomizuka, IEEE Trans. Control Syst. Technol., 19, 1613 (2010).
R. Chi, X. Liu, R. Zhang, Z. Hou and B. Huang, J. Process Control, 55, 10 (2017).
S. J. Qin and T. A. Badgwell, Control Eng. Practice, 11, 733 (2003).
Y. Zhou, D. Li, Y. Xi and Z. Gan, Sci. China Inform. Sci., 63, 1 (2020).
S.-K. Oh and J. M. Lee, Comput. Chem. Eng., 93, 284 (2016).
R. Zhang, S. Wu and J. Tao, IEEE Trans. Ind. Inform., 15, 2905 (2018).
C. L. Smith, Control of batch processes, John Wiley & Sons (2014).
K. S. Lee and J. H. Lee, IEEE Trans. Autom. Control, 45, 1928 (2000).
D. H. Owens and J. Hatonen, Annu. Rev. Control, 29, 57 (2005).
L. Wang, S. Mo, D. Zhou, F. Gao and X. Chen, J. Process Control, 23, 715 (2013).
N. Amann, D. H. Owens and E. Rogers, Int. J. Control, 69, 203 (1998).
J. Shi, F. Gao and T.-J. Wu, Ind. Eng. Chem. Res., 45, 4603 (2006).
J. Shi, F. Gao and T.-J. Wu, Ind. Eng. Chem. Res., 45, 4617 (2006).
I. Chin, S. J. Qin, K. S. Lee and M. Cho, Automatica, 40, 1913 (2004).
S. Wu and R. Zhang, J. Process Control, 81, 172 (2019).
J. Shi and F. Gao, IFAC Proceedings Volumes, 40, 243 (2007).
S. He, W. Chen, D. Li, Y. Xi, Y. Xu and P. Zheng, IEEE T. Cybern., 52, 7492 (2022).
J. Lu, Z. Cao and F. Gao, IEEE Trans. Ind. Electron., 66, 6230 (2018).
J. M. Lee and J. H. Lee, Automatica, 41, 1281 (2005).
R. Chi, Z. Hou, S. Jin and B. Huang, IEEE Trans. Neural Netw. Learn. Syst., 29, 5971 (2018).
R. Chi, Z. Hou, S. Jin, D. Wang and C.-J. Chien, IEEE Trans. Neural Netw. Learn. Syst., 26, 2939 (2015).
P. Janssens, G. Pipeleers and J. Swevers, IEEE Trans. Control Syst. Technol., 21, 546 (2012).
M.-B. Rădac, R.-E. Precup, E. M. Petriu, S. Preitl and C.-A. Dragoş, IEEE Trans. Ind. Inform., 9, 2327 (2012).
J. H. Lee, S. Natarajan and K. S. Lee, J. Process Control, 11, 195 (2001).
K. S. Lee and J. H. Lee, J. Process Control, 13, 607 (2003).
K. S. Lee, I.-S. Chin, H. J. Lee and J. H. Lee, AIChE J., 45, 2175 (1999).
J. H. Lee, K. S. Lee and W. C. Kim, Automatica, 36, 641 (2000).
D. Li, S. He, Y. Xi, T. Liu, F. Gao, Y. Wang and J. Lu, IEEE Trans. Ind. Electron., 67, 3116 (2019).
D. Li, Y. Xi, J. Lu and F. Gao, Ind. Eng. Chem. Res., 55, 13074 (2016).
Q. Zhang, J. Yu and L. Wang, IEEE Access, 7, 126842 (2019).
A. Cinar, S. J. Parulekar, C. Undey and G. Birol, Batch fermentation: Modeling, monitoring, and control, NY: CRC press, New York (2003).
P. Mhaskar, A. Garg and B. Corbett, Modeling and control of batch processes, Springer, London, UK (2015).
L. Wang, R. Zhang and F. Gao, Iterative learning stabilization and fault-tolerant control for batch processes, Springer, Singapore (2020).
S. J. Qin, Annu. Rev. Control, 36, 220 (2012).
Z. Ge, Z. Song and F. Gao, Ind. Eng. Chem. Res., 52, 3543 (2013).
S. X. Ding, P. Zhang, A. Naik, E. L. Ding and B. Huang, J. Process Control, 19, 1496 (2009).
X. Z. Wang Data mining and knowledge discovery for process monitoring and control, Springer Science & Business Media (2012).
M. Weese, W. Martinez, F. M. Megahed and L. A. Jones-Farmer, J. Qual. Technol., 48, 4 (2016).
Y. Zhou, K. G. Vamvoudakis, W. M. Haddad and Z.-P. Jiang, IEEE T Cybern., 51, 4648 (2020).
M. I. Jordan and T. M. Mitchell, Science, 349, 255 (2015).
J. Yu, J. Process Control, 45, 84 (2016).
C. Tong and X. Yan, Chemometrics Intell. Lab. Syst, 130, 20 (2014).
S. Chen, J. Yu and S. Wang, J. Process Control, 87, 54 (2020).
C. Aldrich and L. Auret, Unsupervised process monitoring and fault diagnosis with machine learning methods, Springer (2013).
S. Yin, S. X. Ding, X. Xie and H. Luo, IEEE Trans. Ind. Electron., 61, 6418 (2014).
Q. Jiang, X. Yan and B. Huang, Ind. Eng. Chem. Res., 58, 12899 (2019).
K. Severson, P. Chaiwatanodom and R. D. Braatz, Annu. Rev. Control, 42, 190 (2016).
Z. Gao, C. Cecati and S. X. Ding, IEEE Trans. Ind. Electron., 62, 3757 (2015).
L. H. Chiang, E. L. Russell and R. D. Braatz, Fault detection and diagnosis in industrial systems, Springer Science & Business Media (2000).
