Modelling and Controlling Level of Stress and

Displacement Speed at Sheet Metal Processor

Sujono
a
, Yan Everhard R
b

a
Faculty of Engineering
Budi Luhur University, Jakarta 12260
Tel : (021) 5853753 ext 255 Fax : (021) 7371164
E-mail : soejon@yahoo.com

a
Faculty of Information Technology
Budi Luhur University, Jakarta 12260
Tel : (021) 5853753 ext 255 Fax : (021) 7371164
E-mail : yaneverhard@yahoo.com


In this paper will be discussed about simulation of operation of actuator system at metal slab processor
using two direct current electric motor as the main actuator. The first motor is used to control the level of
stress (tension) and the second motor is utilized to control the displacement speed of metal slab. The
operation applies PID controller to maintain the level of stress ( tension) and displacement speed of metal
slab by controlling the voltage at the motors anchor coil. The continuity equation of system dynamics is
created based on electromechanical characteristics to obtain system model in the form of state equation.
The obtained system is multivariable with two inputs and two outputs. System contains decoupling that
will compicate operation of system. For control operation, decoupler and PID controller is designed with
Ziegler Nichols oscillation method and heuristic method. The system is simulated using Simulink from
software MatLab 6.5.

Keywords
Metal slab, tension control systems, decoupling, PID, Ziegler Nichols


1. Introduction
The sheet metal processing system using 2 DC motor as a prime mover is a multivariable which consist of two
inputs and two outputs. As in Figure 1, the first motor will control the tension of sheet metal (F) and the other one
is used to control the displacement speed of sheet metal (V). The speed controlling to those motor is a real
important thing. In this paper will be simulated the control system using the Proportional Integral Differential (PID)
controller.

2. Metal Sheet Processing Systems
In a simple way, system can be described as in Figure 1
[3]
. The system consists of several mounted on a roller
which is driven by a DC motor.




Figure 1. Metal Sheet Processing Systems

The block diagram of metal sheet processing system as a multivariable system can be represented as in Figure 2.




Figure 2. Metal sheet processing system as a multivariable system.

The inputs of the systems consists of two input voltage. The first input voltage (E1) is applied to motor 1, and the
other one (E2) is applied to motor 2. The system output consists of two outputs. The first output is displacement
speed of sheet metal (V) and the other one is the tension of sheet metal (F).

3. Sheet Metal Processing Systems Model
Model systems based on mathematical equations derived from the individual components making up the system.
The equations representing the electromechanical characteristics of the motor 1 and motor 2 are :

1 1 m 1 1 1
1
1
i . K f . r .
dt
d
J = + e | +
e
....... (1.1)
1 1 1
. r x u = atau
1 1
1
. r
dt
dx
e = ............... (1.2)
1 1 1 b 1 1
1
1
e . K i . R
dt
di
L = e + + ........ (1.3)
2 2 m 2 2 2
2
2
i . K f . r .
dt
d
J = + e | +
e
..... (1.4)
2 2 2
. r x u = atau
2 2
2
. r
dt
dx
e = ............. (1.5)
2 2 2 b 2 2
2
2
e . K i . R
dt
di
L = e + + ...... (1.6)

The equations of level of tension on the sheet metal between the roller 1 and the roller 2 are :
)
dt
dx
dt
dx
( D ) x x ( K f
1 3
1 1 3 1
+ + + = ......... (1.7)

)
dt
dx
dt
dx
( D ) x x ( K f
3 2
2 3 2 2
+ = ....... (1.8)
2
x x
x
1 2
3

= .............................................. (1.9)

with :
J : Inertia of a roller (kg . m
2
)
|

: a roller friction coefficient (N . m . s)
r

: The radius of a roller (m)
K
m
: Constant of motors torque (V . s)
K
b
: Constant of back emf motor (V / rad)
D : Damping factor of sheet metal (N/m/s)
K : Spring Constant of sheet metal (N/m)
e

: a roller speed (rad/s)
f : Tension of the sheet metal (N)
e : Voltage of motors anchor (Volt)
R : Resistance of motors anchor (Ohm)
L : inductance of motors anchor (mH)
u : Angle position of roller (rad)
x : The position of sheet metal (m)
dt
dx
v
3
= : The displacement speed of sheet metal (m/s)

