Study On The Cooperative Intelligent Control System Of The Carbon Fiber Spinning Process

The spinning process of the carbon fiber is one of the industrial processes that yield high complexity and high uncertainty. Its components and the corresponding devices differ with the detailed conditions that the whole manufacturing process asks for, and the requirements for the adequate quantity and excellent quality of the as-spun fiber should be met simultaneously. Consequently, these features make the establishment of a reliable, effective and integrated control system for the carbon fiber spinning process a giant task with great challenges. The natural creatures provide inspirations for designing novel intelligent control algorithms. The features that the spinning process of carbon fiber enjoys, e.g. the high complexity and uncertainty, are similar to those in the natural creatures, which reveal the potential of applying bio-inspired control and regulating methods to the manufacturing process. Based on the principle regulating mechanisms of the natural livings and human body, e.g. the neuro-endocrine-immune system, this work makes designing of the intelligent and cooperative controllers and their corresponding algorithms. The generated intelligent schemes can be used in the controlling and optimization of the carbon fiber spinning process or other similar large-scale industrial manufacturing processes so that the control performance of such systems can be raised, and the cooperative mechanisms can also be realized during the production. The main contributions of this thesis lie in:(1) An introduction of the neuro-endocrine-immune regulation mechanism that has been widely accepted is made. The cooperative mechanisms between the neural system and the endocrine system, the regulating principles of the endocrine system towards the host body and the complementary regulating mode between the neural system and the immune system are the key points in it. The detailed interacting modes among these systems are also analyzed. This part lays a theoretical foundation for building different types of intelligent controllers (systems) for the spinning procedures with features in different working conditions and quality requirements on the basis of such comprehensive bio-inspired regulating mechanism. (2) An intelligent cooperative decoupling controlling scheme based on the neuroendocrine regulating mechanism for the multivariable tuning is derived to conduct the control of the coagulation bath in the carbon fiber spinning process which also has several variables to be controlled simultaneously. According to the requirements of the coagulation bath, the original decoupling scheme is also expanded to multiple variables. The proposed intelligent cooperative decoupling mechanism has the ability to separate the coupling variables from each other while the detailed decoupling procedure is still kept simple, which brings benefits for the industrial realization of such mechanism. Experiment results show the proposed intelligent cooperative decoupling scheme can maneuver the variables of the coagulation bath independently and effectively, while keeping good transient response at the same time.(3) A multi-layered intelligent cooperative control scheme based on the endocrine feedback regulation of human body is proposed. The stretching process of the carbon fiber spinning system is taken as the object of the proposed scheme. After analyzing the production requirements and configuration of the stretching process, it can be generalized to a combination of different working units that ask for information exchange among them, which therefore makes it possible to apply the proposed control scheme. Experiment results show that the proposed multi-layered intelligent cooperative control scheme can connect the different parts of the stretching process together with efficiently, and a long-term stability of the stretching ratio can therefore be guaranteed through the cooperative regulation.(4) The natural endocrine regulation principle is taken as the foundation of a series of novel intelligent controllers, and a data-driven intelligent controller based on such mechanism is proposed to solve the controlling problem of the spinning process whose accurate model is difficult to acquire. The proposed controller roots from the idea of data-driven control but also embedded with an endocrine regulating module as an enhancement. Meanwhile, a series of instances of such kind of intelligent controller can be deducted due to the different working modes. Experiment results on the stretching process of the fiber production indicate that the proposed controller raise the agility and accuracy of the original data-driven controller, which is beneficial for maintaining the target plant at a stable working status for long time.(5) A bi-directional process modeling and intelligent optimizing approach with its expert system for spinning production is proposed based on the cooperative mechanism of the neural system and immune system. This model has not only the potential of acquiring reasonable configurations for the spinning process, but also the ability to conduct prediction and assessment for the produced fiber products. Such computerized solution provides the academicians with a useful tool for analyzing the details of the fiber production, meanwhile has great meaning for the fiber manufacturing unit and related people to optimize the production techniques and design new fiber products at a lower cost.Finally, a conclusion is made for the whole contents of this dissertation with the disadvantages of the current work being noted, and the perspectives of this field for the next step have also been discussed.