DESIGN AND IMPLEMENTATION OF INTELLIGENT CONTROLLER FOR PLASTIC EXTRUSION PROCESS USING EMBEDDED SYSTEMS S.Ravi Reg. No.

4083042120

UNDER THE GUIDENCE OF

Dr. M.SUDHA Ph.D.,

PROFESSOR & HOD/ECE Karpagam Institute of Technology, Coimbatore.

Doctoral Committee Members

Dr.V.Subbiah
Dean, Electrical Sciences Sri Krishna College of Engineering and Technology Coimbatore

Dr.K.Porkumaran
Vice Principal Dr.N.G.P . Institute of Tech. Coimbatore

INDIAN EXAMINER Dr.N.Sivakumaran Associate Professor Department of Instrumentation and Control Engg. National Institute of Technology Tiruchirappalli FOREIGN EXAMINER Dr. James Arthur Swart Lecturer Vaal University of Technology South Africa

OUTLINE OF THE PRESENTATION

Introduction about Plastic Extrusion plant. Problems in controlling the temperature of the plastic extruder. Literature Survey. Design of conventional and proposed controllers using MATLAB/Simulink. Neuro Fuzzy controller design using LabVIEW. Real time implementation. Result analysis and Conclusion.

INTRODUCTION

Extrusion is a high volume manufacturing process. Used in the different industries. Plastic extrusion process is chosen which is widely used in polymerization industry. The industrial data is collected from the Arya Plastics Industry, SIPCOT, Perundurai The temperature control of the plastic machine decides the quality of the plastic products.

Three to five heating stages-Coupling problem. Plastic Extrusion barrel temperatures have slow responses. Transitions between the machines idle state and the operation state. Inconsistent and inhomogeneous product quality. Product Development Process.

BLOCK DIAGRAM of PVC PLANT

PLASTIC EXTRUSION PIPELINE

PLANT HEATER DETAILS

LITERATURE REVIEW
Title
Control of Plastic Extruders with Multiple Temperature Zones Using a Microprocessor Based Programmable Controller System Temperature Control of a Plastic Extrusion Barrel Using PID Fuzzy Controllers

Author Details
WilliamWare .E (1984), IEEE Transactions on Industry Applications, Vol.IA-20, No.4, pp.912917.

Consolidated Results
The problem is eliminated by an integration of the variety of individual controllers into a single system accomplishes a high degree of co-ordination and extruder performance.

Taur .J.S, Tao .C.W and Tsai .C.C (1995), Proceedings of the International IEEE/IAS conference on Industrial Automation and Control Emerging Technologies, Taipei, Taiwan, May 22-27, pp.370-375. Ching Chih Tsai and Chi-Huang Lu (1998), Journal of the Chinese Institute of Engineers, Vol.21, No.5, pp.619-624.

Temperature control of a plastic extrusion barrel using proportional integral derivative fuzzy controllers implies a traditional fuzzy controller.

Fuzzy Supervisory Predictive PID Control of a Plastic Extruder Barrel

The problem of tuning of PID controllers eliminated and proposes a method that makes the weighting term of the PID control and its gains are adjusted by fuzzy controller.

LITERATURE REVIEW
Title
Adaptive Decoupling Predictive Temperature Control for an Extrusion Barrel in a Plastic Injection Molding Process

Author Details
Chi Huang Lu and Ching Chih Tsai (2001), IEEE Transactions on Industrial Electronics, Vol.48, No.5, pp.968-975.

Consolidated Results
A recursive least square estimation method is implemented by TMS320C31 processor. This improves the capabilities of set-point tracking, disturbance rejection, and robustness by appropriate adjustments to the tuning parameters in the criterion function.

Hybrid Fuzzy Logic Control with Input Shaping for Input Tracking and Sway Suppression of a Gantry Crane System

Ahmad .M.A and Mohamed .Z (2009), American Journal of Engineering and Applied Sciences, Vol.2, No.4, pp.241-251.

The hybrid Fuzzy PI for the temperature control improves the performance of industrial process by supplementing conventional controls

A Genetic Based NeuroFuzzy Controller for Thermal Processes

Ashok Kumar Goel, Suresh The method has effectively built accurate linguistic Chandra Saxena and Surekha neuro fuzzy models and competes well with other Bhanot 2005, Journal of existing approaches. computer science and Technology, Vol.5, No.1, April 2005.