From equation (1.9) and (1.8), for K
1
= K
2
= K then :
|
.
|

\
|
+ + + =
dt
dx
dt
dx
2
D
) x x (
2
K
f
1 2
1 2
...........(1.10)

From equation (1.1) to (1.10) can be stated :
1 1
1
. r
dt
dx
e = ...............................................(1.11)
1
1
1 m
2
1
2 1
2
1
1
1
1
2
1
1
1
1
1
1 1
i .
J
K
J . 2
r . r . D
x
J . 2
r . K
J . 2
r . D
J
x
J . 2
r . K
dt
d
+ e e
(

+
|
=
e
(1.12)
2 2
2
. r
dt
dx
e = .................................................(1.13)
2
2
2 m
2
2
2
2
2
2
2
2
2
1
2
2 1
1
2
2 2
i .
J
K
J . 2
r . D
J
x
J . 2
r . K
J . 2
r . r . D
x
J . 2
r . K
dt
d
+ e
(

+
|
e =
e
(1.14)
1
1
1
1
1
1
1
1 b 1
e .
L
1
i .
L
R
.
L
K
dt
di
+ e = ....(1.15)

2
2
2
2
2
2
2
2 b 2
e .
L
1
i .
L
R
.
L
K
dt
di
+ e = ....(1.16)
2
2
2 1
1
1
2
r . D
x
2
K
2
r . D
x
2
K
f e + + e + = ........(1.17)
1
1
2
2 3
.
2
r
.
2
r
dt
dx
v e e = = ........................(1.18)

From equation (1.11) to (1.18), can be derived a state space and output equations of the systems as follows :
u . B x . A x + =
-
....................................(1.19)

u . D x . C y + = ..................................(1.20)

With the elements of the matrix equation (1.19) and (1.20) are :
T 2 1 2 2 1 1
dt
di
dt
di
dt
d
dt
dx
dt
d
dt
dx
x
(

e e
=
-

| |
T
2 1 2 2 1 1
i i x x x e e =
(

=
2
1
e
e
u

(

=
v
f
y
(
(
(
(
(
(
(
(
(
(
(
(

+
|


(

+
|

=
2
2
2
2 b
1
1
1
1 b
2
2 m
2
2
2
2
2
2
2
2
2 1
2
2
2
1
1 m
1
2 1
1
1
1
2
1
1
1
1
1
1
L
R
0
L
K
0 0 0
0
L
R
0 0
L
K
0
J
K
0
J . 2
r . D
J J . 2
r . K
J . 2
r . r . D
J . 2
r . K
0 0 r 0 0 0
0
J
K
J . 2
r . r . D
J . 2
r . K
J . 2
r . D
J J . 2
r . K
0 0 0 0 r 0
A

(
(
(
(
(
(
(
(
(
(

=
2
1
L
1
0
0
L
1
0 0
0 0
0 0
0 0
B
(
(
(

=
0 0
2
r
0
2
r
0
0 0
2
r . D
2
K
2
r . D
2
K
C
2 1
2 1

(

=
0 0
0 0
D

4. Preparation of matrix elements A, B, C and D.
Preparation of the matrix state space equation is based on constant values that exist. The amount of the constants
are as follows :

Table 1. The constant composition of the system
[1] [2]

Elemen Constant Unit
Sheet metal
K 40 N/m
D 5 N/(m/s)

Roler r1 = r2 0.2 m
Motor 1 dan 2
J 2 Kg.m2
| 0.5 N.m.s
Km 5 N.m/Amper
Kb 0.5 V/(rad/s)
R 1 Ohm
L 0.1 Henry

Based on the above data it can be arranged matrix A, B, C, and D as follows :

(
(
(
(
(
(
(
(

=
10 0 5 0 0 0
0 10 0 0 5 0
5 . 2 0 3 . 0 2 05 . 0 2
0 0 2 . 0 0 0 0
0 5 . 2 05 . 0 2 3 . 0 2
0 0 0 0 2 . 0 0
A ;

(
(
(
(
(
(
(
(

=
10 0
0 10
0 0
0 0
0 0
0 0
B ;

(

=
0 0 1 . 0 0 1 . 0 0
0 0 5 . 0 20 5 . 0 20
C ;

(

=
0 0
0 0
D


5. Control System Simulation With PID
Simulation is done by using simulink of matlab 6.5. The simulink diagram representing the system is like the picture
below.



