Abstract
In high-pressure die casting processes, proper control of die temperature is essential for producing superior quality components and yielding high production rates. However, die temperature distribution depends on various die design and process variables for which accurate models are normally very difficult to obtain. In this paper, a new intelligent control scheme is proposed for die thermal management. In this scheme, extra cooling waterlines controlled by a pump and solenoid valves are attached to the established cooling channels. A fuzzy PID controller is designed to minimize the temperature differences between channels. The experimental results obtained from a laboratory die casting process simulator indicate that the developed control system is capable of adjusting the desirable supply of cooling water into multiple cooling lines. Hence, the local temperature distribution of the die insert may become more homogeneous.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
References
Bishenden, W., & Bhoia, R. (1999). Die temperature control. In Proceedings of the Transactions of 20th International Die Casting Congress (pp. 161–164).
Booth, S. E. (1970). A die temperature cycle time controller. In Proceedings of the Sixth SDCE International Die Casting Congress (p. 54).
Chen, F. (2002). Data acquisition system for die casting processes. M.A.Sc. Thesis, University of Windsor.
Dent, B. K., & Fifer, R. (1972). Production operation with the Llzro-Battelle die temperature controller. In Proceedings of the Seventh SDCE International Die Casting Congress (p. 5572).
Guzelkaya M., Eksin I. and Yesil E. (2003). Self-tuning of PID-type fuzzy logic controller coefficients via relative rate observer. Engineering Applications of Artificial Intelligence 16: 227–236
He S.Z., Shaoua T.D. and Xu F.L. (1993). Fuzzy self-tuning of PID. Fuzzy Sets and Systems 56: 37–46
Hu, H., Chen, F., Chen, X., Chu, Y., & Cheng, P. (2002). Development of a computer-based data acquisition and control system for die casting Processes. In Proceedings of the EPD Congress 2003 (pp. 439–451). TMS.
Hu H., Chen F., Chen X., Chu Y. and Cheng P. (2004). Effect of cooling water flow rates on local temperatures and heat transfer of casting dies. Journal of Materials Processing Technology 148: 57–67
Huang, T. T., Chung, H. Y., & Lin, J. J. (1999). A fuzzy PID controller being like parameter varying PID. In IEEE International Fuzzy Systems Conference Proceeding (pp. 269–275).
Larkin, R. J. (1970). Automatic control die temperature in zinc die casting. In Proceedings of the Sixth SDCE International Die Casting Congress (p. 62).
Lin C.T. and Lee C.S.G. (1996). Neural fuzzy systems: A neuro-fuzzy synergism to intelligent systems. Prentice Hall, Upper Saddle River, NJ
Peterson, A. P. (1975). Thermocycling control of aluminum die casting machines. In Proceedings of the Eighth SDCE International Die Casting Congress (pp. B-t75–Bt024).
Qiao W.Z. and Mizumoto M. (1996). PID type fuzzy controller and parameters adaptive method. Fuzzy Sets and Systems 78: 23–35
Reddy, R. (1975). Temperature control of die casting dies. In Proceedings of the Eighth SDCE International Die Casting Congress (pp. B-t75–B-t025).
Takagi, T., & Sugeno, M. (1983). Derivation of fuzzy control rules from human operator’s control actions. In Proceeding of IFAC Symposium on Fuzzy Information, Knowledge Representation and Decision Analysis (pp. 55–60).
Tsoukalas L.H. and Uhrig R.E. (1996). Fuzzy and neural approaches in engineering. Jonh Wiley & Sons, New York, NY
Yang, T., Hu, H., Chen, X., Chu, Y., & Cheng, P. (2005a). On-line thermal management system for die casting processes. In Proceedings of 5th International Workshop on Advanced Manufacturing Technologies (pp. 189–196). National Research Council Canada.
Yang, T., Hu, H., Chen, X., Chu, Y., & Cheng, P. (2005b). An intelligent control system for die thermal management. In Proceedings of Materials Science & Technology, Sub-symposium on Automation & Control (pp. 11–20).
Yang T., Hu H., Chen X., Chu Y. and Cheng P. (2007). Thermal analysis of casting dies with local temperature controller. International Journal of Advanced Manufacturing Technology 33: 277–284
Xu J.X., Hang C.C. and Liu C. (2000). Parallel structure and tuning of a fuzzy PID controller. Automatica 36: 673–684
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Yang, T., Chen, X., Hu, H. et al. A fuzzy PID thermal control system for casting dies. J Intell Manuf 19, 375–382 (2008). https://doi.org/10.1007/s10845-008-0089-1
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s10845-008-0089-1