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PID-Fuzzy Controller For Grate Cooler in Cement Plant
PID-Fuzzy Controller For Grate Cooler in Cement Plant
* Control Department
Indonesia Cement and Concrete Institute
Jalan Raya Ciangsana, Bogor, 16969, Indonesia.
Phone: +62-21-82403650 Fax: +62-21-82403654
e-mail: awang.wardana@telkom.net
rk 6 PID uk yk
In this paper, we used a PID-controller proposed by Clarke
Controller
PLANT
[1] is used because of its better derivative part. The
controller is of the form
§ 1 · K pTd s
U (s) K ¨¨ 1 s ¸¸ E ( s ) Y (s)
p
© T i ¹ 1 aT d s (2)
Figure 2: PID-Fuzzy Control Scheme
These fuzzy algorithms that adjust the PID controller are
where a is the filtering constant at the interval (0,1), and
discussed in the next section.
U(s) is Laplace transform of the plant output. The
implementation of the derivative part is more realistic than
in (1). The low pass filter reduces the effect of the 3 Fuzzification, Rule Base Establishment and
measurement noise, and only the plant output, which is Defuzzification
continuous, is differentiated. This controller can be
discretized with an approximation s | 1 d / h , where h is The fuzzy PID controller was designed by following the
the sampling interval, and d is the delay operator. Thus, the standard procedure of fuzzy controller design, which
discretized controller is of the form: consists of fuzzification, control rule base establishment,
and defuzzification as shown by figure 3.
H
u pi ( k ) u pi ( k 1) K p ( de ( k ) e( k )),
Ti Linguistic
Defuzzification
u min d u pi ( k ) d u max (3)
Fuzzification Rule Set
Td
Output
u d (k ) ( au d ( k 1) K p dy ( k ))
Input
h Td IF….
u (k ) u pi ( k ) u d ( k ), u min d u ( k ) d u max
THEN….
§ §xa c x· · (6)
where am is amplitude of limit cycle and p is the relay P ( x : a, b, c) max ¨¨ min ¨ , ¸ , 0 ¸¸
© ©ba cb¹ ¹
amplitude
2.2 PID-Fuzzy Controller where the parameters a and c locate the "feet" of the
The PID controller that described by equation (3) is triangle and the parameter c locates the peak. Inputs for
adjusted with fuzzy controller that described in figure 2. fuzzy algorithms are set point and output of process and the
outputs for these fuzzy algorithms are proportional, integral
and derivative constant.
4 Application of PID-Fuzzy Controller in Grate
1
NB NM NS ZO PS PM PB
Cooler
0.8
These fuzzy rules that shown by figure 5 applied to control
grate cooler in cement plants with specification:
0.6 x Rotary kiln
x Clinker cooler with grate hydraulic drive
0.4
x Preheater two strings 4 stage with precalciner
0.2
x Total capacity 4,600 M Ton per day
0
4.1 PID Controller
In first time, we used conventional PID controller to control
-1 -0.8 -0.6 -0.4 -0.2 0 0.2 0.4 0.6 0.8 1
under grate pressure #1. Using Ziegler-Nichols formula in
Figure 4: Symmetrical Membership Function equation (3) at normal condition we get Kp= 150% Ti = 80
s and Td= 20 s. This calculation used to control grate
3.2 Rule cooler and the result as shown in figure 6.
In this research, classic interpretation of Mamdani [5]
logic operations are applied, for ‘and’ minimum is used,
for ‘or’ also with ‘maximum’. So with IF-THEN rule, we
can describe the rule of fuzzy algorithm with the following
two dimensional table rules.
ek
dek NB NM NS ZO PS PM PB
PB ZO PS PM PB PB PB PB
PM NS ZO PS PM PB PB PB
PS NM NS ZO PS PM PB PB
ZO NB NM NS ZO PS PM PB
NS NB NB NM NS ZO PS PM
Figure 6: PID Controller Result
NM NB NB NB NM NS ZO PS
NB NB NB NB NB NM NS ZO From figure 6 we can calculate that approximation normal
probability density function under grate pressure # 1.
Figure 5: Used Rule Base for Kp, Ti and Td Figure 7 show this calculation. From experiment we can
get some data:
3.3 Defuzzification x Standard deviation of under grate pressure is 50
In this paper we used centre of area method for mmH2O
defuzzification. This method determines the centre of the x Clinker temperature output 1500
area of the combined membership functions. This method is 200
100
q 80
¦
j 1
z jP (z j ) (7) 60
z q 40
¦ j 1
P (z j )
20
0
600 650 700 750 800 850 900 950
level j, P(zj) is membership value in zj and q is number of Figure 7: Probability Density Function Under-Grate
quantization levels of the output Pressure (#1) with Conventional PID Controller with
Ziegler- Nichols Formula
4.2 PID-Fuzzy Controller x With PID-Fuzzy, under grate pressure # 1 as
To build PID-Fuzzy controller, first we examine three output variable of process was not deviate more
extreme conditions and calculated with equation (3) the than 5 mmH2O. This is means that reduced more
optimal PID controller. This three extreme condition yield that 90 % than controlled with conventional PID
result as shown in figure 8: controller. This condition described by
approximated normal probability density function
condition start up snowman kiln upset of under grate pressure # 1 that shown in figure 7
proportional 80 % 120 % 200 % and 10.
constant x Because under grate pressure #1 stable so the bed
integral 40 s 12.5 s 20 s depth of clinker on grate cooler relative constant.
constant Due to that temperature of secondary air that
derivative 0s 40 s 90 s increases more than 1500C after using PID-Fuzzy
constant controller. Its means increase efficiency of
calcinations in precalciner.
Figure 8: Calculation Result of Kp, Ti and Td in extreme x Also temperature of clinker output is reduce from
condition around 150oC to around 90oC, its means that with
PID-Fuzzy burn out material can be reduced.
From this calculation we build rule for PID-Fuzzy
controller as shown in figure 9.
5 Conclusions
References
Figure 9: PID-Fuzzy Controller Result [1] Clarke D., Automatic tuning of PID regulators, Expert
400
Systems and Optimization in Process Control,
Technical Press, Aldershot, England, 1986.
350
mmH O
GmbH,1990
2
Figure 10: Probability Density Function Under-Grate [5] Mamdani, M, Application of Fuzzy Algorithm for
Pressure #1 with PID-Fuzzy Controller Control of Simple Dynamic Plant, Proc. IEE, v. 121,
no.12, pp. 1585-1588, 1974.
After PID-Fuzzy controller was applied in operation with [6] Tang K. S., Man K.F., Chen G. and Kwong S, An
full 2 strings suspension preheater, we can observe the Optimal Fuzzy PID Controller, IEEE Transactions on
result that: Industrial Electronics, Vol. 48, No. 4, pp.757-765,
2001.
[7] Viljamaa P. and Koivo H.N., Fuzzy Logic in PID Gain
Scheduling, Third European Congress on Fuzzy and
Intelligent Technologies EUFIT’95, Aachen,
Germany, August 28í31, 1995.
[8] Ziegler, J.B. and N.B Nichols, Optimum Setting for
Automatic Controllers, Trans. ASME, vol.64, pp.759-
768, 1942.