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A Simple Method of Designing Dual loop Controller for Cold Rolling Mill

A Simple Method of Designing Dual loop Controller for Cold Rolling Mill

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Published by ijcsis
The mathematical model (Interval Plant) of the web guide in rolling mill is controlled using PID controller. The given interval plant is approximated to first order plus time delay with integrator (FOPTDI) system. The dual loop control (DLC) method proposed by Jacob and chidambaram for design PID controllers is extended for FOPTD+I systems. The performance of the closed loop system is evaluated for both the original and the approximated model. The controllers are also tuned using Internal Model Control (IMC) and the performance is compared by simulation.

Index Terms -Interval plant, Double loop control , Direct synthesis method, IMC(Internal Model Control)
The mathematical model (Interval Plant) of the web guide in rolling mill is controlled using PID controller. The given interval plant is approximated to first order plus time delay with integrator (FOPTDI) system. The dual loop control (DLC) method proposed by Jacob and chidambaram for design PID controllers is extended for FOPTD+I systems. The performance of the closed loop system is evaluated for both the original and the approximated model. The controllers are also tuned using Internal Model Control (IMC) and the performance is compared by simulation.

Index Terms -Interval plant, Double loop control , Direct synthesis method, IMC(Internal Model Control)

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Published by: ijcsis on Feb 12, 2010
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03/09/2013

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(IJCSIS) International Journal of Computer Science and Information Security,Vol. 7, No.1, 2010
 A Simple method of designing dual loopcontroller for cold rolling mill
 
S.Umamaheswari, Dept. of EIE, V.Palanisamy M.Chidambaram
 
Mahendra Engg, College,
 
Principal/ Info Institute of Technology,
 
Director/ NIT,Namakkal(Dt), INDIA
 
Coimbatore, INDIA
 
Trichy, INDIA
 Abstract-
The mathematical model (Interval Plant) of the web guidein rolling mill is controlled using PID controller. The giveninterval plant is approximated to first order plus time delay withintegrator (FOPTDI) system. The dual loop control (DLC) methodproposed by Jacob and chidambaram for design PID controllersis extended for FOPTD+I systems. The performance of theclosed loop system is evaluated for both the original and theapproximated model. The controllers are also tuned using InternalModel Control (IMC) and the performance is compared bysimulation.
 Index Terms -
Interval plant, Double loop control , Direct synthesismethod, IMC(Internal Model Control)
I.
 
I
NTRODUCTION
There are many intermediate web guides in cold rolling millsprocess such as CRM (cold rolling mill), CGL(Continuousgalvanizing line) and so on. The main functions of the webguide are to adjust the center line of the strip to the center lineof the steel process, so they are called centre position control(CPL). Rapid process speed cause large deviation between thecenter position of the strip and the process line. So thedifference between the center position of the strip and theprocess line should be compensated. In general, the centreposition control (CPC) of the web is obtained by hydraulicdriver and electrical controller. The model of the web guidesystem is obtained from Sang Min Kim et.al( 2004)[1].For the purpose of designing controllers, the dynamics of manyprocesses can be described by first-order plus time delay withan integrator (FOPTDI) model.Methods for tuning PID controllers for such models are basedon stability analysis such as Internal model controller (Riveraet.al.(1986)[5]. The dual loop method is extended for designingPID controller for FOPTD+I systems. The inner loop is of PDcontroller and the outer loop is of PID controller designed usingdirect synthesis method proposed by shesagiri Roa[ 6]. PIDcontrollers are also designed by IMC method. The performanceof the controller is compared by simulation.II. INTERVAL PLANTThe model of the web guide system by using geometricalrelations of the guide ignoring the mass and stiffness of the webis given by Sang Min Kim et.al.(2004).
32132105432143210
()
asasasaGssbsbsbsbsb
+ + +=+ + + + +
 Where the coefficients are of interval in nature, which is givenby,
3
a
= [4.5 24] ;
2
a
= [5 29] ;
1
a
= [0.9 5] ;
0
a
=[0.05 3]
5
b
= [0.05 0.3] ;
4
b
= [ 4 9 ] ;
3
b
=[ 4 9] ;
2
b
= [0.7 2] ;
1
b
= [0.03 0.08];
0
b
= [0 0]This is represented as model1, model2 and model3 byconsidering only the minimum, maximum and average valuesof the interval. The mode1, model2
 
and model3 of the plant aregiven by,Model1 =
12312345
0.050.954.50.030.744
ssssssss
+ + ++ + + +
 Model2
 
=
12312345
0.3529240.08299
ssssssss
+ + ++ + + +
 Model3=
12312345
0.1752.951714.250.0551.356.56.5
ssssssss
+ + ++ + + +
 These models have been approximated to FOPTD+I system.Approximation is done by taking 1/s from the actual modelseparately, and applying step input, the time constant
τ 
iscalculated. Letting s to zero, the magnitude k is calculated.
116http://sites.google.com/site/ijcsis/ISSN 1947-5500
 
(IJCSIS) International Journal of Computer Science and Information Security,Vol. 7, No.1, 2010
Hence the FOPTD is obtained in which the 1/s term is againcombined to get FOPTD+I model.The approximated system is given by,RModel1 =
0.3526
1.667(0.55841)
s
ess
+
 RModel2 =
0.793
3.75(1.2561)
s
ess
+
 RModel3 =
0.673
3.1818(1.06591)
s
ess
+
 In the present paper dual loop system in which the inner loop isof PD controller and the outer loop is of PID for FOPTD+Isystem is designed. The performance of the control system iscompared with that of the IMC method.III.
 
