Advanced Temperature Measurement and Control

Unit 3 - Controllers

UNIT 3

Controllers

This unit discusses the practical considerations for the use of controllers, the relative merits of different types of auto tuners, and the advantages of fuzzy logic controllers.

Learning Objectives When you have completed this unit you should:

  1. Understand why auto tuners are needed.

  2. Recognize the most common reasons why auto tuners fail.

  3. Appreciate the relative advantages and disadvantages of different types of tuner interfaces and methods.

  4. Understand the fundamental performance advantages of closed-loop tuning and fuzzy logic temperature controllers.

3-1. Auto Toner Facts of Life

From the inception and integration of the control loop, most have not been properly tuned. Since the peak and integrated error for a loop are inversely proportional to controller gain and the product of gain and reset (repeats per minute) settings, respectively, most loops have not reached their full potential The consequences for poorly tuned temperature loops are of particular concern because of their importance.

One might think that after fifty years of articles on tuning, users might be able to gain some proficiency in the adjustment of two to three settings. Unfortunately, many of the documented tuning procedures use an open-loop method that is not suitable for loops with nonlinearities, nonself-regulation, frequent load disturbances, large valve dead band, and an unknown controller algorithm- or, in other words, most loops. Closed-loop tuning methods are not discussed as often and, while more foolproof, require considerable courage to purposely create oscillations while an operator looks over one's shoulder.

In actuality, there has been, some regression in that the "old timers" who had developed a "seat of the pants" tuning methodology by trial and error have retired, and the current leaner organizations do not offer much opportunity to experiment (Ref. 1).

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