V. Venkatasubramanian, R. Rengaswamy, S. N. Kavuri and K. Yin, Comput. Chem. Eng., 27, 327 (2003).
S. Heo and J. H. Lee, IFAC-PapersOnLine, 51, 470 (2018).
C. Zhao, F. Wang, N. Lu and M. Jia, J. Process Control, 17, 728 (2007).
C. Zhao and F. Gao, Chemometrics Intell. Lab. Syst, 133, 1 (2014).
Y. Yao and F. Gao, Annu. Rev. Control, 33, 172 (2009).
N. Lu and F. Gao, Ind. Eng. Chem. Res., 44, 3547 (2005).
J. Camacho, J. Picó and A. Ferrer, J. Chemometr., 22, 632 (2008).
J. Liu and D. S. H. Wong, J. Chemometr., 22, 385 (2008).
X.-T. Doan and R. Srinivasan, Comput. Chem. Eng., 32, 230 (2008).
C. Zhao, F. Wang, Z. Mao, N. Lu and M. Jia, Ind. Eng. Chem. Res., 47, 3104 (2008).
A. K. Smilde, J. A. Westerhuis and S. De Jong, J. Chemometr., 17, 323 (2003).
C. Undey and A. Cinar, IEEE Control Syst. Mag., 22, 40 (2002).
S. J. Qin, S. Valle and M. J. Piovoso, J. Chemometr., 15, 715 (2001).
S. W. Choi and I.-B. Lee, J. Process Control, 15, 295 (2005).
N. Lu, F. Gao and F. Wang, AIChE J., 50, 255 (2004).
A. Pariyani, W. D. Seider, U. G. Oktem and M. Soroush, AIChE J., 58, 812 (2012).
A. Pariyani, W. D. Seider, U. G. Oktem and M. Soroush, AIChE J., 58, 826 (2012).
Z. Wu and P. D. Christofides, Process operational safety and cyber-security, Springer (2021).
F. Gao and C. Zhao, US Patent, 6,309,571 (2001).
J. H. Lee, Int. J. Control Autom., 9, 415 (2011).
D. Q. Mayne, Automatica, 50, 2967 (2014).
B. Corbett and P. Mhaskar, AIChE J., 62, 1581 (2016).
I. S. Chin, K. S. Lee and J. H. Lee, Ind. Eng. Chem. Res., 39, 693 (2000).
C. Duchesne and J. F. MacGregor, Chemometrics Intell. Lab. Syst, 51, 125 (2000).
Y.-H. Chu, Y.-H. Lee and C. Han, Ind. Eng. Chem. Res., 43, 2680 (2004).
C. Zhao, F. Wang, Z. Mao, N. Lu and M. Jia, Ind. Eng. Chem. Res., 47, 825 (2008).
J. Zhang, E. Martin, A. Morris and C. Kiparissides, Comput. Chem. Eng., 21, S1025 (1997).
A. Kusiak, Nature, 544, 23 (2017).
S. Aumi and P. Mhaskar, AIChE J., 58, 2105 (2012).
H. Khayyam, A. Jamali, A. Bab-Hadiashar, T. Esch, S. Ramakrishna, M. Jalili and M. Naebe, IEEE Access, 8, 111381 (2020).
J. H. Lee, J. Shin and M. J. Realff, Comput. Chem. Eng., 114, 111 (2018).
J. Shin, T. A. Badgwell, K.-H. Liu and J. H. Lee, Comput. Chem. Eng., 127, 282 (2019).
J. W. Kim, B. J. Park, H. Yoo, T. H. Oh, J. H. Lee and J. M. Lee, J. Process Control, 87, 166 (2020).
H. Yoo, B. Kim, J. W. Kim and J. H. Lee, Comput. Chem. Eng., 144, 107133 (2021).
S. Yin and O. Kaynak, Proc. IEEE, 103, 143 (2015).
J. Shin and J. H. Lee, Comput. Chem. Eng., 91, 114 (2016).
G. Kanagachidambaresan, R. Anand, E. Balasubramanian and V. Mahima, Internet of things for industry 4.0: Design, challenges and solutions, Springer (2020).
H. Qu, D. Li, R. Zhang and F. Gao, Neurocomputing, 315, 322 (2018).
H. Qu, D. Li, R. Zhang, S.-H. Yang and F. Gao, Neurocomputing, 397, 70 (2020).
Y. Zhou, D. Li and F. Gao, Asian J. Control, 24, 2352 (2022).
Y. Zhou, D. Li and F. Gao, IEEE Trans. Syst. Man Cybern. -Syst. Doi:https://doi.org/10.1109/TSMC.2022.3184001 (2022).
Y. Zhou, D. Li, Y. Xi and F. Gao, Automatica, 136, 110039 (2022).
A. Fuller, Z. Fan, C. Day and C. Barlow, IEEE Access, 8, 108 952 (2020).
B. He and K.-J. Bai, Adv. Manuf., 9, 1 (2021).
Acknowledgements
This work was supported in part by the Hong Kong Research Grant Council under grant 16208520; in part by the Foshan-HKUST Project under grant FSUST19-FYTRI01; in part by the Guangdong scientific and technological project (202002030323 and 2014B 050505002); and in part by the SJTU Global Strategic Partnership Fund (2021 SJTU-HKUST).
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Zhou, Y., Cao, Z., Lu, J. et al. Objectives, challenges, and prospects of batch processes: Arising from injection molding applications. Korean J. Chem. Eng. 39, 3179–3189 (2022). https://doi.org/10.1007/s11814-022-1294-x
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11814-022-1294-x