Yes / A study has been carried out to investigate controlled release performance of caplet shaped injection moulded (IM) amorphous solid dispersion (ASD) tablets based on the model drug AZD0837 and polyethylene oxide (PEO). The physical/chemical storage stability and release robustness of the IM tablets were characterized and compared to that of conventional extended release (ER) hydrophilic matrix tablets of the same raw materials and compositions manufactured via direct compression (DC). To gain an improved understanding of the release mechanisms, the dissolution of both the polymer and the drug were studied. Under conditions where the amount of dissolution media was limited, the controlled release ASD IM tablets demonstrated complete and synchronized release of both PEO and AZD0837 whereas the release of AZD0837 was found to be slower and incomplete from conventional direct compressed ER hydrophilic matrix tablets. Results clearly indicated that AZD0837 remained amorphous throughout the dissolution process and was maintained in a supersaturated state and hence kept stable with the aid of the polymeric carrier when released in a synchronized manner. In addition, it was found that the IM tablets were robust to variation in hydrodynamics of the environment and PEO molecular weight. / The research was funded by AstraZeneca, Sweden.

Yes / A novel process chain for serial production of polymer-based devices incorporating both micro- and nano-scale features is proposed. The process chain is enabled by the use of Zr-based bulk metallic glasses (BMG) to achieve the necessary level of compatibility and complementarity between its component technologies. It integrates two different technologies, namely laser ablation and focused ion beam (FIB) milling for micro-structuring and sub-micron patterning, respectively, thus to fabricate inserts incorporating different length scale functional features. Two alternative laser sources, namely nano-second (NS) and pico-second (PS) lasers, were considered as potential candidates for the first step in this master-making process chain. The capabilities of the component technologies together with some issues associated with their integration were studied. To validate the replication performance of the produced masters, a Zr-based BMG insert was used to produce a small batch of micro-fluidic devices by micro-injection moulding. Furthermore, an experimental study was also carried out to determine whether it would be possible by NS laser ablation to structure the Zr-based BMG workpieces with a high surface integrity whilst retaining the BMG's non-crystalline morphology. Collectively, it was demonstrated that the proposed process chain could be a viable fabrication route for mass production of polymer devices incorporating different length scale features.

Verdrängergesteuterte hydrostatische Antriebssysteme mit drehzahlvariablem Pumpenantrieb zeichnen sich durch ihre im Vergleich mit ventilgesteuerten Antrieben gute Energieeffizienz und die Möglichkeit der einfachen Stillsetzung aus, weisen jedoch durch die mangelnde Einspannung des Aktors geringere Eigenfrequenzen auf, was die Einstellung von Standardregelkreisen erschwert und meist eine geringere Dynamik und Positioniergenauigkeit zur Folge hat. Hydraulische Achsantriebe, die ohnehin über zahlreiche dominante Nichtlinearitäten verfügen und schwach gedämpft sind können in der Folge das ihnen innewohnende Potential nicht ausschöpfen. Mit einem Vergleich von Dynamik und Präzision verschiedener Antriebssysteme an Hauptantriebsachsen von Kunststoff-Spritzgießmaschinen mittlerer Baugröße wird zunächst das Leistungspotential analysiert. Auf dieser Basis werden Methoden zur Verbesserung der statischen und dynamischen Eigenschaften drehzahlvariabler verdrängergesteuerter Antriebe in Positions- und Druckregelung entwickelt, welche sich durch eine einfache Parametrierung und hohe Robustheit auszeichnen, da sie ohne einen geschlossenen Regelkreis funktionieren. Die dynamische