LITERATURE REVIEW
Title Mold Temperature Control of a Rubber Injection Molding Machine by TSK Type Recurrent Neural Fuzzy Network Implementation of MATLABSIMULINK Based Real Time Temperature Control for Set Point Changes Author Details Chia Feng Juang, Shui Tien Huang and Fun Bin Duh (2006), Journal of Neurocomputing, Vol.70, No.3, pp.559567. Emine Dogru Bolat (2007), International Journal of Circuits, Systems and Signal Processing, Vol.1, No.1, 2007, pp.5461. Consolidated Results The recurrent structure eliminates the need of prior knowledge of molding machine order and with the use of simple gradient, descent algorithm, practical experiments results in the elimination of the complicated time delay property and make the sampling interval even. The temperature set point with Ziegler Nichols step response method, relay tuning method, integral square time error, and disturbance criterion method. The relay based PID controller provides the best response among other methods.

FINDINGS FROM THE LITERATURE REVIEW

The effect of coupling with a large peak time, delay time with peak overshoot , more number of heaters are not considered.

The fine tuning of the controller with the controlled variable to achieve the set point temperature is not obtained.
Not provide contented results for non linear and dead time process.

Real time implementation for multistage is not achieved. None of these papers has jointly focused on a intelligent controller with the embedded system and considering the effect of coupling effects, set point tracking for more number of heaters with real time experimental set up.

PROPOSED METHODOLOGY

A real time intelligent temperature controller for plastic extrusion process is developed using PIC microcontroller considering the coupling effects, set point tracking, more number of heaters to eliminate the temperature control problem.

PID CONTROLLER DESIGN

The PID control is designed to ensure the specifying desired nominal operating point. The PID control gain values and time constant values are designed using Zeigler Nichols tuning method. The delay time and time constant are determined by drawing a tangent line.

S- SHAPED CURVE OF STEP RESPONSE OF TEMPERATURE CONTROL MODEL

Delay time L=10S and time constant T=50s

The Ziegler-Nichols tuning rules suggest the PID control optimal setting values. The simulation uses the first order transfer function for the simulation work.

0.92 10 s G(s) e 1 s144

SIMULINK MODEL OF PID CONTROLLER

RESULTS FOR PID CONTROLLER

PERFORMANCE SPECIFICATION OF PID CONTROLLER

Performance Specification Delay Time(td) Rise Time(tr) Peak Time(tp) Settling Time(ts) PID Controller Output 170 Seconds 250 Seconds 400 Seconds 1900 Seconds

Peak Overshoot

21%

DRAWBACKS OF PID CONTROLLER

Self tuning of PID Control. Lagging in identify process variations. The timing specification of the controller takes more time. Intelligent controllers are implemented to control the temperature.

NEURAL NETWORK CONTROLLER

Alternative for classical controllers. Interconnection of simple processing element. Data processing system consisting of large number of simple highly interconnected processing elements in architecture.

FEED FORWARD NEURAL NETWORK

Feed forward improves reference tracking Stabilize the system. Suppress the disturbances. Modifiable.

SIMULINK MODEL OF NEURAL NETWORK CONTROLLER

NEURAL NETWORK SIMULATED OUTPUT AT DIFFERENT TEMPERATURE SET POINTS

PERFORMANCE SPECIFICATION FOR THE NEURAL NETWORK CONTROLLER

Performance Specification Delay Time(td) Rise Time(tr) Peak Time(tp) Settling Time(ts) Peak Overshoot Neural Network Controller Output 127 Seconds 150 Seconds 120 Seconds 1820 Seconds 6%

FUZZY LOGIC CONTROLLER

Fuzzy classification. Two dimensional fuzzy controller model Fuzzification, Fuzzy Inference Engine, Defuzzification

DESIGN OF FUZZY LOGIC CONTROLLER

FUZZY RULE BASE

IF THEN rules. NB, NS, Z, PS, and PB.

FUZZY CONTROL MODEL IN SIMULINK

RESULTS OF FUZZY CONTROLLER

PERFORMANCE SPECIFICATION FOR THE FUZZY LOGIC CONTROLLER

Performance Specification Delay Time(td) Rise Time(tr) Peak Time(tp) Settling Time(ts) Peak Overshoot Fuzzy Logic Controller Output 25 Seconds 80 Seconds 100 Seconds 1800 Seconds 5.25%

PERFORMANCE COMPARISON
Performance Specification Rise Time(tr) Fuzzy Logic Controller

3.13 times less than PID controller

Peak Time(tp)

1.88 times less than Neural Network controller 4 times less than PID controller

1.2 times less than Neural Network controller Settling Time(ts) 1.06 times less than PID controller 1.01 times less than Neural Network controller

 The disturbance rejection and set point tracking is achieved effectively. FLC control is with minimum overshoot Take a time delay to settle with reference value.

