DESIGN PID CONTROLLER FOR FURNACE

SYSTEM
Hoàng Đình Thái 1, Nguyễn Hoàng Quân 1
1
Ho Chi Minh University of Technology and Education.
Abstract— Due to need of apply the knowledge throughout the Automatic Control System subject and
do the final report. After consulting and considering, we found that the temperature control of heat
furnace system is used widely in industries, it is also a good example for us for aplly what we have learn.
In this report, we’ll present the mathematical modeling and take the values that given in the articles we
reseached of an electrical heat furnace then design a PID controller for it.
1. INTRODUCTION:
Combine with the knowledge throughout the Automatic control system, we have learn lots of knowledge
for designing and evaluating the stable control for a specialized object include: Bode, Nyquist, Hurwitch,
Poles and zeros, Root locus,PID.
For the furnace PID controller here are the abstract of the article that we found out:

 In paper [1], ỨNG DỤNG SIMULINK ĐIỀU KHIỂN HỆ THỐNG LÒ NHIỆT, show
how we use Matlab and Simulink to design a PID controller
 In paper [2], [3], Thiết kế bộ điều khiển nhiệt độ cho lò nhiệt điện trở dùng PID, show
how to apply PID controller for heat furnace and simulate
 In paper [4], NGHIÊN CỨU XÂY DỰNG HỆ ĐIỀU KHIỂN NHIỆT ĐỘ LÕ SẤY DẦU
NGUYÊN LIỆU, show how to optimize the PID value design for a furnace system.
From the 5 report the we have done research, we design the PID controller for the object: Heat furnace
temperature
The organization of the paper is as follows. We will describe the mathematical model of the heat furnace
in Section 2. Method for design PID controller is described in the Section 3. An the last section we obtain
the transfer function model of the system and stablability using the experimental data through Simulink.
[1] ỨNG DỤNG SIMULINK ĐIỀU KHIỂN HỆ THỐNG LÒ NHIỆT,
[2] Thiết kế bộ điều khiển nhiệt độ cho lò nhiệt điện trở dùng PID
[3] ĐỀ TÀI :THIẾT KẾ MẠCH ĐIỀU KHIỂN NHIỆT ĐỘ BẰNG PHƯƠNG PHÁP THAY ĐỔI THỜI
GIAN ĐỐT CHO LÒ ĐIỆN
[4] NGHIÊN CỨU XÂY DỰNG HỆ ĐIỀU KHIỂN NHIỆT ĐỘ LÕ SẤY DẦU NGUYÊN LIỆU
[5] temperature-control-system-and-its-control-using-pid-controller
2. MATHEMATICAL MODEL AND CONTROL REQUIREMENT:
2.1. Mathematical model:
a) Model Explain:

Cái này lấy luận văn thạc sỹ sấy dầu [4]

A resistance furnace is a device that converts electrical energy into heat through a heating wire
(heating wire). From the heating wire, create radiation, convection, and conduction, heat is delivered
to the object to be heated [5].
Throughout the articles and reports, they has conclude that the mathematical model of the heater and
any real subjects have fast transient response, S-shaped damping people often approximate this type
of object to return to first order inertia with hysteresis [4]. As Ziegler-Nichols, we have a furnace
system that can be represented by given transfer funtion:

K .e− Ls
H ( s )= (1)
Ts+1
This funtion consists of an inertial link gain K and time constant T, and a time delay L, these
parameters can be obtained by drawing a tangent at the inflection point for the transition graph of the
step functon as shown. The gain K is calculated as follows [1]:
Steady State Temperature
K= (2)
%Work
When the initial temperature different from zero, K is calculated by DeltaT – which mean the
different of the initial to the desired temperature degree.