inversionsbasierte Vorsteuerung ermöglicht dabei ein initial gutes Folgeverhalten, das durch die Anwendung einer iterativ lernenden Regelung in jedem Zyklus weiter verbessert wird. Um die Dynamik von Folgeregelungen mit weiteren Randbedingungen zu maximieren wird eine Methode entwickelt, mit der es möglich ist, eine Bewegungsvorgabe entlang der physikalischen Leistungsgrenzen des Antriebssystems zu berechnen und die wirkenden Begrenzungen aufzuzeigen. Die Erstellung von Bewegungsvorgaben sowie die Einstellung der lernenden Regelung sind dabei jeweils mit einem einzigen Parameter möglich. Die experimentelle Untersuchung und der Funktionsnachweis der entwickelten Methoden am Beispiel der Kunststoff-Spritzgießmaschine zeigt eine deutliche Steigerung der möglichen Dynamik verdrängergesteuerter Antriebssysteme, ein gutes Folgeverhalten sowie eine erhöhte Positioniergenauigkeit bei gleichzeitiger Unabhängigkeit von der Betriebstemperatur.:1. Einleitung und wissenschaftliche Problemstellung 7 2. Zielsetzung der Arbeit 11 3. Stand der Forschung und Technik 13 3.1 Architekturen hydraulischer Linearantriebe 13 3.2 Betriebsverhalten drehzahlvariabler verdrängergesteuerter Antriebe 16 3.3 Regelung hydraulischer Achsantriebe in Verdrängersteuerung 18 3.4 Vorsteuerungen und iterativ lernende Regelungen 21 4. Antriebstechnik in Kunststoff-Spritzgießmaschinen 25 5. Analyse der Leistungsfähigkeit von Antriebssystemen in SGM 27 5.1 Aufbau und Funktionsweise von Spritzgießmaschinen 28 5.2 Auswahl der Antriebssysteme 31 5.3 Analyse der Bewegungsdynamik 34 5.4 Analyse der Positioniergenauigkeit 37 5.5 Analyse der Druckregelung 39 5.6 Identifikation von Potentialen für die Leistungssteigerung 44 6. Trajektoriengenerierung entlang der Systemleistungsgrenzen 47 6.1 Kniehebel-Schließeinheit 48 6.2 Analyse statischer und dynamischer Restriktionen 50 6.3 Trajektorienentwurfsmethodik 59 7. Modellbasierte dynamische Vorsteuerung 67 7.1 Methodik 68 7.2 Mathematisch-physikalische Beschreibung 69 7.3 Inversionsbasiertes Steuergesetz 75 8. Modellbasierte lernende Vorsteuerung 77 8.1 Methodik 78 8.2 Entwurf modellbasierter normoptimaler iterativ lernender Regelungen 79 8.3 Stabilitätsnachweis 84 8.4 Generierung von Lernmodellen 86 9. Anwendung der Verfahren und Diskussion 91 9.1 Positionsregelung im geschlossenen hydrostatischen Kreis 93 9.2 Lastkraftregelung im offenen Kreis 108 9.3 Ablösende Regelung: Geschwindigkeit - Last 123 10. Zusammenfassung 127 11. Literatur 133 12. Anhang 145 / Displacement-controlled hydrostatic drive systems with variable-speed pump are characterized by their good energy efficiency and the possibility of simple shutdown compared with valve-controlled drives, but they have lower natural frequencies, which makes the application of standard closed-loop control more difficult and usually results in lower dynamics and positioning accuracy. As a result hydraulic drives, which already have numerous dominant nonlinearities and are weakly damped, cannot exploit their full potential. The work starts with a comparison and an analysis of the dynamics and precision of different drive systems on main drive axes of medium-size plastic injection molding machines. On this basis, methods are developed for improving the static and dynamic properties of variable-speed displacement-controlled drives in position and pressure control. These methods are characterized by simple parameterization and high robustness without relying on a closed-loop control. In this context, the dynamic inversion-based feedforward control allows for a good tracking performance, which is further improved by applying a cycle-wise iterative learning control. In order to fulfill the dynamics of follow-up control with position boundary conditions, a method is developed which allows for calculating a motion specification along the physical performance limits of the drive system and to show the existing limitations. The creation of motion presets as well as the setting-up of a learning