Inline viscosity and molecular weight monitoring system with sensor fusion
Innovative system combining piezoelectric and ultrasonic sensors with hybrid modeling for real-time viscosity and molecular weight monitoring in polymer melts. Enhances accuracy and adaptability through sensor fusion and data integration.
Overview
The proposed inline monitoring system revolutionizes the accuracy of viscosity and molecular weight measurements in polymer melts. By integrating piezoelectric pressure, temperature sensors, and ultrasonic sensors on the nozzle, it captures real-time data that is processed through a hybrid modeling framework. This approach combines physics-based and data-driven models to predict melt viscosity, which is then mapped to molecular weight using a modified Mark-Houwink equation. This system is particularly adaptable, allowing updates to model parameters for different polymer grades, enhancing precision and application versatility.
Technical specifications
Key features:
- Sensor Fusion: Combines direct piezoelectric pressure, temperature sensors, and ultrasonic sensors to improve data accuracy.
- Hybrid Models: Utilizes a combination of PVT/rheological models and data-driven techniques for precise viscosity estimation.
- Data Integration: Employs an open-source DAQ system for seamless data acquisition and integration with injection molding machine data.
- Software: Scripts and front-end module developed in Python for easy integration and flexibility.
Technology readiness level
The system is currently at Technology Readiness Level 5, having completed the initial stages of sensor integration and hybrid model development. Future validation plans include testing with standard polymers to ensure accuracy and repeatability, followed by real-time trials on an R&D injection molding machine to assess system responsiveness and robustness.
About Clemson University
Clemson University is a comprehensive public land‑grant research university in Upstate South Carolina with a main campus and statewide outreach. Industry engages through co‑located facilities: an automotive innovation campus in Greenville, an energy testing complex in Charleston, and a research and technology park near the main campus with labs and offices. A strong co‑op program and corporate engagement team connect companies with faculty expertise and student talent, while the Extension network supports field trials and regional pilots. Research is backed by competitive federal funding from agencies such as NSF, NIH, DOE, USDA, and DOD. A dedicated technology transfer office provides IP, licensing, and startup support with clear pathways for industry‑sponsored agreements.
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