FUZZY PID CONTROLLER

Tuning of the PID controllers are Difficult. Optimized gain values can be obtained through fuzzy logic controller. Combining the fuzzy with PID controller produces a good control output.

FUZZY PID CONTROLLER DESIGN PROCEDURE

1) 2) 3) 4)

Identification of input and output variables. Construction of control rules. Describing system state in terms of fuzzy sets Establishing fuzzification method and fuzzy membership functions. 4) Selection of the compositional rule of inference. 5) Defuzzification

CONTROLLER DESIGN
The outputs of fuzzy controller are Kp, Ki, Kd. The fuzzy subsets of e and ec are {NB, NM, NS, ZE, PS, PM, PB}. Fuzzy subsets of output for Kp, Ki, Kd are {ZE, VS, MS,ME, MB, VB,VL}. The membership functions of each language values are triangular membership functions. The triangular membership function is with minimum steady state error. Due to the simplest formulation the triangular membership function is chosen.

Membership functions of input fuzzy variable error

Membership functions of input fuzzy variable change in error.

Membership functions of fuzzy controller output variable Kp

Membership functions of fuzzy controller output variable Ki

Membership functions of fuzzy controller output variable Kd

SIMULINK MODEL OF FUZZY TUNED PID CONTROL

SIMULINK RESULT OF FUZZY TUNED PID CONTROL

PERFORMANCE SPECIFICATION OF FUZZY LOGIC TUNED PID CONTROLLER

Performance Specification Fuzzy Logic Tuned PID

Controller Output Delay Time(td) Rise Time(tr) Peak Time(tp) Settling Time(ts) Peak Overshoot
152 Seconds 175 Seconds 100 Seconds 1830 Seconds 5.25 %

PERFORMANCE COMPARISON
Performance Specification Rise Time(tr) Fuzzy PID Controller

1.43 times less than PID controller

Peak Time(tp)

0.46 times less than Neural Network controller 4 times less than PID controller
1.2 times less than Neural Network controller

Settling Time(ts) 1.04 times less than PID controller Settling time is equal with Neural Network controller

FLC tuned PID controller elimination of overshoot is less. Considering the percentage of peak overshoot, the proposed method provides negligible value. The set point tracking is achieved effectively compared to other controllers The disturbance rejection is obtained effectively for the proposed FLC tuned PID controller.

NEURO FUZZY CONTOLLER

Neuro Fuzzy Controller is used in the form of sugeno model. Integrate the best features of fuzzy systems and neural networks. Representation of prior knowledge.

PROPOSED NEURO FUZZY CONTROL RULES

DESIGN OF NEURO FUZZY CONTROLLER

DESIGN STEPS FOR THE NEURO FUZZY CONTROLLER

Training data of a desired input/output pair of the target system to be modeled. Input FIS Structure is designed. The error tolerance and number of training epochs are designed. The training fuzzy data is exported to workspace as a .Mat file. The ANFIS window is opened. The data is trained from workspace. The .MAT file imported to workspace. The FIS is selected loaded from file.

NEURO FUZZY CONTROLLER MODEL TRAINING DATA

SIMULINK MODEL OF NEURO FUZZY CONTROLLER

NEURO FUZZY CONTROL SIMULATED OUTPUT

PERFORMANCE SPECIFICATION OF NEURO FUZZY CONTROLLER

Performance Specification Delay Time(td) Neuro Fuzzy

Controller Output
20 Seconds

Rise Time(tr)
Peak Time (tp) Settling Time(ts) Peak Overshoot

37 Seconds
No Peak Time 1370 Seconds No Peak Overshoot

COMPARISON OF SIMULATION RESULTS OF DIFFERENT CONTROLLERS

PERFORMANCE SPECIFICATION OF CONVENTIONAL AND PROPOSED CONTROLLERS

Performance PID Neural Fuzzy FLC
PID

Neuro
Fuzzy

Specification Controller Controller Controller

Controller Controller Delay Time(td) Rise Time(tr) 170 sec 250 sec 127 sec 150 sec 25 sec 80 sec 152 sec 175 sec 20 sec 37 sec

Peak Time (tp)

Settling Time(ts) Peak Overshoot

400 sec
1900 sec 21%

120 sec
1820 sec 6%

100 sec
1800 sec 5.25%

100 sec

No Peak
Time 1370 sec No Peak Overshoot

1830 sec 5.25%

PERFORMANCE COMPARISON
Performance Specification Delay Time( td) Neuro Fuzzy Controller 8.5 times less than PID controller 6.35 times less than Neural Network controller 1.25 times less than Fuzzy Logic controller 7.6 times less than Fuzzy tuned PID controller Rise Time(tr) 6.76 times less than PID controller 4.05 times less than Neural Network controller