controller may be done with one single parameter. Experimental investigation of the developed methods using the example of the plastic injection molding machine shows a significant increase in dynamics of displacement-controlled drive systems, good follow-up behavior, and increased positioning accuracy while remaining independent of the operating temperature.:1. Einleitung und wissenschaftliche Problemstellung 7 2. Zielsetzung der Arbeit 11 3. Stand der Forschung und Technik 13 3.1 Architekturen hydraulischer Linearantriebe 13 3.2 Betriebsverhalten drehzahlvariabler verdrängergesteuerter Antriebe 16 3.3 Regelung hydraulischer Achsantriebe in Verdrängersteuerung 18 3.4 Vorsteuerungen und iterativ lernende Regelungen 21 4. Antriebstechnik in Kunststoff-Spritzgießmaschinen 25 5. Analyse der Leistungsfähigkeit von Antriebssystemen in SGM 27 5.1 Aufbau und Funktionsweise von Spritzgießmaschinen 28 5.2 Auswahl der Antriebssysteme 31 5.3 Analyse der Bewegungsdynamik 34 5.4 Analyse der Positioniergenauigkeit 37 5.5 Analyse der Druckregelung 39 5.6 Identifikation von Potentialen für die Leistungssteigerung 44 6. Trajektoriengenerierung entlang der Systemleistungsgrenzen 47 6.1 Kniehebel-Schließeinheit 48 6.2 Analyse statischer und dynamischer Restriktionen 50 6.3 Trajektorienentwurfsmethodik 59 7. Modellbasierte dynamische Vorsteuerung 67 7.1 Methodik 68 7.2 Mathematisch-physikalische Beschreibung 69 7.3 Inversionsbasiertes Steuergesetz 75 8. Modellbasierte lernende Vorsteuerung 77 8.1 Methodik 78 8.2 Entwurf modellbasierter normoptimaler iterativ lernender Regelungen 79 8.3 Stabilitätsnachweis 84 8.4 Generierung von Lernmodellen 86 9. Anwendung der Verfahren und Diskussion 91 9.1 Positionsregelung im geschlossenen hydrostatischen Kreis 93 9.2 Lastkraftregelung im offenen Kreis 108 9.3 Ablösende Regelung: Geschwindigkeit - Last 123 10. Zusammenfassung 127 11. Literatur 133 12. Anhang 145

Factory shop floors of the future will see a significant increase in interconnected devices for monitoring and control. However, if a Service Orientated Architecture (SOA) is implemented on all such devices then this will result in a large number of permutations of services and composite services. These services combined with other business level components can pose a huge challenge to manage as it is often difficult to keep an overview of all the devices, equipment and services. This thesis proposes an SOA based novel assimilation architecture for integrating disparate industrial hardware based processes and business processes of an enterprise in particular the plastics machinery environment. The key benefits of the proposed architecture are the reduction of complexity when integrating disparate hardware platforms; managing the associated services as well as allowing the Micro Injection Moulding (µIM) process to be monitored on the web through service and data integration. An Enterprise Service Bus (ESB) based middleware layer integrates the Wireless Sensor Network (WSN) based environmental and simulated machine process systems with frontend Google Gadgets (GGs) based web visualisation applications. A business process framework is proposed to manage and orchestrate the resulting services from the architecture. Results from the analysis of the WSN kits in terms of their usability and reliability showed that the Jennic WSN was easy to setup and had a reliable communication link in the polymer industrial environment with the PER being below 0.5%. The prototype Jennic WSN based µIM process monitoring system had limitations when monitoring high-resolution machine data, therefore a novel hybrid integration architecture was proposed. The assimilation architecture was implemented on a distributed server based test bed. Results from test scenarios showed that the architecture was highly scalable and could potentially allow a large number of disparate sensor based hardware systems and services to be hosted, managed, visualised and linked to form a cohesive business process.

