Experiment No.

3
Temperature Control System
AIM: To obtain the process reaction curve and hence design controllers for temperature control
system.

APPARATUS REQUIRED: A temperature system simulator kit containing a digital display for
Temperature (in degree Celsius) and ammeter to observe controller output, an oven and a fan
connected to the temperature system simulator kit, Stopwatch.

THEORY:

Introduction to PID controllers:

A PID controller is a simple three term controller. The term P, I and D stands for:
P: Proportional
I: Integral
D: Derivative

The transfer function of most common form of PID Controller is:

C(S): Kp+KI/s+KDs = (KDs2+Kps+KI)/S
KD is Derivative gain.
KI is Integral gain.
KP is Proportional gain.

The effect of increasing each of the three controller parameters on performance characteristic
is summarized in a tabular form:

Response Rise time Overshoot Settling time SS error

Kp Decrease Increase N.T. Decrease
Ki Decrease Increase Increase Eliminate
Kd N.T. Decrease Decrease N.T.
N.T. : No definite trend.

PID CONTROLLER STRUCTURE:

The controller is used as a closed-loop unity feedback system. The variable e denotes the
error signal that equals to (reference input -actual output), which is sent to the PID controller.
u = KPe + KI∫edt + KDde/dt
u= control signal from the controller to the plant.
e= magnitude of the error.
Three qualities of a good control system:

1) Accuracy: It depends on error constants, which is related to steady state error.so, K I is used
to eliminate steady state error.
2) Stability: It depends on Maximum overshoot, and KD is used to reduce maximum overshoot
and settling time.
3) Speed of response: It depends on rise time, and KP is used to reduce rise time.

Hence in order to design an accurate, fast and stable system, we need a controller which gives a
control signal (u) to the plant and hence our system is designed as per the required condition.

Determination of values of KP, KI and KD using Ziegler and Nichols tuning rule.

First of all a step input is given to the plant and its response is observed as a graph which we
call process reaction curve. The plant should be free from any dominant conjugate pole and
integrator. This curve look like ‘S’ shaped, this is used for calculating two constants L & T.
Inflection point is observed, which is nearly at 63% of steady state value and a tangent is
drawn at inflection point. Intersection of tangent with time axis and steady state level line is
seen and a horizontal projection is drawn from that point on time axis.

For different type of controllers, values of gain constants are obtained using values of L & T.
Zeiglus Nicholas rule gives an initial estimate of parameters.

Type of controller Kp Ki Kd
P T/L 0 0
PI 0.9T/L 0.27T/L 2
0
PID 1.2T/L 0.6T/L 2
0.6T

Using TI =KP/KI and Td = Kd/Kp ,we get:

 Type of controller Kp Ti Td
P T/L Inf 0
PI 0.9T/L L/0.33 0
PID 1.2T/L 2L 0.5L

Procedure:

a) To observe the process characteristics.

1. Connect the oven to setup. Keep ‘ion’ and heater switch in off position. The D
control at minimum and P control at Centre 12’o clock position (dial setting 5).
2. Switch on the power. Select temperature switch to oven side. Note the temperature
when heater is off.
3. Now select the temperature selector to S.D. side. Adjust SET POINT control to
raise the reference temperature about 20 degree.
4. Select the temperature selector again to oven. Switch on the heater and start the
stop watch simultaneously. Note the oven temperature at 5, 10, 20, 30 seconds till
the temperature becomes stable at any degree.
5. Plot the curve between the temperature and time. Find out the inflection point
(where it is 63 % of the final value of temperature). Draw the tangent and find out
the value of T and L.
b) The P control
1. Switch off the heater and I control by means of switch by keeping D control to
minimum using knob 6.
2. Select S.P. and adjust the temperature to 60° C. and then switch to oven and note
the current temperature. Set P control at midway Kp=10.
3. Switch on the heater and start the stop watch at the same instant. Note the
temperatures at 10 second interval till it get nearly stable.
4. Switch off the heater and switch on the fan. Allow time to cool down the heater.
When temperature approaches to previous value, switch off the fan.
5. Now adjust Kp=16 (8th major gradient). Switch on the heater and stop watch. Note
the temperatures at 10 second interval.
6. Repeat step 4 and 5 setting Kp at maximum equal to 20.
7. Plot the graph between time and temperature. Find steady state error (ess) from the
plot. It is observed that ess is reduced when Kp is increased but it does not goes to
minimum.
c) The PI control:
1. From the response curve taken in part a, apply Kp and Ki values from the table.
2. Set S.P. at 60°. Select oven temperature at display reading. Switch on the heater
and start stop watch. Note the temperature at regular intervals of 10 seconds.
3. Plot the response curve from the results obtained from the experiment.
d) The PID control:
1. From the response taken in part a. Apply Kp, Ki, Kd values from the table.
2. Set S.P. at 60°. Select oven temperature at display reading. Switch on the heater
and start the stop watch simultaneously. Note the temperature.

OBSERVATIONS:
 A. For P control:
1. Set Temperature= ___°C, P=___.

Table 1: Variation of oven temperature versus time:

Time Oven Temp. Time Oven Temp.

(steps of 10s) (°C) (steps of 10s) (°C)
 GRAPH FOR P CONTROL
1. Set Temperature=___°C, P=____

Table 2: Variation of oven temperature versus time:

Time Oven Temp. Time Oven Temp.

(steps of 10s) (°C) (steps of 10s) (°C)
 GRAPH FOR P CONTROL

B. For PI control:
1. Set Temperature=___°C, P=____, I=____.

Table 3: Variation of oven temperature versus time:

Time Oven Temp.

(steps of 10s) (°C)
 Time Oven Temp.
(steps of 10s) (°C)

GRAPH FOR PI CONTROL

C. For PID control

1. Set Temperature=___°C, P=___, I=____ ,D=____.

Table 3: Variation of oven temperature versus time:

Time Oven Temp.

(steps of 10s) (°C)
 Time Oven Temp.
(steps of 10s) (°C)
 GRAPH FOR PID CONTROL

Calculations:

i. Using process reaction curve

T =____, L=___.
ii. For P control:
Kp=T/L=___.
iii. For PI control
Kp=0.9×T/L=___. Ki=0.27×T/L2 =___.
iv. For PID control
Kp=1.2×T/L=___. Ki=0.6×T/L2=___. Kd=0.6×T=___.

Conclusion:
1. Initial setting of parameters will give a response with an overshoot of about 25%
and a good settling time, we may then further tune it to adjust the parameters for a
desired response.
2. Adding a gain or constant value decreases rise time, so as we increase gain rise
time decreases and we observe rapid response.
3. Adding an integrator, adds a pole to the system as a result of which lagging phase
arises resulting in instability of the system. Hence overshoot and oscillations are
there.
4. Adding a differentiator, adds a zero and as a result of it stability arises and hence
overshoots decreases and damping arises.