Name of student : Hameed Kadhim Mohsin

Number of student : (19)

Name of experiment : (( Temperature Control ))

Number of experiment : ( 4 )

Date of experiment : 9 \ 11 \ 2015

Group : ( A 2 )

The objective of the experiment

 To control the heater temperature in the process duct using an on/off
controller to automatically switch the heater on or off as necessary to
maintain the required heater temperature in the process duct .
 To determine the variation in heater temperature due to the dead band
inherent in an on/off controller .
 To change the heater temperature inside the process duct by changing the
set point on the on/off controller .
 To determine the effect of disturbances to the process .
 To investigate the effect of changes in air flow through the duct .
Introduction
Temperature control in manufacturing is a quintessential part of proper product
formation. If the temperature slips above or below the ideal range needed for a
particular stage in a manufacturing process, the results can be harmful—
improperly adhered coatings, a weakened base material, or an overall
compromised component—so it becomes increasingly important that the
manufacturer not only determine the proper temperature for each stage, but also
monitor the temperature inside the machine and receive appropriate feedback.
Temperature controllers in manufacturing operations serve exactly this function:
they ensure that a machine is running properly by gauging the temperature at
different stages in the process and comparing the data to the programmed
temperature specifications. As a result, manufacturers can quickly and easily
discover temperature related machine malfunctions, and treat them as necessary.

There are three general kinds of temperature controllers that are used to monitor
temperature during manufacturing processes: on-off, proportional, and PID
controls.

On/Off Temperature Controls

An on/off temperature control is the least expensive of the control types, and also
the most simple in terms of how it works. The control is either on or off—if the
temperature drops below a certain point, the control signals to the machine to turn
raise the temperature. Likewise, if a temperature goes above a certain point, the
control is triggered to tell the machine to lower the temperature. A common
example of on/off systems is a household thermostat. When the temperature drops
below a certain point, the controller triggers the heater to raise the temperature
back to the programmed value. With air-conditioning it works the other way: if the
temperature rises past a certain point, the controller triggers the air-conditioner,
dropping the temperature back to the programmed norm.

On/off controls are often used in processes where the temperature change is very
slow, and precise control of temperature isn’t necessary.
Proportional Control

Unlike on/off controls, which only respond when a set limit is reached,
proportional controls are designed to respond to temperature change before it slips
out of the desired range. Essentially, proportional controls increase or decrease the
power supply as the temperature reaches its upper or lower limit, or setpoint, which
slows or speeds the heater and helps stabilize the temperature. The temperature
range in which proportional controls either lessen or increase the power supply to
slow or speed heating is known as the “proportional band.” If a temperature
reaches the lower or upper setpoints, the control then functions as a full on/off
control—the temperature is either turned fully on to increase the temperature, or
fully off to drop the temperature. When the temperature is within the proportional
band, and the power supply is decreased or increased, the heat is raised or lowered
in relation to how far the temperature is from the setpoint.

PID (proportional-integral-derivative) Control

This control combines proportional control with integral and derivative control
(PID). Operating within a proportional band in the same way a proportional control
does, a PID system has two added features that enhance overall temperature
regulation. The proportional feature allows the control to react to the current
circumstances and adjust accordingly. The integral value takes into consideration
the sum of recent events (in other words, past proportional control rhythms) and
the derivative value determines the appropriate reaction based on the rate at which
past rhythms have been changing. Combined, the three use current data, past data,
and the rate at which data is changing to set a case-specific algorithm to control
temperature. By compensating for temperature error between the process variable
and the setpoint, a steady temperature can be maintained.

Considerations When deciding which kind of control is best for a specific

process, there are several things to keep in mind. First of all, consider the kind of
input sensor (thermocouple or RTD) and the temperature range the process calls
for. Secondly, consider the form the ouput should be represented in:
electromechanical relay, SSR, or analog output. Thirdly, decide what kind of
control algorithm is necessary (on/off, proportional, PID). Lastly, consider the
number and type of outputs needed for the application, such as heat, cool, alarm,
and limit. Once these factors have been determined, it will be much easier to
determine which type of temperature controller is suited to a specific application.
Theory
An on-off controller is the simplest form of temperature control device. The output
from the device is either onor off, with no middle state. An on-off controller
willswitch the output only when the temperature crossesthe setpoint. For heating
control, the output is on whenthe temperature is below the setpoint, and off
abovesetpoint.Since the temperature crosses the setpoint to changethe output state,
the process temperature will be cyclingcontinually, going from below setpoint to
above, andback below. In cases where this cycling occurs rapidly,and to prevent
damage to contactors and valves, an onoffdifferential, or “hysteresis,“ is added to
the controller operations. This differential requires that thetemperature exceed
setpoint by a certain amountbefore the output will turn off or on again. On-
offdifferential prevents the output from “chattering” (that is,engaging in fast,
continual switching if thetemperature’s cycling above and below the setpointoccurs
very rapidly).On-off control is usually used where a precise control isnot
necessary, in systems which cannot handle theenergy’s being turned on and off
frequently, where themass of the system is so great that temperatureschange
extremely slowly, or for a temperature alarm.One special type of on-off control
used for alarm is alimit controller. This controller uses a latching relay,which must
be manually reset, and is used to shut downa process when a certain temperature is
reached.
An On/Off controller is a simple and effective way of controlling many processes
but does have disadvantages because its output can only be on or off. In the case of
the temperature process in this exercise the heater is switched on (full Heater
Power) or off.
An On/Off controller incorporates a dead band to avoid rapid swrtching'of №e
controlled variable when at the setpoint i.e. in this case the temperature must nse
above the setpoint by a fixed amount before the heater switches off and the
temperature must fall below the setpoint by a fixed amount before the heater
switches off again.
On PCT52 an On/Off controller with fixed dead band is created by setting the
Proportional Band to 0% in the PID controller. In a commercial On/Off controller
the dead band can be varied to suit the process. This allows the choice of tess
frequent switching but larger variations in the process variable or closer control of
the process variable but more frequent switching with attendant wear etc. of the
components.
To control the heater temperature in the process duct using an On/Off controller to
automaticalty switch the heater on or off as necessary to maintain_thereqLiired
heatertemperatureinprocessduct.
To determine the variations in heater temperature due to the dead band inherent in
an on/off controller. To change the heater temperature inside the process duct by
changing the set point on "the on/off controller and to determine the effect of
disturbances to the process. To investigate the effect of changes in airtiow through
the duct.