Dans les dernierès années la politique des entreprises s'est concentrée sur la recherche de solutions industrielles plus écologiques pour réduire l'impact sur l'environnement et l'énergie consommée. La tendance s’est élargie aux machines stationnaires dans l'automatisation industrielle. Il inclut la technologie d’entraînement pour contrôler le mouvement séquentiel de plusieurs axes dans les presses à injecter. La conception des systèmes se focalise sur une approche conduisant à l’amélioration du rendement énergétique aussi bien que l’augmentation de la pression de service, la réduction de cycle de la machine et l’amélioration de sa répétabilité. Toutes ces exigences ont poussé la technologie d’entraînement à se développer en augmentant l'intérêt pour les modules électromécaniques et électro-hydrostatiques (EHM). Dans cette thèse, une solution innovatrice d'EHM est proposée qui associe un convertisseur, un servomoteur AC brushless et la pompe à palettes Parker. En détail, l'intérêt de recherche concerne le développement d'un modèle à niveau système de la pompe à palette. L'objectif principal est de permettre l'évaluation des pertes d'énergie de la pompe et la performance de module pendant des phases spécifiques du cycle de la machine : accélération, dépressurisation et phase de maintien de la pression. Premièrement analysée au moyen de l'approche analytique, la dynamique est alors évaluée par des modèles plus avancés basés sur le prototypage virtuel construit dans l'environnement LMS-AMESim. Les avantages concernant la prévision des performances du module EHM et sur l’évaluation des paramètres fondamentaux inconnus (comme la compressibilité du fluide et le contenu d’air dans le fluide) sont montrés par comparaison avec des résultats expérimentaux obtenus dans le laboratoire. Les phénomènes de la cavitation et d’aération sont aussi pris en compte pendant les phases d'accélération et des modèles sont ainsi développés pour prévoir les conditions de fonctionnement qui promeuvent ces phénomènes. La consommation d'énergie de l'EHM est alors analysée au moyen des modèles thermo-hydrauliques capables de déterminer les échanges de chaleur entre les composants de module et l'environnement. / In last years companies’ policy has been focusing on research of more eco-friendly solutions in order to reduce the environmental impact and the consumed energy. The trend has been affecting the stationary machinery in the industrial automation too. It includes the drive technology for motion control in the injection moulding machines. The design studies concern energy efficiency improvement, as well as increased service pressure, shorter cycle time and repeatability over a long period of time. All these requirements have led the drive technology to evolve by increasing the interest for the electro-mechanical and electro-hydrostatic modules (EHM). In this thesis an innovative solution of EHM is proposed that associates industrial inverter, AC brushless servo motor and fixed-displacement low-noise Parker vane pump. In detail, the research interest concerns the development of a system level model of the vane pump. The main objective is to enable assessing the pump energy losses and full module performance in specific phase of machine’s cycle: acceleration, depressurisation and holding pressure phases. Firstly analysed by means of analytical approach, dynamics are then evaluated through more advanced models based on virtual prototyping built in LMS-AMESim environment. The advantages on predicting the EHM performance and on estimating the unknown fundamental parameters (e.g. Bulk Modulus and fluid air content) are showed through comparison with experimental results obtained in laboratory. The cavitation/aeration phenomena are also taken into account during acceleration transients and models are thus developed in order to predict the operating conditions which promote these phenomena. Energy behaviour of the EHM is then analysed by means of thermal hydraulic models able to determine the heat exchanges between module components and environment.

