射出成型是一極為高度非線性之製程，有許多外在因素會對產品品質造成影響，其中因環境變化如溫度、濕度等因素或者材料生產批次不同而有分子量差異或新舊料混合比例不同等因素，造成不穩定的材料熔融性質，使材料射出成型工件的品質變異，直接影響其材料性質，使其在長時間生產下會造成產品品質不穩定之現象。本研究以三種不同黏度材料針對自適應控制系統做測試，在生產過程中機台能夠結合系統自我調控關鍵射出參數，以此穩定每一模次之產品品質。
本文定義產品重量為產品品質指標，並以每一模次穩定產品重量為首要目標，根據高分子材料之P-V-T關係，在固定熔膠溫度(T)設定下，若每一模次的壓力曲線(P)一致，便可推斷射出成型過程中每一模次熔膠之比容(V)變化皆相同，進而使產品重量一致，並由前期實驗以及相關文獻發現射出過程中射嘴端壓力峰值和黏度因子與產品重量有高度相關的趨勢，藉由此關係瞭解到讓不同模次產品壓力曲線維持穩定便能維持產品重量一致性，同時藉由射出鎖模力峰值探討模面分離與產品重量之關係，以此穩定生產過程，整合定義黏度因子、射嘴壓力峰值及射出鎖模力峰值為品質監控特徵，納入本研究所開發之自適應控制系統，並結合在前期實驗所得出的針對不同黏度材料分別之關鍵射出參數做適當設定，使生產狀況趨於穩定，並經由機台與系統連線，透過量測射嘴端熔膠壓力，從熔膠壓力中擷取峰值，並即時計算黏度因子，並以黏度因子以及射嘴壓力峰值分別作為保壓切換位置以及射出速度調控之基準，同時在系統之使用介面上監測每一模次之射出鎖模力峰值，使系統在能在保有穩定生產過程的狀況下進行參數調控，以此增加產品品質穩定性。
本研究以產品重量變異量(Var)、產品重量標準差("σ" )，產品重量變異係數("C" _"v" )等品質指標作為評斷自適應控制系統表現之依據，在使用自適應系統控制的狀況下，能於有效調整每一模次適當之保壓切換位置以及射出速度並同時穩定射出鎖模力峰值維持趨近0值。本研究僅以模外擷取資訊達全面機台化生產，並能夠穩定每一模次的產品品質，經計算得出高中低黏度材料調控後之產品重量變異係數("C" _"v" )分別降低至為0.024%, 0.020%, 0.031%，其產品品質表現均優於無使用系統之狀況，以此驗證了自適應調控系統的可行性及確效性。

Injection molding is a popular process for mass production of polymer products, but due to the complexity of the process, there are many factors that will affect the product quality after long run of the fabrication processes. In this study, product weight is defined as product quality, the goal of research is to minimize the variation of product weight. An adaptive control system was developed by C++ programming to adjust V/P switchover point and injection speed which are highly related to product weight during the injection molding process in order to minimize the variation of the product weight.
Three polypropylene materials with low to high MI values were used to test the response of the adaptive control system. Based on a series results of preliminary experiments, it indicated appropriate V/P switchover points and clamping force which could be judged from the peak pressure and clamping force peak for materials with different viscosity, respectively. Viscosity index and peak pressure had a strong correlation with the weight of the injection-molded parts toward the materials of different viscosity.
Viscosity index, peak pressure and clamping force peak are defined as the characteristics of quality monitoring to guide the adjustment and increase the stability of process in the presented control system, and strain sensor and nozzle pressure sensor are used in the system.
The response of the system also reveals that a combination of nozzle pressure curve based adaptive process control incorporating with clamping force peak monitoring can decrease the weight variation of the injection molded parts. With this system, the coefficient of variation of product weight of different viscosity materials from low to high can be decreased to 0.031%, 0.020% and 0.024%, respectively.

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