Figure 3. Simulink Diagram of Control System using PID Controller



Controller 1 and 2 is a PID controller in a parallel structure like the following picture.



Figure 4. The Parallel Structure of PID Controller

PID parameter tuning is done by using heuristic methods to obtain parameter values Kp, Ti and Td as in the
following table.

Tabel 2. Parameter PID PID parameters
Parameter Loop pengendalian
PID Tension (F) Laju (V)
K
p
2 0.8
T
i
0.5 0.4
T
d
0.6 0.25


6. Simulation Results
Simulations done with a change in the setpoint of each of both F and V output in step. This is intended to determine
system response to changes in setpoint and disturbance inputs that may occur to the system. From the simulation
results have been obtained as shown below.




Figure 5. Response output tension (F) and rate (V) to change the setpoint tension (F) in step (at t = 5 seconds).
0 5 10 15 20 25
0
0.2
0.4
0.6
0.8
1
1.2
1.4
Waktu (detik)
T
e
n
s
i
o
n

(
N
)
0 5 10 15 20 25
-0.05
-0.04
-0.03
-0.02
-0.01
0
0.01
Waktu (dtk)
L
a
j
u

(
m
/
d
t
k
)
Setpoint F
F (Tension)
Setpoint V
V (Laju)




Figure 6.
The response speed and motor coil current anchors 1 and 2 to change the setpoint motor tension (F) in step
(at t = 5 seconds).

Response output tension (F) and rate (V) to change the setpoint rate (V) in step (at t = 5 seconds).
0 5 10 15 20 25 30 35 40 45 50
-0.2
0
0.2
0.4
0.6
Waktu (detik)
W
1

(
R
a
d
/
d
t
k
)
0 5 10 15 20 25 30 35 40 45 50
-0.5
0
0.5
1
Waktu (detik)
I
1

(
A
m
p
e
r
e
)
0 5 10 15 20 25 30 35 40 45 50
-0.01
0
0.01
0.02
0.03
0.04
Waktu (dtk)
W
2

(
R
a
d
/
d
t
k
)
0 5 10 15 20 25 30 35 40 45 50
0
0.02
0.04
0.06
Waktu (dtk)
I
2

(
A
m
p
e
r
e
)
0 5 10 15 20 25
-0.2
0
0.2
0.4
0.6
0.8
Waktu (detik)
T
e
n
s
i
o
n

(
N
)
0 5 10 15 20 25
0
0.2
0.4
0.6
0.8
1
1.2
1.4
Waktu (dtk)
L
a
j
u

(
m
/
d
t
k
)
Setpoint F
F (Tension)
Setpoint V
V (Laju)



Figure 8.
The response speed and motor coil current anchors 1 and 2 to change the motor speed setpoint (V) in step (at t = 5
seconds)

Figure 9.
Response output tension (F) and rate (V) against several changes are a step in the setpoint tension (F) and the
setpoint rate (V)
0 5 10 15 20 25 30 35 40 45 50
-6
-4
-2
0
Waktu (detik)
W
1

(
R
a
d
/
d
t
k
)
0 5 10 15 20 25 30 35 40 45 50
-1.5
-1
-0.5
0
Waktu (detik)
I
1

(
A
m
p
e
r
e
)
0 5 10 15 20 25 30 35 40 45 50
0
2
4
6
Waktu (dtk)
W
2

(
R
a
d
/
d
t
k
)
0 5 10 15 20 25 30 35 40 45 50
0
0.5
1
1.5
Waktu (dtk)
I
2

(
A
m
p
e
r
e
)
0 20 40 60 80 100 120 140 160 180
0
0.5
1
1.5
2
2.5
3
Waktu (detik)
T
e
n
s
i
o
n