For the automotive sector, plastics play the most important role when designing interior and exterior parts for cars. Currently, most parts are made from petroleum-based plastics but alternatives are needed to replace environmentally harmful materials while providing the appropriate mechanical performance and preferably reduce the cost for the final product. The objective of this work was to explore the use of soy flakes as natural filler in a composite with polypropylene and to investigate the mechanical properties, water absorption and thermal behaviour. For a better understanding of the filler, the soy flakes were characterized extensively with analytical and microscopic methods. Two types of soy fillers were investigated, soy flakes, provided by Bunge Inc., with a 48 wt-% protein content and an industrial soy based filler with 44 wt-% protein content and provided by Ford. The size of the soy flakes after milling was mainly between 50 and 200 µm and below 50 µm for the industrial filler. The aspect ratio for all filler was below 5. The soy flakes were used after milling and subjected to two pre-treatment methods: (1) one hour in a 50 °C pH 9 water solution in a 1 : 9 solid-liquid ratio; (2) one hour in a 50 °C pH 9 1M NaCl solution in a 1 : 9 solid-liquid ratio. A control filler, without pre-treatment was considered. The soy flakes were also compared to an industrial soy based filler provided by Ford (soy flour (Ford)). The thermogravimetric analysis showed an onset of degradation at 170 °C for the treated filler (ISH2O and ISNaCl) and 160 °C for the untreated filler. The biocomposites formulation consisted of 30 wt-% filler, and polypropylene with/without 0.35 wt-% anti-oxidant Irganox 1010 and with/without the addition of MA-PP as coupling agent. All biocomposites were compounded in a mini-extruder, pressed into bars by injection moulding and tested subsequently. The mechanical properties of the biocomposites are promising. An increase of the E-modulus was observed when compared to pure polypropylene. The addition of MA-PP as coupling agent increased the yield strength of the biocomposites. When pure polypropylene and the biocomposites were compared no difference could be seen for their yield strength. The thermal behaviour deduced from differential scanning calorimetry, revealed a similar behaviour for the biocomposites and the pure polypropylene. Only the samples treated in the presence of NaCl and without a coupling agent, appear to have a slightly higher degree of crystallinity. The melt flow index was slightly increased for the biocomposites containing soy flakes pre-treated with NaCl and decreased for biocomposites containing the soy flour. The water absorption behaviour of the biocomposites was quite similar at the beginning with a slightly lower absorption for the materials with coupling agent. After three months, all samples except the ones treated with water showed a weight loss that can be due to the leaching of the water soluble components in the untreated filler and the NaCl treated filler. In conclusion, soy flakes represent an attractive filler when used in a polypropylene matrix if an aqueous alkaline pre-treatment is performed. The aqueous alkaline extraction also leads to the recovery of the proteins that can be used in food products while the remaining insoluble material is used for the biocomposites, avoiding the competition with the use of soy for food products...

For the automotive sector, plastics play the most important role when designing interior and exterior parts for cars. Currently, most parts are made from petroleum-based plastics but alternatives are needed to replace environmentally harmful materials while providing the appropriate mechanical performance and preferably reduce the cost for the final product. The objective of this work was to explore the use of soy flakes as natural filler in a composite with polypropylene and to investigate the mechanical properties, water absorption and thermal behaviour. For a better understanding of the filler, the soy flakes were characterized extensively with analytical and microscopic methods. Two types of soy fillers were investigated, soy flakes, provided by Bunge Inc., with a 48 wt-% protein content and an industrial soy based filler with 44 wt-% protein content and provided by Ford. The size of the soy flakes after milling was mainly between 50 and 200 µm and below 50 µm for the industrial filler. The aspect ratio for all filler was below 5. The soy flakes were used after milling and subjected to two pre-treatment methods: (1) one hour in a 50 °C pH 9 water solution in a 1 : 9 solid-liquid ratio; (2) one hour in a 50 °C pH 9 1M NaCl solution in a 1 : 9 solid-liquid ratio. A control filler, without pre-treatment was considered. The soy flakes were also compared to an industrial soy based filler provided by Ford (soy flour (Ford)). The thermogravimetric analysis showed an onset of degradation at 170 °C for the treated filler (ISH2O and ISNaCl) and 160 °C for the untreated filler. The biocomposites formulation consisted of 30 wt-% filler, and polypropylene with/without 0.35 wt-% anti-oxidant Irganox 1010 and with/without the addition of MA-PP as coupling agent. All biocomposites were compounded in a mini-extruder, pressed into bars by injection moulding and tested subsequently. The mechanical properties of the biocomposites are promising. An increase of the E-modulus was observed when compared to pure polypropylene. The addition of MA-PP as coupling agent increased the yield strength of the biocomposites. When pure polypropylene and the biocomposites were compared no difference could be seen for their yield strength. The thermal behaviour deduced from differential scanning calorimetry, revealed a similar behaviour for the biocomposites and the pure polypropylene. Only the samples treated in the presence of NaCl and without a coupling agent, appear to have a slightly higher degree of crystallinity. The melt flow index was slightly increased for the biocomposites containing soy flakes pre-treated with NaCl and decreased for biocomposites containing the soy flour. The water absorption behaviour of the biocomposites was quite similar at the beginning with a slightly lower absorption for the materials with coupling agent. After three months, all samples except the ones treated with water showed a weight loss that can be due to the leaching of the water soluble components in the untreated filler and the NaCl treated filler. In conclusion, soy flakes represent an attractive filler when used in a polypropylene matrix if an aqueous alkaline pre-treatment is performed. The aqueous alkaline extraction also leads to the recovery of the proteins that can be used in food products while the remaining insoluble material is used for the biocomposites, avoiding the competition with the use of soy for food products...