For example, when we want to control a heater that can work or desired temperature at 600 ° C at
100% power, so we will have K=600. And if the initial temperature is 30° so the K=570.
To apply to a linear system, we take the Taylor expansion of e-LS, the transfer function becomes:
K
H ( s )= (3)
(Ts+1)(Ls+1)
In summary, Ziegler-Nichols approximates the furnace transfer function with a first-order system
with hysteresis or a linear second-order system, and allows to find the transfer function
experimentally when plotting the system transition with the input as a step function.
b) Method to determine the function values:
At first we have to operate the heat furnace to claim the experimental data from the step response of
the open loop system. Then through some method, the transfer function model is obtained.
In this report, we obtain that the most suitale method is 2 reference points: We see the method of the
estimated tangent model parameters are subjective and imprecise, but they can also hard to be used on
machines count. So to partially overcome the weakness of the human tangent method. We use the two
reference point method [3].
Parameter values are defined in terms of t1 and t2 as follows:

T =1.5(t 2−t 1) (4)

t2
And L=1.5( t 1− )
3
(5)
With t1 and t2 are determined by belown:

Fig. Step response to open loop system and parameters

We can test this by the given funtion and then do the reverse calculation to find the T and L by the
simulated graph in Simulink:
>>K=200
>>L=600
>>T=900

After get the graph of the trasnfer function, we start to calculate the T and L value by “2 Reference
points” method:
 Fig. Step response graph of the furnace transfer function

T =1.5 × ( t 2−t 1 )=1.5 × (1504,961−900,450 )=906.7665 (Tog=900)

L=t 2−T =1504.961−906.7665=598.194 5 (Log=600)

Compare to the seted-up value, we can find the acceptable approximate value of T and L compare to the
original value.

2.2. Control requirement:

To design a complete PID controller for any system, we must base on the
 3. DESIGN PID CONTROLLER:
A Proportional Integral Derivative (PID) controller is a generalized control loop feedback mechanism
widely used in industrial control systems.
The most commonly used PID controller among feedback controllers. A PID controller calculates an
"error" value as the difference between the controller value and the desired set value. The controller will
minimize the error by adjusting the input control value.
given performance specifications is known as controller tuning. Ziegler and Nicholas suggested rules for
tuning PID controllers (meaning to set values Kp, Ti and Td ) based on experimental step responses or
based on the value of Kp that results in marginal stability when only proportional control action is used.
Ziegler–Nichols rules, which are briefly presented here, are useful when mathematical models of plants
are not known. There are two methods called Ziegler–Nicholas tuning rules: the first method and the
second method.
A. First Ziegler- Nichols method:

This method is designed based on the approximation of the transfer function of the object becomes a first-
order inertial link with hysteresis[3], the overshoot does not exceed the limit for permission 40%. This
method applies if the response to a step response S-shaped curve. The S-shaped curve be characterized by
two constants, delay time L and time constant T [5].

T
If we use only P: R ( s )=Kp and Kp= (6)
k.L

1 0,9. T 10
If we use PI: R ( s )=Kp(1+ ) with Kp= , Ti= L (7)
Ti . s k. L 3

1 1,2.T
If we use PID: R ( s )=Kp(1+ + Td . s) with Kp= , (8)
Ti. s k.L
L
Ti=2. L, Td=
2

B. Second Ziegler-Nichols method:

Replace PID with amplifier (or gain),which mean we only adjust increase K up to Kth that make closed
system is at border is stable and has a harmonic oscillation, determining the period Tth of the oscillation.
Define the controller parameters as follows:

If we use only P: R ( s )=Kp and Kp=0,5. Kth (9)

1
If we use PI: R ( s )=Kp(1+ ) with Kp=0,45. Kth, Ti=0,85. Tth (10)
Ti . s

1
If we use PID: R ( s )=Kp(1+ + Td . s) with Kp=0,6. Kth, (11)
Ti. s
Ti=0,5. Tth, Td=0,12. Tth
 Fig. Example for tunning K to Kth to make the closed system is at border stable
Base on the feature of each method, the first method of Ziegler- Nichols is the most suitable to the heat
furnace system. Due to the S-shape graph or transfer funtion of a first-order inetial link with hysteresis.
So in the next part, simulation result, we will apply this method to design a PID controller.
4. SIMULATION RESULT:

4.1. Values of system:

As the mission is to give a system value by ourselves and design a PID controller for that system also
base on the object that we have considered. The heat furnace will have 3 values:
K:Gain =200 ( with 200° C at 100% Power)

L: Time delay = 600

T: Time constant =1000

200 .e−600 s
We have the system transfer funtion: H ( s )=
1000 s +1