APRTC: advanced precise rapid thermal cycling in blow molding by applying fuzzy controller on thermoelectric devices for cooling and heating applications

AbstractThis study presents an innovative approach to enhance thermal control in the blow molding production process, specifically focusing on achieving rapid and precise temperature regulation. To address the significant time consumption during mold closure, strategically deploying thermoelectric modules (TEMs) arranged according to the mold’s geometry enables meticulous temperature monitoring through integrated thermocouples. The configuration forms a matrix of interconnected TEMs, thermocouples, and controllers, orchestrating precise temperature adjustments across the mold surface. The research integrates fuzzy algorithms to facilitate seamless communication between thermoelectric devices and thermocouples for precise mold temperature control. Simulation of thermoelectric devices using COMSOL Multiphysics and implementation of fuzzy controllers in Matlab, connected through a live-link, enables real-time. I have  adjustments and precise control. This integrated approach allows for a comprehensive analysis and optimization of the thermal control system, ensuring effective and adaptive temperature regulation. TEMs, operating as solid-state heat pumps, offer size versatility, adaptability to diverse mold shapes, and maintenance-free operation. Leveraging individual control capabilities significantly enhances heat transfer resolution, enabling precise manipulation of heat flux. Emphasizing the reduction of cooling time and achieving high-gloss surface quality, the study introduces the Advanced Precise Rapid Thermal Cycling in Blow Molding (APRTC) method. APRTC strategically employs TEMs to expedite cooling and elevate temperature determination accuracy, guaranteeing enhanced temperature resolution on the core mold surface. Furthermore, the study optimizes energy utilization through a closed-loop fluid circulation system, harnessing waste energy from other stages. Comparative analysis highlights APRTC's superiority, revealing a remarkable$$91 \%$$91%reduction in temperature differentials during the cooling cycle and an$$89 \%$$89%decrease in the heating stage. These findings underscore APRTC's efficacy in maintaining minimal temperature variations throughout the entire molding process.