Proportional controls are designed to eliminate the cycling associated with on-
off control. A proportionalcontroller decreases the average power being supplied to
the heater as the temperature approaches setpoint.This has the effect of slowing
down the heater, so that it will not overshoot the setpoint but will approach
thesetpoint and maintain a stable temperature. This proportioning action can be
accomplished by turning theoutput on and off for short intervals. This “time
proportioning “ varies the ratio of ‘on’ time to ‘off‘ time to control the temperature.
The proportioning action occurs within a “proportional band” around the setpoint
temperature. Outside this band, the controller functions as an on-off unit, with the
output either fully on (below the band) or fully off (above the band). However,
within the band, the output is turned on and off in the ratio of the measurement
difference from the setpoint. At the setpoint (the midpoint of the proportional
band), the output on:off ratio is 1:1; that is, the on-time and off-time are equal. If
the temperature is further from the setpoint,the on- and off-times vary in proportion
to the temperature difference. If the temperature is below setpoint, the output will
be on longer; if the temperature is too high, the output will be off longer. The
proportional band is usually expressed as a percent of full scale, or degrees. It may
also be referred to as gain, which is the reciprocal of the band. Note, that in time
proportioning control, full power is applied to the heater, but is cycled on and off,
so the average time is varied. In most units, the cycle time and/or proportional
band are adjustable, so that the controller may better match a particular process. In
addition to electromechanical and solid state relay outputs, proportional controllers
are also available with proportional analog outputs, such as 4 to 20 mA or 0 to 5
Vdc. With these outputs, the actual output level is varied, rather than the on and off
times, as with a relayoutput controller.

The Proportional Band, P. setting on a process controller makes a change to the

output (Heater Power on PCT52) that is proportional to the current error value (the
difference between the measured temperature T1 and the set point on the
controller). The proportional response can be adjusted by multiplying the error by a
constant Kp, called the Proportional Gain. This is related to the Proportional Band
setting on the controller as follows; Proportional Gain (Kp) = 100% / Proportional
Band_% i.e. 100% P term means unity gain (change in controller output = error at
input) and 50% P term means a gain of 2 (change in controller output = 2x en-or at
input) A low setting of the P term (large gain) results in a large change in the
output for a given^angem- the error. If the P term is too low. frie system can
become unstable. In contrast, a large setting of the P term (low gain) results in a
small output response to a large input error, and a less responsive or less sensitive
controller If the P term is too high, the control action may be too small when
responding to system disturbances resulting in slow response and offsets of the
resulting process variable from the set point.

A Proportional-only controljer will not always settle at the set point, but may retain
a steady-^it offset. Offset can be reduced in Proportional-only control by reducing
the P term setting. However, the P-term is set too small then hunting or osdtlating
wilt-occur. The offset can be minimised by^ adding a bias to the set point (setting
the set point above or below the required value to compensate for the offset) but
this technique is only appropriate if the system characteristics are fixed. A better
solution is to remove the offset by addingIntegral action to Jiecpnbpller (P+l) as
described below.

Integralterm
The contribution from the integral term is proportional to magnitude and duration
of the error. Theintegral term in a PID controller is the sum of the instantaneous
en-or_over time and gives ttie^ accumulated offeet that should have been corrected
previously. The resulting controller output is the "sum of the contribution from the
Integral term and the contribution from the P term. When the I term is correctly
adjusted any residual offset in the process variable due to the term" will be
gradually reduced by the Integral term until the offset is eliminated. If the time
setting of the I" term is too long then correction to any offset will be very slow.
However, since the integral term responds to accumuiated errors from the past, it
can cause the present value to overshoot the setpoint value or to make the process
completely unstable № the time setting of the 1 term is too short, tf this occurs the
I term makes adjustments to the controiter output faster than the process can
respond. l.e. the I term winds up the controller output so that the process
overshoots considerably, hence the term Integral Wind-up or Integral saturation.
Careful selection of the I term in combination with the P term will give efficient
response to changes in the system.