(
N
)
0 20 40 60 80 100 120 140 160 180
-0.5
0
0.5
1
1.5
2
2.5
Waktu (dtk)
L
a
j
u

(
m
/
d
t
k
)
Setpoint F
F (Tension)
Setpoint V
V (Laju)



Figure 10. The response speed and motor coil current anchors 1 and 2 several changes are a step in the setpoint
tension (F) and the setpoint rate (V)
7. Conclusion
Based on the analysis and simulation have been presented, a conclusion it can be taken include the following :

1. Sheet metal rolling system discussed in this paper is a multivariable system with two inputs (voltage spindle
motor 1 and motor anchor 2) and two outputs (tension and rate of shift of sheet metal) where there is coupling
between the two output with two inputs of the system.

2. Using of decoupler (D12 = D21 = -1 and 1) to eliminate the coupling of the inputs to the system output in
steady state

3. Parameter tuning of PID controllers using Ziegler-Nichols reaction curve generate PID parameter settings
- To loop tension control : Kp = 12.209 ; Ti = 0.55 ; Td = 0.1375
- For the speed control loop : Kp = 18.65 ; Ti = 0.11 ; Td 0.0275

4. In the system without dekopler, applying a tuned PID controller using Ziegler-Nichols reaction curve produces
an oscillating output response with greater amplitude

5. On equipped dekopler system, the application of PID controller are tuned using Ziegler-Nichols reaction curve
to produce outputs that are less good response. This is indicated by a significant jump (59.9%) at the output of
tension at the time given by the step change in setpoint

6. On PID controller tuning parameters with heuristic methods to produce setting PID parameters
- To loop tension control : Kp = 2 ; Ti = 0.5 ; Td = 0.6
- For the speed control loop : Kp = 0.8 ; Ti = 0.4 ; Td 0.25

0 20 40 60 80 100 120 140 160 180
-15
-10
-5
0
5
Waktu (detik)
W
1

(
R
a
d
/
d
t
k
)
0 20 40 60 80 100 120 140 160 180
-2
-1
0
1
Waktu (detik)
I
1

(
A
m
p
e
r
e
)
0 20 40 60 80 100 120 140 160 180
-5
0
5
10
15
Waktu (dtk)
W
2

(
R
a
d
/
d
t
k
)
0 20 40 60 80 100 120 140 160 180
-0.5
0
0.5
1
1.5
2
Waktu (dtk)
I
2

(
A
m
p
e
r
e
)

7. In the system without dekopler, applying a tuned PID controller with heuristic methods produce output
responses that are less good. This is a pretty big jump in output at the current tension in a step change setpoin
given at the rate of shift sheet metal

8. On equipped dekopler system, the application of PID controller is tuned with the heuristic method produces the
best output response. It is shown from the simulation results
- At the time of a step change given to the tension setpoint, in the increase of 1.73% and the system is able to
achieve a given output in accordance setpoin in a short amount of time that is 4 seconds. These changes do
not affect the output rate of the shift sheet metal
- At the time of a step change given to the setpoint speed, there was a surge of 1:55% and the system is able
to achieve a given output in accordance setpoin in a short amount of time is 7.5 seconds. These changes do
not affect the output of sheet metal tension

8. References

[1] Gene F Franklin, J David Powell, Abbas E. N., Feedback Control of Dynamics Systems , Edisson
Wesley, USA, 1987.

[2] Fitzgerald, A.E. , Charles Kingsley, Jr dan Stephen D. Umans, Electric Machinery , McGraw-Hill, Inc,
1984.

[3] DAzzo, J.J. dan Houpis, C.H., Feedback Control System Analysis & Synthesis , 2nd Edition, McGraw-
Hill, 1966.

[4] Bogart, F. T., Laplace Transforms And Control System Theory For Technology , John Wiley & Sons,
Inc, USA, 1982.

[5] Ogata, K., Solving Control Engineering Problem with Matlab , Prentice Hall, New Jersey,. 1994.

[6] Frans Gunterus, Falsafah Dasar : Sistem Pengedalian Proses ,Edisi 2, Elex Media Komputindo, Jakarta,
1997