Observer-based volumetric flow control in nonlinear electro-pneumatic extrusion actuator with rheological dynamics
Consistent volumetric flow control is essential in extrusion-based additive manufacturing, particularly when printing viscoelastic materials with complex rheological properties. This study proposes a control framework incorporating simplified rheological dynamics via a Kelvin-Voigt model that integr...
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| Main Authors: | , , , , |
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| Format: | Article (Journal) |
| Language: | English |
| Published: |
14 October 2025
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| In: |
Actuators
Year: 2025, Volume: 14, Issue: 10, Pages: 1-20 |
| ISSN: | 2076-0825 |
| DOI: | 10.3390/act14100496 |
| Online Access: | Verlag, kostenfrei, Volltext: https://doi.org/10.3390/act14100496 Verlag, kostenfrei, Volltext: https://www.mdpi.com/2076-0825/14/10/496 
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| Author Notes: | Ratchatin Chancharoen, Chaiwuth Sithiwichankit, Kantawatchr Chaiprabha, Setthibhak Suthithanakom and Gridsada Phanomchoeng |
| Summary: | Consistent volumetric flow control is essential in extrusion-based additive manufacturing, particularly when printing viscoelastic materials with complex rheological properties. This study proposes a control framework incorporating simplified rheological dynamics via a Kelvin-Voigt model that integrates nonlinear dynamic modeling, an unknown input observer (UIO), and a closed-loop PID controller to regulate material flow in a motorized electro-pneumatic extrusion system. A comprehensive state-space model is developed, capturing both mechanical and rheological dynamics. The UIO estimates unmeasurable internal states - specifically, syringe plunger velocity - which are critical for real-time flow regulation. Simulation results validate the observer’s accuracy, while experimental trials with a curing silicone resin confirm that the system can achieve steady extrusion and maintain stable linewidth once transient disturbances settle. The proposed system leverages a dual-mode actuation mechanism - combining pneumatic buffering and motor-based adjustment - to achieve responsive and robust control. This architecture offers a compact, sensorless solution well-suited for high-precision applications in bioprinting, electronics, and soft robotics, and provides a foundation for intelligent flow regulation under dynamic material behaviors. |
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| Item Description: | Veröffentlicht: 14. Oktober 2025 Gesehen am 03.12.2025 |
| Physical Description: | Online Resource |
| ISSN: | 2076-0825 |
| DOI: | 10.3390/act14100496 |