Die in der vorliegenden Arbeit untersuchten Metall-Keramik-Verbunde wurden mittels Pulverspritzgießen hergestellt. Unter Anwendung der teilautomatisierten Verfahrensoptionen Mehrkomponentenspritzgießen und Inmould-Labelling, welches u. a. die Verwendung tiefgezogener Grünfolien beinhaltete, wurden hierzu 2K-Prüfkörpergeometrien (Zugstab, Biegebruchstab, Ringverbund) und 2K-Demonstratoren (Innenzahnrad, Fadenführer, Greifer) jeweils bestehend aus Stahl 17-4PH und ZrO2 (3%Y2O3), im Co-Sinterverfahren unter H2-Atmosphäre bei 1350°C, entwickelt. Schlüssel zur Darstellung schwindungskonformer ZrO2- und Stahl 17-4PH-Formgebungsmassen war der Angleich der Pulverpackungsdichte. Untersucht wurde neben der Werkstoff- und Gefügeausbildung das sich während dem Formgebungs- und Sinterprozess ausbildende Metall-Keramik-Interface sowie die sich bevorzugt in diesem Bereich manifestierenden Verbundeigenspannungen. Neben der stoffschlüssigen Versinterung beider Partner konnte eine Steigerung der Verbundfestigkeit durch Legierungsmodifikation unter Ausschluss technologischer Fehlerquellen erreicht und spezifiziert werden.

Spritzgießbare Duroplaste zeichnen sich durch hohe thermo-mechanische Beständigkeit, geringe Schwindung und niedrige Materialkosten aus. Damit können die Anforderungen an spritzgegossene Präzisionsbauteile für den Automobilbau erreicht werden. Im Rahmen der vorliegenden Arbeit werden unterschiedliche Novolak-Phenolformmassen hinsichtlich ihres hygroskopischen Verhaltens und dessen Auswirkung auf die Spritzgießverarbeitung und die Bauteilqualität untersucht. Das Absorptionsverhalten kann mithilfe der Fick’schen Diffusionsgesetzte näherungsweise beschrieben werden. Auf Basis von mechanischen Untersuchungen sowie der Beurteilung der Maßhaltigkeit eines Präzisionsdemonstrators hinsichtlich Schwindung und Verzug wird zudem der Einfluss der Prozessparameter beim Spritzgießen bestimmt. Die vorgestellten Untersuchungen zeigen die Grenzen der Verarbeitung und der realisierbaren Bauteilqualität auf, die auf die großserientaugliche Verarbeitung von duroplastischen Bauteilen übertragen werden können. / Injection moldable thermosetting materials show excellent material properties, e.g. high thermo-mechanical resistance and reduced shrinkage in combination with low material cost. Thus, technical requirements for high performance parts for automotive applications can be achieved. In the scope of this work different phenolic novolac compounds were investigated regarding their hygroscopic behavior with its influence for injection molding and product quality. The absorption can be approximately described by Fick’s-Diffusion-Model. The interrelationship of injection molding parameters and the thermo-mechanical behavior is examined on the basis of mechanical testing and the assessment of the dimensional accuracy for a thermoset high precision part. The presented investigations point to the limit of processing and realizable part quality which can be transferred for high performance parts molded in mass production.

This Diploma Thesis deals with modern technologies such as 3D scanning, rapid prototyping and vacuum casting to production of prototype form. It considers advantages and disadvantages of the modern technologies compared to traditional process of manufacturing prototype form and economical contribution using the modern technologies. Part of the thesis considers a choice of suitable manufacturing technology of a particular product.