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  • Temperature Control Basics - Consulting-Specifying Engineer

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    Okan Ülgen
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    Laser Temperature Control

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    Temperature Control Basics  _ Consulting-Specifying Engineer

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    Laser Temperature Control

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    © All Rights Reserved
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    12 visualizzazioni4 pagine

    Temperature Control Basics - Consulting-Specifying Engineer

    Caricato da

    Okan Ülgen
    Laser Temperature Control

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    © All Rights Reserved
    Scarica in formato PDF o leggi online su Scribd
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    19072016 “Temperature cot basies | Consting-Spetfying Engineer CeO Me aL Oe ac ee ee ser "Sete Be Se om fees Hagan (| Temperature control basics ae A temperature controller is merely a part of a bigger system that depends on feedback (Fig. 1). f you apply heat to a process: let Without knowing the actual temperature ofthe process, eventually you would have too much heat, oF to litle. The temperature ‘of process must be known inorder to control accurately. Penne Share Heb Beceem “*y concerts ‘YMC2 magnetic bearing chiller + Types + Considerations YORK) — ~ *ricatons onan Wb + Troubleshooting Sections: Sensors losing the lop Gna control Proportanal PID, ‘Applications Sidebars: ‘Troubleshooting temperature contol Systeme ecg te wars SY toprmctnc, eet, re nicaaing gre," A temperature controller is merely a part of a bigger system that depends on feedback (Fig. 1). you apply heat to a process ‘aithout knowing ine actual temperature ofthe process, eventually you wouls have foo much Neat, orto ite. The temperature ‘fa process must be xrown in err fo controll accurately. A sensor must be used ta provide temperature measurement and process feedback i any controle. Sensors ‘Sensors used for madern temperature controllers are thermacouples and resistance temperature detectors (RTDs). A thermocouple produces a vatage inthe mV range directly proportional to the temperature senses, It operates on the galvanic action principle, which makes use of predictable and measurable vaiage when two dssimilar metals are bonded (ig: 2). ip hwwrw-esemag.com/homelsingle-ariclelemperaure-conrl-basics/Sidata7S2na6 4c tabSWdb63a Hil 1“ 19072016 “Temperature corr basics | Consuting-Speciying Engineer £a,2 Amos mast wy ata, esi DE ere a ace secre koiascaer eC Eel ‘hermoslecromotve force is developed when the measuring junction and the reference junction are at diferent temperatures. teal resistance of an RTD changes according tothe temperature it Senses. The sensing slement can be a wire-wouna conductor or deposited thin fim RTDs are usually constucted of platnum. However, other materials, such as rnickel, have Deon used to sense lomperature and tomporature changes, r 503 wearer _‘W UnedHealdwearé | Jyst as a sensor is necessary for temperature contol, so ts controller output. It 6 ‘does no good 6 accurately measure a process if there no way fo conal the ‘amount of Meal or coating applied fo thal process. + ete Closing the loop “The process itself ties the system togethor. The process materials absorb the energy applied to the process. The sensor detects tne temperature ofthe process and feeds tis information back othe temperature controle” The controle affects ts ‘Utbut te apply more or less heating or cooling tothe process. Thus we have closed loop temperature conta, ‘of althe ferent tomperature controler on the market, there are sill only three basic types — on-off, proportional, and PID. ‘When to use which controller depens onthe application and the other equpmentn the system. Onvotf control ‘On-off contro is the simplest form of temperature contol All temperature controls use a setpoint. The setpoint estabishes {he temperature at whieh a process Is maintained (Fg. 3) For exams, sating a temperature convollr that mainains a food ‘mixture ina vat at 196 F should ensure tat the temperature of ingredients In that vats around that temperature. Fig, 3a. The output ofan on-off temperature controllers either on or of. In (a), the output relay is actuated (on) when the ‘emperatre in the furnace is tess than the setpoint. tis not actuated (of) when the temperature reaches setpoint The ‘resulting temperature response is llistated in (b). Ono tomperaturo control is cyclical fr mast process applications ‘A controtr that uses or-of control supplies an output to increase heat when the process temperature i lowor than the ‘sipoint and no output when the process temperature fs higher than the setpint. tis 100% on when heating is called for; is ftfwnen the process lomperature is ator above tne selpoir. This arangorment is reversed for cooling coral ‘Theoretically, the controller switches on-off tates exacly al the eolpoint. However, in realty this isnot practical, I ths condition were alowed to exist the output device would switch on an of so quickly that would ether make the process unsiable or Infiectve. Another reason 's because rapid stale changes would quickly wear out the output actuation device Rather than have an on-off temperature contoller switch on and of exactly atthe setpoint, manufacturers provide for an ‘adlustable range around the setpoint. Invoducing a small range above, andor below te setpolnt effectively desensiizes the ontaller to rapid on-ffcycing around the setpoint. Some manufacturers cal this adjustable range deadand, Others refer to fective in stabizing the operation of an on-off corvller if adjusted In some applications, or-off control produces a cyclical temperature response. The actual lomperalure of a process could vary {fom a minimum temperature o a maximum temperature. I the process can tolerate this, an on-ll controler may be a simple Imexpensive soluton toa temperature contol need In other applications, the thermal mass ofthe