INDIAN INSTITUTE OF TECHNOLOGY

BOMBAY

DEPARTMENT OF AEROSPACE ENGINEERING

Control Systems Laboratory - AE 427

PROCESS CONTROL TRAINER

GROUP 5

Name Roll Number

Swarit Sood 180010056
Panshikar Anay Rajan 18D180020
P.Raghav Rajeev 170010056
Atharva Gurudatta Telange 180010014

Instructors :
Prof. Arnab Maity
Prof. Shashi Ranjan Kumar
Experiment 3 Thermal Process Control

Contents
1 Objectives 2

2 Theory 2

3 Calibration of Wattmeter 4
3.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Observations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4 Relationship between air temperature rise and change in heater power 6

4.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.2 Observations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5 Time domain system identification 8

5.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.2 Observations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.3 SIMULINK Plots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.3.1 Near Fan location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.3.2 Middle location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.3.3 Near Exit location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.4 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

6 Two Step Control 18

6.1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.2 Observations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.3 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

AE 427 1 Group 5
Experiment 3 Thermal Process Control

1 Objectives
1. To model PT 326 (Process Trainer 326) operations by experimental methods.

2. Use proportional control to set temperature with different proportional gain and see
the effect of adding the proportional controller to the system.

2 Theory
In the PT 326 (Process Trainer 326) Apparatus, the process which governs the behaviour is
the balance of heat energy. The equation formed by the process as mentioned in the below
figure is given by
q a = q + qi − qo − qt (1)
where
q :- Rate at which heater supplies heat
qi :- Rate at which heat is carried into the volume V by the coming air
qo :- Rate at which heat is carried out of the volume V by the outgoing air
qt :- Heat lost from the volume V

Figure 1: Heat Transfer through volume V

Derivation for the above process:-

We know that heat and change in temperature of a body is given by
dT
qa = C (2)
dt
where
C - Heat capacity of the air occupying the volume V

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Experiment 3 Thermal Process Control

Thus, we get similar equation for other heat transfers as shown below:-

qi = CmTa

qo = CmT
where
m - mass flow rate
Ta - Ambient Temperature
From the above eqautions, we conclude that,
1
qi − qo − qt = − ∆T (3)
R
From eq. (1), (2) and (3), we get,

d∆T 1
C + ∆T = q (4)
dt R
Then we take Laplace transform (assuming ∆T to be small) which gives us the equation
mentioned below
∆T (s) k1
= (5)
qi (s) τs + 1
where
k1 - 1/R
τ - RC (Time constant)
Now, we assume that the heat supplied by the heater is proportional to the heater input
voltage and thus, eq (5) changes in this way:-

∆T (s) k1 k2
= (6)
qi (s) τs + 1

where
k2 - proportionality constant between q and Vi
As the sensor is physically located far away from the volume V which we are measuring, the
results will be affected with a time delay τd . Sensor has a voltage Vo = k3 ∆T So, we will
update the transfer function as shown below:-

Vo (s) ke−τd s
= (7)
Vi (s) τs + 1

where
k - k1 k2 k3 (DC Gain of the system)
The term e− τd s arising due to fluid transport is called a transport delay, while the term
(τ s + 1)−1 arising due to the heat transfer dynamics is called transfer delay.
Taking the input voltage as a step response, we get,

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Experiment 3 Thermal Process Control

Figure 2: Block Diagram for the Process

ke−τd s
Vo (s) = (8)
s (τ s + 1)
After taking the Inverse Laplace Transform, we get,

∆Vo (t) = ke−(t−τd )τ (9)

3 Calibration of Wattmeter
3.1 Procedure
1. On the left side of panel box, move the switch to ’heater/wattmeter’ make connection
as shown in fig.(3) and start increasing set value from 0 to 10 V at the interval of 1 V
and keep noting the required AC voltage & AC current to find heater power

Figure 3: Wattmeter Connections

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Experiment 3 Thermal Process Control

3.2 Observations
Below is the observation table: -

Below is the plot for the above table between set value and Heater Power: -

Figure 4: Set Value Vs Heater Power

3.3 Conclusion
1. The heater power increases with the increase in the Set Value.

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Experiment 3 Thermal Process Control

4 Relationship between air temperature rise and change

in heater power
4.1 Procedure
1. On the left side of panel box, move the switch to ’heater’ and set throttle to 20%.

2. Thermistor is used to measure the temperature at different locations.

3. Make connections as per the fig (5).

4. Start increasing set value from 0 to 10 V at the interval of 2 V and keep noting the
temperature output in voltage (V) at Y point with respect to ground

5. Repeat above 2 steps for throttle 40%, 80% at 3 different temperature sensor location.

Figure 5: Connections Diagram

4.2 Observations
Observations for effect of throttle on air temperature

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Experiment 3 Thermal Process Control

Below is the observation table: -

Below is the plot for the above table between set value and Heater Power: -

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Experiment 3 Thermal Process Control

Figure 6: Air Temperature Rise above ambient Vs Heater Power

4.3 Conclusion
• Air temperature rise decreases as throttle increases. Throttle increment increases the
flow speed. So there will be increased flow of cooler air which resists the rise in
temperature.
• Air temperature rise remains similar at all three sensor locations.

5 Time domain system identification

5.1 Procedure
1. Set the switch on the left side to ’heater’ and adjust ’set value’ to 3 V.
2. Set throttle to 20%.
3. Connect a function generator to port D and generate a 2 V, 0.1 Hz square wave.
Observe the function generator output in oscilloscope.
4. Air temperature (V) can be measured at port Y as the output of thermistor. Connect
port Y to oscilloscope to observe the air temperature (V).
5. Find gain, time constant and time delay.
6. Repeat above steps for throttle 40%, 80% and 100%.