Derivativeterm
The derivative term slows the rate of change of the controller output. Derivative
control is used -to reduce the magnitude of the overshoof produced by the i term
and improve the.combinedconfroite'r- process stability. However, the derivative
term slows the response of the conti-oller. Also. differentiation of a signal
amplifies noise and thus this term in the conb-oller is highly senative'to noise in the
error term, and can cause a process to become unstable if the noise and the
derivative gain are sufficiently large.
Experimental procedure
 Using a PC to operate the process , the heater (heat into the process duct)
will be switched on and off by the controller in an attempt to maintain a
steady heater surface temperature .
 disturbances can be applied to the process by increasing and decreasing the
air flow by changing the speed of the fan motor . Increasing the air flow
reduces the surface temperature of the heater because more heat is
transferred from the heater to the air .
 Temperature sensor measures the heater and air temperature (T1 and T2 ,
respectively ) in the process duct and indicate the values on the PC .

Equipment required :

 PCT52 Temperature process .

 PC with PCT52 software loaded .

Equipment set up :

Ensure that the apparatus has been set up according to the installing section and the
power supply connected to the socket marked 24V in at the rear of the electrical
enclosure .
 Temperature Temperature

0.0
0.0
5.0

10.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
45.0
50.0

20.0
Calculations

00:00 00:00
00:11 00:09
00:22 00:18
00:33 00:27
00:44 00:36
00:55 00:45
01:06 00:54
01:17 01:03
01:28 01:12
01:39 01:21

Time
Time
01:50 01:30
02:01 01:39
02:12 01:48
02:23 01:57
02:34 02:06
02:45 02:15
Set point (40)_ proportional band (5)

Set point (80)_ proportional band (0)

02:56 02:24
03:07 02:33
03:18 02:42
03:29 02:51
 Temperature Temperature

0.0
5.0
0.0

15.0
20.0
25.0
30.0
35.0
40.0
10.0
20.0
30.0
40.0
50.0
60.0

10.0
00:00 00:00
00:19 00:10
00:38 00:20
00:57 00:30
01:16 00:40
01:35 00:50
01:54
01:00
02:13
01:10
02:32
01:20
02:51
03:10 01:30
01:40

Time
Time

03:29
03:48 01:50
04:07 02:00
04:26 02:10
04:45 02:20
05:04 02:30
Set point (50)_ proportional band (0)

05:23

Set point (30)_ proportional band (20)

02:40
05:42 02:50
06:01 03:00
06:20 03:10
DISCUSSIONS
When the control system of the type (ON/OFF)
And be a set point (50), the heat transfer and the transfer of heat load in this case
appears curvy and wobbling and be the difference between the first temperature
and the second very large, as in Figure (1)
When set up points (80), the transmission of heat load in this case is relatively
stable, at least the difference between the first and second degree temperature as in
Figure( 2)

On off control is like operating a switch. This type of temperature controller will
turn on the heat when the process variable is below the set point and turn it off
when the process variable is above the set point. These controllers normally
include a delay, hysteresis and or a cycle time to reduce the cycling or "hunting"
when the process variable is close to the set point.
60.0
50.0
40.0
Temperature

30.0
20.0
10.0
0.0
00:20
00:00
00:10

00:30
00:40
00:50
01:00
01:10
01:20
01:30
01:40
01:50
02:00
02:10
02:20
02:30
02:40
02:50
03:00
03:10

Time
Set point (50)_ proportional band (0)

90.0
80.0
70.0
60.0
Temperature

50.0
40.0
30.0
20.0
10.0
0.0
00:00
00:11
00:22
00:33
00:44
00:55
01:06
01:17
01:28
01:39
01:50
02:01
02:12
02:23
02:34
02:45
02:56
03:07
03:18
03:29

Time

Set point (80)_ proportional band (0)

When the control system of the type proportional band
And be a set point (30) and proportional band (20) the heat transfer and the
transfer of heat load is relatively stable, the difference and the difference between
the temperatures and wobbling a little and be a stable process control
The proportional control mode is the proportional change of the control output to a
change in the input signal. The proportional mode coefficient is expressed in a unit
known as proportional band . This band, in engineering units of the input range, is
the amount of change over which the input process variable must change to effect a
0% to 100% or 100% to 0% change in the output of the controller. Often control
systems are designed using Proportional Control. In this control method, the
control system acts in a way that the control effort is proportional to the error. The
control effort is proportional to the error in a proportional control system.
40.0
35.0
30.0
Temperature

25.0
20.0
15.0
10.0
5.0
0.0
01:54

04:07

06:20
00:00
00:19
00:38
00:57
01:16
01:35

02:13
02:32
02:51
03:10
03:29
03:48

04:26
04:45
05:04
05:23
05:42
06:01

Time

Set point (30)_ proportional band (20)