process may be large enough to resist rap thermal changes. An example of this |S de casting, Some gie casting machines maintain a reservar of molten molal alan optimum tomperlure to allow the ‘machine o operate effeienty. Because of the amount of material and ts resistance to thermal change, an on-off conal is ‘Beoquate for mainiaiing precise temperature control ove this process. Proportional Proportional conta takes on-off contra a stop futhar. A temperature controller can be propertional with respect to ime, ait ‘can be analog proportional ‘Time-proportonal controllers apply power tothe output asa percentage of a cycle time. Ifcycle time is adjustable. the ime proparional contra divides this eye time into percentage ofthat time. I the cycle ime is 10'sec, and the controler outputs 45%, the oulputs are energized fr 4.5 sac ofthe cycle time. Obviously, or the remaining 8.8 sec the outputs are ‘deonergzes. Thre proportional cntoller outputs canbe relay, ac, sol-state relay (SSR), or de pulse, which drives an ‘extemal SSR. ‘Analog proportional contolers can have volage or curtent outputs, Popular oulpul ranges are 0-6 Ve and 4-20 mA. Analog ip hwwrw-esemag.com/hamalsingle-aicletemperatre-corrl-bascs/escata7s2naf8 dc aabsSt3db68a Hm 2 19072016 “Temperature cot basies | Consuting-Spetfying Engineer proporuorat convoners are useu win Sur power ConsoNerS oF valve pasOnNg MOIOTS (Hy. 5). Fig. 8, Proportional band s a region above and bolow the setpoint within which the output ofthe controllers nether full on nor {ull of but somewhere In betwean. When the proportional band is a0 narrow, facts mare Ike an anof controller with a ‘cyclical temperature response, When the proportional band fs too wide, he oscilalone disappear, ul the controler i sluggish ‘and may never reach setpaln When proportional band is correct, Some inital asellation may occur but the temperature wil Stabilize, feet occurs, use Integral ar reset to corect. ‘Ta set proportional control, the user selects a proportional band. Proportional band is a region above an below the setpoint within whieh th ourput ofthe controllers nether ful on nor ful of, but somewhere in between (Fig. 8) The drection and ‘deviaton Between the setpoint and process temperatures determines the exact output level Proportional integral-cerivatve (PID) control combines proportional corral with two other actons. Integral action is also refered to as roset. Its introduced when a stable process does not coincide withthe selpomt. Derivative acon is also refered twas rat. Its introduced when abrupt or rapid changes inthe load affect controler response. Reset and rate are intended to compansate for temperature sets and shits, More often than not, heaters and bumers donot match the application. Typically, systems are desigred using ine if enough BTUs are good, nen moro are balla concept. Nel {tuo, na perfect world, heater oF burnor output wauld bo 50% when the process and the contol are a spot. I eal ie, ‘here are Usually many more BTUs avalaole than are actualy needed. Raset helps to minimize thls mismatch. Rate is used when the process or load changes. Extrome variances in load size and thermal mass necessitate the uso ofthe ‘ate parameter. Since the process behaves diferent wih diferent loads, the contol must compensate for ths diference as. if there haa been no load change. When Used correctly rate is effective only when there are rapid changes In pracess physics. Applications From food processing to HVAC, and from chemical processing to heat teatng, there is plethora of application for which femperature controler can be used, ‘Some plants use embedded temperature conta inherent in automated manufacturing lines, Others use temperature controls to maintain the temperature of molten metalin die-casting machines. Then there are injection and Blow molding machines, pant drying ovens, industralfood processing ovens and foezors, ane many custom-designed temperature contol Applications. Regardless ofthe application, al torperature conolers work in basicaly the same Way. PLANT ENGINEERING magazine extands ts appreciation to Honeywal, Omron Electronics, and Watlow Electric fore use of ‘heir materials inthe preparation of his arte. Trouble hooting temperature control systems Most modern temperature control systems are quite reliable. However, problems can be encountered fom time to time. Listed {are a few tings to look for Symptom Look for Solution Controller shows ‘maximum temperature Thermocouple is open. Most Noheat — Indletion,butather contolers have upecaie TC Replace thermocouple sources show that _Burmout, ort canbe programmed. temperature fs (Output section of contaler is nat ‘operating propel power controle, Valve contoler, SCR, oF other ‘extol contral davies isnot operating, “Temperature indication is accurate ana ontoller scaling for he Check controler output. Check external control devices, Replace defective component “Temperature indication Is accurate, eotrller Sutputs ard extemal’ Heaters or burners defective, devices working propery. Replace heating elements. Repair or replace bumers, “Temperature indication Tondeney Jempsate ination Locate shor eck or TE wees oueing toward” Hambert conmlet's Thermocouple leds are shored grounded abject uth au TC wellhead roraway call erheat acl ose sim process area over lad fos wi bar eur tha oud feat” ‘embers Be touching acabnt or cach oor ip hwwrw-esemag.com/homelsingle-ariclelemperare-conrl-basics/isdataS2na6 4c tabSW3b63a Hil a4 19072016 “Temperature cot basies | Consting-Spetfying Engineer ‘Temperature contol is not calorated corecty affecting Temperature tymperature contaler Calibrate temperature controller. Replace Frain Zotar conoler | Seeuracy. Themmoteunl ae to inaccurate libration, faulty ‘deteriorating. Type J rusts; Type K ple cemodes wii aroon rt" Thien connecton wherver thy are Eratc Looee connections a the contr Greraion; Loose thermocouple rmination pat, wallnend, MeEuTared, Dor ute sl iad wre to Strate” comectons fry plas slong thommacouplo,* cameo convofe; use sanded, Dor over | Seplsy iat a al {othe contr,

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