DUAL
 
LOOP
 
PID
The general transfer function of the process to becontrolled is given by,
(1)
 p Ls
ess
τ 
+
(1)where
 p
is the process gain
τ 
is the time constant and
 L
isthe process lag.Figure 1. Block diagram of the dual loop controlThe inner loop is of PI controller and the outer loop is of PIDcontroller designed using direct synthesis method proposed bysheshagiri roa for unstable system. In this paper it has beenextended for stable system. The closed loop Transfer functionof the inner loop is given by,
 Lscp Lsincp
kke y yskke
=+
, the delayis approximated to
( )( )
1212
 Ls
 Les Ls
= +
 
( )
( )
( )
( )
( )
( )
121122
cpcp
 Lkks LLsskks
=+ +
 
( )
( )
( )
( )
( )
( )
121122
 Lscpcp
 Lkkse LLsskks
+=+ +
 
( )
( )
2
12122
 Lscpcpcp
 LkksekkL Lsssk
+=+ +
 Closed loop transfer function of the inner loop is given by,
( )
( )
2
12122
rin
 Lscp y ycpcp
 LkksekkL Lsssk
+=+ +
 
Figure 2. Block diagram of the simplified dual PIDafter simplification the controller is obtained as,ses
1(1)(1)(1)
cci
sGksss
α τ τ β 
+= + ++
 
where
1212
(31.50.5)
c
η λ θλ θη η 
=+ +
 
11213212
0.50.5,(31.50.5)
τ η η τ η θλ α θ β τ λ θλ θη η 
=== =+ +
 in which and
3222222
(0.5)(31.5)30.5(0.5)
θ τ λ τ θτ λ θτ λ θ τ η τ θ τ 
+ + +=+
 
117http://sites.google.com/site/ijcsis/ISSN 1947-5500
 
(IJCSIS) International Journal of Computer Science and Information Security,Vol. 7, No.1, 2010
Tuning Parameter Selection
The tuning parameter
λ 
should be selected in such a way thatthe resulting controller gains should be positive for positivevalues of k. Hence, as per the method given by Seshagirirao et.al. [6] to get positive values of controller gain(kc), theconstraint to be followed is,
221
31.50.5
η λ θλ η θη 
< + +
 Also,
λ 
should be selected in such a way that the resultingcontroller gives good robust control performances. The initialvalue of the tuning parameter can be taken as equal to half of the time delay of the process to get good control performances.If not then, the tuning parameter can be increased from thisvalue till good nominal and robust control performances areachieved. For suitable value of 
λ 
and
 β 
, the controllerdesigned on DS method gives good control performances.However for high value of 
 β 
, the phase lag imposed by theterm
(1)
s
 β 
+
in the controller is more and thus the designedcontroller with this value of 
 β 
is not able to give robust controlperformances which results in low gain and phase margins of the open loop system than the required values (gain marginshould be >1.7 and phase margin should be >35
0
for robustcontrol of a process [6].Based on many simulation studies, it is observed that taking‘0.1
 β 
’ instead of 
 β 
gives good compromise between nominalperformances and robust control performances. Thus, in thepresent work, the value of 
 β 
obtained is modified as ‘0.1
 β 
for simulation studies.The performances of the closed loop system are evaluated bygiving a unit step in the set point. Fig.1-3 shows the comparisonof Rmodel 1, 2 & 3 with the controller tuned using double loopMRC method.5. IMC METHODThe IMC based PID controller settings for FOPTDI system isgiven by, (Dale, et. al. (2004) and Rivera et.al. (1986)[2&5]respectively.
2
(2)()
ccc
k
τ τ θ τ θ 
= + + +
 
(2)
 Ic
τ τ τ θ 
= + +
 
(2)(2)
 Dcc
τ τ θ τ τ τ θ 
= + + +
 The choice of design parameter
c
τ 
is a key decision in both thedirect synthesis (DS) and IMC design methods. In generalincreasing
c
τ 
produces a more conservative controller because
c
decreases while
 I 
τ 
increases. Several IMC guidelines for
c
τ 
have been published for FOPTD with an integrator system.As per Rivera et al., (1986),
c
τ θ 
> 0.8 and
c
τ 
>0.1
τ 
,
exp()(1)
 p
ksss
τ τ 
+
. By simulation it was foundthat
c
τ 
=4 as per Rivera et. al., gives best result for all threemodels.6. SIMULATION RESULTSLet us consider the Rmodel2 plant with
 p
=,3.75
τ 
= 1.256and
τ 
= 0.793. The PID controller settings by the dual loopmethod are
c
=0.452
i
τ 
= 0.96 and
 D
τ 
=0.366 The PIDsettings by IMC method are
c
=0.12 and
i
τ 
=0.012
 D
τ 
=0.1319. Figure 1, 2 and 3 show the comparison of the servoresponse of all three models. The robustness of the closed loopis evaluated by using the maximum controller settings on theother two models of the system. Figures 4, 5 and 6 show theregulatory response of the systems. Comparison of ISE and IAEvalues of the Rmodel1, Rmode2 and Rmodel3 for both theservo problem and the regulator problems using the controllersettings for the IMC and the dual loop method are shown intable I.Fig.1 Servo response of Rmodel1Solid -> DLC ; dash-dot –> IMCFig.2 Regulator response of Rmodel1;Legend as in Fig.1
118http://sites.google.com/site/ijcsis/ISSN 1947-5500

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