基于MPC算法的热焓控制法铝合金半固态浆料智能制备系统设计

半固态流变成形技术能够以短流程、低成本、产品性能好等优势生产复杂形状零部件。但传统流变制浆工艺的复杂性和控制难度让其难以投入生产。本研究基于热焓控制法流变制浆技术，开发了一种智能制浆系统。该系统结合自动化与智能化技术，解决了铝合金半固态制浆过程中的温度控制难题，从而提高最终产品的质量。研究的主要内容和成果包括：

（1）设计了一套智能制浆系统，该系统能够进行浆料温度的精确控制、工艺参数的实时监测和自动优化。该系统的整体架构包含物理实体层、模型交互层以及用户交互层，来实现系统监测与管理能力；并分别对软件和硬件进行了详细的规划和设计，实现了热焓控制法制浆流程的动作自动化和数据采集分析功能。

（2）利用COMSOL仿真软件，建立了制浆过程的传热仿真模型，通过对热传导、对流和辐射三种关键传热方式和电磁场仿真对不同加热条件下的浆料温度分布特性进行了瞬态仿真分析，建立了准确的仿真模型。通过分析仿真，得知感应加热能调节浆料温度，使其温差沿半径方向下降到6.8℃以内，但纵向温差仍然在20℃以上，为实际操作过程中工艺参数的选择提供指导。

（3）对制浆过程中的传热机制进行了细致的数学建模，获得了浆料温度场的理论数学模型。
通过在实仿真模型中进行参数辨识，使用LM算法修正和优化模型参数，获得精确的线性系统方程，其中辨识的热流密度相对误差小于4\%，系统方程拟合相关系数大于0.95，能较准确地描述浆料的温度分布。
根据修正后的线性系统方程，本章成功设计并通过仿真验证了MPC控制器，显示出其在半固态制浆过程控制中相较于其他控制方案的能更快更精准达到目标温度，并能有效减低浆料内部温差。

（4）搭建并测试了智能制浆系统，实现了制浆过程的自动化，数据的实时采集和处理；验证了所提出辨识算法和MPC算法的有效性。实验结果显示，通过对制浆流程的自动控制和优化，智能制浆系统能够在30s内完成浆料制备并且浆料内部最大温差控制在3℃以内，相比传统的制浆方案，这套系统能实现更低的能耗和在更短的时间内达到稳定状态，为铝合金半固态流变成形技术的工业化生产提供了新的视角和有效路径。

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