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2. Available Tools
3. Control Strategies
Material flow
steady
Reject Flow
Finish product
Feed rate
• Functional layout
• Controller objective
• Controller ON-OFF
• Controller P.I.D.
• Expert system
Manipulated Controlled
Quantities Quantities
PROCESS
Setpoints
Slegten grinding course 6
PROCESS
Manual Control
Disturbances
Manipulated Controlled
Quantities Quantities
PROCESS
Actions
Needed
Measured
Values
Feedback Control
Hardware
Setpoints
Slegten grinding course 7
Functional Layout of a Feedback Loop
Disturbances
Manipulated
Setpoints final Controlled
input + feedback transmission
controller system control PROCESS
elements error element
- signal
sensor
transmission
system
Controllerbox On site
Time
Reality
Setpoint
Time
Setpoint
Time
Controlled variable:
room temperature
Dead Zone
Setpoint
On
Fuel valve
Off
Time
Manipulated variable:
quickly changes to either a maximum or
a minimum value (minimum = 0 or off).
Discontinuous control
Mechanism = usually a simple relay
Slegten grinding course 10
Controllers : Proportional
E Kc E
e K c m
Control algorithm: m = K e c
+ Rapid response
Dynamicaly relatively stable
- Offset
Steam
Undercharge 3
Steam
2
1
Rotational Charge
speed application Offset
Setpoint
Time
Integral action
Slegten grinding course 12
Controllers : Integral
Et
E
Ti
1
e Tp m
i
Ti = integral time
p = action of integration with respect to time (dt)
m= Manipulated variable
e=error
P+I:
+ Combines advantages of proportional
and the reset of the offset
E
Ed Td
e Tp d
m
Td = derivative time
p = action of derivation with respect to time (dt)
m= Manipulated variable
e=error
P:
Simple
Inherently stable when properly tuned
Easy to tune
Experiences offset at steady state
P+I+D: the most sophisticated P+ I:
No offset
Characteristics of controller algorithms Better dynamic response than reset alone
Possibilities exist for instability due to lag
introduced
P + D:
Stable
Less offset than proportional alone
(use of higher Kc possible)
Reduces lags, i.e. more rapid response
P + I + D:
Most complex
Most expensive
Rapid response
No offset
Difficult to tune
Best control if properly tuned
Slegten grinding course 15
Expert Systems
• Rule-based
• Combines several methods, and tries to emulate human
responses to given conditions
• Based on a decision table, which gives each possible
combination of conditions which could occur for x number
of measured parameters
• Although these systems are becoming more and more
common, it must be remembered that a considerable amount
of study and tuning is required to get the program right.
The programmer must, in essence, teach the computer
to operate the mill
• The current restriction on these systems is that they act only on one
parameter at a time.
• Elevator Control
• Ear Control
• Reject Flow Control by Fresh Feed
• Total Feed Control
• Reject Flow Control by Separator Speed
Separator speed
Reject
Finish product
P.I.
Elevator Fresh feed
+ -
Set Point
- High Lag time
- Poor Signal from Elevator
Separator speed
Reject
Finish product
P.I.
Sound Fresh feed
+ - EAR
Set Point
- Uneven Mill Flow
Separator speed
Reject
Finish product
-
+ P.I.
Total feed Fresh feed
Set Point
- Long lag time
- No detection of build up in mill
Separator Speed
+
Reject
+
Finish product
-
P.I.
+
Reject setpoint Fresh feed
Separator speed
+
Reject
P.I.
setpoint -
Reject
Finish product
Fresh feed
- Not suitable with uneven clinker
Filling Degree
Elevator Power
Mill Power
Feed
Set Point
ear k1 %
reject + Feed
k %
2 PI D
+ +
elevator k %
3
power
k +k +k = 100 %
1 2 3
Pid-1 :
Fresh regulation set point = Fresh set point + F (pid) (Mill set point Mill flow)
« Grits/fresh » Fresh Setpoint
Mill set point = Fresh set point (1 + Grits/fresh)
Mill flow = SFresh + Grits
Then :
Prediction
Separator
Speed
Finish product
Finish product
Reject Reject
Mill
Feed rate