1. Feedback control of liquid metal coating
- Author
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Scheid, Benoît, Mendez, Miguel Alfonso, Bersini, Hugues, Semeraro, Onofrio, Gallaire, François, Gardin, Pascal, Gosset, Anne, Papageorgiou, D.T., Parente, Alessandro, Pino, Fabio, Scheid, Benoît, Mendez, Miguel Alfonso, Bersini, Hugues, Semeraro, Onofrio, Gallaire, François, Gardin, Pascal, Gosset, Anne, Papageorgiou, D.T., Parente, Alessandro, and Pino, Fabio
- Abstract
This project aims to mitigate one of the significant industrial problems in the coating industry affecting thesurface quality of liquid metal coatings: the undulation instability. In the hot dip galvanizing process, a metalsheet is dipped and then withdrawn from a bath of molten zinc. This produces a thin liquid film of zinc flowingover the surface of the metal, which then solidifies into a corrosion-protective coating. With more than 100millions tons of steel coated worldwide every year, the hot dip galvanizing process is used nowadays in mostproduction lines, thanks to its simple, continuous, and cost-effective configuration. However, its operatingconditions are limited by the occurrence of a hydrodynamic instability called undulation. Taking the shapeof wavy patterns in the liquid film of zinc, this instability is detrimental to the final product quality and poseslimitations to the maximum production rates.In this project, we developed a closed-loop control strategy to attenuate the 3D undulation waves. Basedon a limited number of liquid film observations, the controller interacts with the liquid through pneumatic orelectromagnetic actuators. The design of an optimal control strategy followed a multidisciplinary approach,combining reduced order modelling of liquid films, numerical methods for solving hyperbolic differentialequations, and advanced feedback and model predictive control theory. The explored control methods includestability analysis based on integral modelling of thin film equations and machine learning techniques such asGenetic Programming and Reinforcement Learning.A clear knowledge of the liquid film dynamics was instrumental in the design of optimal control actions andthe correct placement of observation points. To this end, we studied the linear and nonlinear stability of flat filmsolutions. By solving the Orr-Sommerfeld eigenvalue problem, we calculated the neutral curves, investigatedthe instability mechanism and computed the absolute/convecti, Doctorat en Sciences de l'ingénieur et technologie, info:eu-repo/semantics/nonPublished
- Published
- 2024