5.2 Observations
Input: 2 V square wave with 0.1 Hz frequency.

Output and Input vs Time:

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• Sensor near to fan, throttle = 20%:

Figure 7: Input wave, output temperature vs time

• Sensor near to fan, throttle = 40%:

Figure 8: Input wave, output temperature vs time

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Experiment 3 Thermal Process Control

• Sensor near to fan, throttle = 80%:

Figure 9: Input wave, output temperature vs time

• Sensor near to fan, throttle = 100%:

Figure 10: Input wave, output temperature vs time

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• Sensor in middle, throttle = 20%:

Figure 11: Input wave, output temperature vs time

• Sensor in middle, throttle = 40%:

Figure 12: Input wave, output temperature vs time

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Experiment 3 Thermal Process Control

• Sensor in middle, throttle = 80%:

Figure 13: Input wave, output temperature vs time

• Sensor in middle, throttle = 100%:

Figure 14: Input wave, output temperature vs time

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Experiment 3 Thermal Process Control

• Sensor near to exit, throttle = 20%:

Figure 15: Input wave, output temperature vs time

• Sensor near to exit, throttle = 40%:

Figure 16: Input wave, output temperature vs time

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Experiment 3 Thermal Process Control

• Sensor near to exit, throttle = 80%:

Figure 17: Input wave, output temperature vs time

• Sensor near to exit, throttle = 100%:

Figure 18: Input wave, output temperature vs time

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Experiment 3 Thermal Process Control

Gain:
Steady state output − Initial output
Gain =
∆Input

Throttle % Near to fan Middle Near to exit

20% 1.28 1.26 1.22
40% 1.17 1.11 1.05
80% 0.72 0.81 0.72
100% 0.63 0.59 0.59

Table 1: Gain for different sensor location and throttle%

Time delay:

Throttle % Near to fan Middle Near to exit

20% 0.03 0.2 0.37
40% 0.05 0.21 0.38
80% 0.04 0.16 0.15
100% 0.04 0.13 0.17

Table 2: Time delay (s) for different sensor location and throttle%

Time constant:
Time constant is the time taken to reach 63.2% of the steady state value.
Sample calculation: Case - 20% throttle, near to fan
Steady state output = −4.88
Initial output = −7.64
63.2% of steady state value = −5.89
T ime taken = 0.66s

Throttle % Near to fan Middle Near to exit

20% 0.66 0.77 0.93
40% 0.56 0.76 0.93
80% 0.54 0.71 0.75
100% 0.5 0.56 0.7

Table 3: Time constant (s) for different sensor location and throttle%

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Experiment 3 Thermal Process Control

5.3 SIMULINK Plots

The system was modelled in SIMULINK by obtaining the transfer functions for each config-
uration using the data from the tables above. The initial value was set as -3 V .

5.3.1 Near Fan location

Figure 19: Simulink plot for time domain system identification, near fan location

5.3.2 Middle location

Figure 20: Simulink plot for time domain system identification, middle location

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Experiment 3 Thermal Process Control

5.3.3 Near Exit location

Figure 21: Simulink plot for time domain system identification, near exit location

5.4 Conclusion
1. For lower fan speed, response is highest near to the fan and as the sensor is moved
away from the fan, response decreases and consequently the gain decreases as well.

2. The middle location and near to exit location appear to have almost the same response
rise variation but the near to fan location has slightly less response rise plot.

3. As we move from the fan, time delay increases and gain decreases. On the other hand,
when throttle is increased, both gain and time delay decrease.

4. Time constant clearly increases as we move away from the fan while showing decrease
when throttle is increased.

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Experiment 3 Thermal Process Control

6 Two Step Control

6.1 Procedure
1. Set the switch on the left side of the panel box to ’heater’.

2. Connect socket X and socket Y.

3. Adjust set value to 45 and throttle control to 20%.

4. Set ’max heater power’ to 1 and ’overlap’ to 0.

5. Set ’proportional band’ to 100 and select two-step control.

6. Connect socket C and socket Y to channel 1 and channel 2 of oscilloscope respectively

with 0.5 sec/division time scale.

7. Take measurements at all three sensor locations.

8. Repeat above steps for ’overlap’ 2 and 4.

9. Discuss the obtained results.

6.2 Observations

Set Value Throttle Overlap Sensor Location At which overlap

(V ) (%) (V ) two-step control works
Near To Fan No Output
0 Middle figure (22)
Near to Exit No Output
Near To Fan figure (24)
4.5 20 2 Middle No Output
Near to Exit figure (26)
Near To Fan No Output
4 Middle No Output
Near to Exit No Output

Table 4: Two-step control observations

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Experiment 3 Thermal Process Control

• 0 V overlap at the middle location

Figure 22: Two-step control for 0 V overlap at middle location

• 0 V overlap at the middle location

Figure 23: Two-step control for 0 V overlap at middle location

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Experiment 3 Thermal Process Control

• 2 V overlap at near fan location

Figure 24: Two-step control for 2 V overlap at near fan location

Figure 25: Two-step control for 2 V overlap at near fan location

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Experiment 3 Thermal Process Control

• 2 V overlap at near exit location

Figure 26: Two-step control for 2 V overlap at near exit location

• 2 V overlap at near exit location

Figure 27: Two-step control for 2 V overlap at near exit location

6.3 Conclusion
• The two step control was observed only for 3 cases- middle location for 0 overlap and
the near fan and near exit locations in case of 2 V overlap.

• For other cases, the temperature sensor output does not reach or cross the set values
for the overlap.

• The simulink plots are in good agreement with the experimental findings.

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