This engaging PowerPoint presentation sheds light on the transformation of plastics manufacturing through the powerful combination of machine learning and cloud technology. Plastics manufacturers are increasingly becoming data-driven powerhouses, and this presentation explores how these technologies play a pivotal role in this evolution. Attendees will learn how machine learning algorithms can harness vast amounts of data to optimize processes, improve quality control, and enhance overall operational efficiency. Moreover, the integration of cloud technology enables real-time data access, collaboration, and scalability, fostering a new era of smart manufacturing. Discover the key insights, benefits, and practical applications of machine learning and cloud technology in the plastics industry, and how they are shaping the future of this vital sector.
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How Machine Learning and Cloud Technology turn Plastics Manufacturers into Data-Driven Powerhouses.pptx
1. How Machine Learning and Cloud
Technology turn Plastics Manufacturers
into Data-Driven Powerhouses
automatica 2023 | 30.06.2023
2. WHO IS BEHIND sensXPERT?
Parent Company:
NETZSCH
Family-owned global technology leader with
4100+ employees present in 36 countries
Corporate Venture:
NETZSCH Process Intelligence GmbH
Enhancing productivity through advanced
process analysis technology for the industry 4.0
As a recognised industry expert with 50+ years of experience in material science and sensor
technology, it is the NETZSCH Group that transforms industries with next-level intelligence
for increased efficiency, quality assurance and process reliability for the plastics industry.
&
12. MATERIAL KNOWLEDGE AT THE HEART OF PROCESS ENHANCEMENT
• Measuring material behavior
• resin viscosity, degree of cure, glass-transition,
material condition (mixing ratio, ageing, shrinkage, contamination)
• Combined with third-party measurement devices
(pressure transducers, thermocouples, and more)
• Thermosets, rubbers and thermoplastics
• Fiber reinforced polymers
• Sands or natural stones bonded with resin
• (Reaction) Injection Molding
• Thermoforming & Compression Molding
• Transfer Moulding Processes
• Vacuum infusion & Autoclave Curing
MATERIALS PROCESSES
Real-Time Material Characterization with Dielectric Sensors
13. Dielectric Sensor Information
Introduction of the material
Minimum resin viscosity
Progression of cure / gelation / crystallization
Completion of cure / crystallization
sensXPERT® process data
14. MACHINE LEARNING AND PROCESS OPTIMIZATION
Dielectric Measurements Kinetic Model
Degree
of Cure
Glass Transition
Temperature
Data Preprocessing
...
ML Model
Data Generation Prediction &
Optimization
Training & Testing
+
15. Simulation and Optimization
A data driven solution.
• AI model calculates and predicts
material properties
• Dynamically control and adapt the
process to ensure constant quality
Real-Time Process Optimization
16. CLOUD SERVICE
• Process data transparency
• 24/7 access on any device
• Customizable dashboards
• OpenAPI: flexible data handling
32. • Coming soon:
• Thermoplastic materials
• sensXPERT in your production?
Outlook sensXPERT digital mold
33. We look forward to welcoming you into
the sensXPERT community!
Contact us
NETZSCH Process Intelligence GmbH Dr. Nicholas Ecke
Gebrüder-Netzsch-Str. 19 nicholas.ecke@sensxpert.com
95100 Selb, Germany
Editor's Notes
As a recognized industry expert with almost 50 years of experience in material science and sensor technology, it is the NETZSCH Group that transforms industries with next-level intelligence for increased efficiency, quality assurance and process reliability.
Dielctric analysis is the heart of the sensXPERT solution. It can measure and monitor important material behavior including viscosity, cure, glass transition temperature, and more. It is capable of measuring numerous types of materials used in a variety of plastic processing technologies.
With dielectric analysis, sensXPERT can measure and record valuable process data. The ion viscosity data (blue) is an analog to the mechanical viscosity of the material (the ability for the material to flow).
Point 1 shows when the material was introduced to the mold and reaches the dielectric sensor
Point 2 shows where the minimum viscosity of the material occurs. The viscosity is important because it affects the ability of the resin to fill the mold. Lower viscosity allows for quicker mold filling.
Point 3 shows the increase of viscosity as the material begins to cure at the elevated temperature. The inflection point of the ion viscosity curve indicates the gel point, which is where the resin can no longer flow.Point 4 shows the ion viscosity plateau marking the end of the curing reaction. It is clear the reaction completes around 120 minutes, and there is opportunity to optimize this curing cycle to reduce the cycle time.
sensXPERT is more than just dielectric analysis. We first use sensor data to create a kinetic model, which can predict the degree of cure, glass transition temperature, or other relevant thermal/mechanical properties of your material. Once this kinetic model is created, additional data is collected and used to train and test the machine learning model. With that machine learning model, we can accurately predict the process information and dynamically control the process to ensure constant part quality.
We can also implement information from accessory sensors, including mold temperature, pressure transducers, ambient temperature, humidity, and more. The machine learning model will determine which information is most relevant to the manufacturing process.
[animated version of previous figure]
Example: The curing (solidification) of an epoxy resin.
The in-mold sensor is collecting data (light blue dashed line). This collected data is used in combination with the machine learning model to create a prediction (green dashed line). If the prediction does not match the target value (blue solid line), the process will be dynamically adjusted. In this case, the temperature (pink line) is increased to make sure the target value of degree of cure is reached.
The Cloud Service stores all of the process data and calculations. From here, you can create customized dashboard to observe process trends by serial number, operator, machine, relative humidity, or whatever is important to you. The data is fully accessible to you and built with OpenAPI so it can be easily transferred to other software.