2.16 times less than Fuzzy Logic controller

4.72 times less than Fuzzy tuned PID controller

PERFORMANCE COMPARISON
Performance Specification Peak Time(tp) Neuro Fuzzy Controller 400 times less than PID controller 120 times less than Neural Network controller 100 times less than Fuzzy Logic controller 100 times less than Fuzzy tuned PID controller Settling Time(ts) 1.39 times less than PID controller 1.33 times less than Neural Network controller

1.31 times less than Fuzzy Logic controller

1.34 times less than Fuzzy tuned PID controller

RESULTS OF THE PROPOSED CONTROLLER

The simulation result for the temperature control of plastic extruder using neuro fuzzy controller is outperformed i) In terms of overshoot ii) Disturbance rejection iii) Set point tracking The performance of the temperature control of plastic extrusion is greatly improved in terms of steady state response as well as stability.

Delay time of neuro fuzzy controller is 20seconds and the time required is less.
Neuro fuzzy controller is without peak overshoot.

LabVIEW NEURO FUZZY CONTROLLER

LabVIEW is a powerful and versatile graphical development platform of virtual instrument.
Used mostly in industrial control .

SIMULATION INTERFACE TOOLKIT

SIMULATION INTERFACE TOOLKIT

The LabVIEW/SIT interface behaves differently when data acquisition is involved in the Simulink model. The LabVIEW Simulation Interface Toolkit integrates Simulink and real-time workshop with LabVIEW in a way that allows developing and testing control systems first developed in the simulink simulation environment.

FRONT PANEL OF LABVIEW FOR NEURO FUZZY CONTROLLER

BLOCK DIAGRAM OF LABVIEW FOR NEURO FUZZY CONTROLLER

LabVIEW SIMULATION RESULTS FOR CONVENTIONAL AND PROPOSED CONTROLLERS

Results without any transient overshoots and takes less time to settle with reference temperature.
The proposed controller identifies the process variations quickly and makes the temperature to settle with reference value.

Real time plastic extrusion model temperature can be controlled through by proper interface by using LabVIEW.

BLOCK DIAGRAM OF PIC16F877A MICROCONTROLLER BASED TEMPERATURE CONTROLLER FOR PLASTIC EXTRUSION SYSTEM
Embedded systems are highly specialized, often reactive, sub systems that provide information processing and control.

CIRCUIT DIAGRAM OF THE TEMPERATURE CONTROL FOR THE PLASTIC EXTRUDER

Picture of the temperature controller set up for plastic extruder

HARDWARE IMPLEMENTATION RESULTS

The proposed controller is implemented through the PIC16F877A microcontroller. The control algorithm was written in Hi Tech C code in MPLAB software. After developing the application program, it has been downloaded in to selected target machine.

The set points temperatures 700C, 1000C are applied for the experimental setup.

COMPILING MPLAB hitech C

EXPERIMENTAL RESULTS FOR THE PROPOSED NEURO FUZZY CONTROLLER

FINDINGS OF THE HARDWARE RESULTS

Temperature control for set points can be achieved effectively. Digital neuro fuzzy controllers are effective in dealing with the highly nonlinear characteristics. The hardware significantly decreases at runtimes. The controller provides a quick, accurate set point tracking with reference temperature.

COMPARISON OF SIMULATION AND HARDWARE RESULTS OF NEURO FUZZY CONTROLLER FOR DIFFERENT SET POINTS

COMPARISON OF SIMULATED AND EXPERIMENTAL RESULTS

Performance Neuro Fuzzy Neuro Fuzzy

Specification

Controller

Controller

Simulation Results Hardware Results

Delay Time(td)
Rise Time(tr) Peak Time(tp) Settling Time(ts) Peak Overshoot

20 Seconds
37 Seconds No Peak Time 1370 Seconds

25 Seconds
43 Seconds 5 Seconds 1395 Seconds

No Peak Overshoot 0.26%

RESULTS AND DISCUSSION

The comparison results show the neuro fuzzy controller output is efficient. Good tracking capability. Two different temperature set points 70C, 100C is used. PID controller output is with very high initial transient overshoot. Oscillating and takes more time to settle with the reference temperature. The other proposed controllers are without initial transient overshoots.

Neuro Fuzzy controller is without overshoot. It eliminates the initial transient overshoot and oscillations. Proposed Neuro Fuzzy controller is suitable for set points changes and for stability. The proposed controller identifies the process variations quickly and provides good control for the set point changes and for sudden disturbances. The set points tracking and disturbance rejection is obtained in the proposed method.

The hardware results are closer to the simulation results. The proposed controller implemented through the embedded system and shows the desired outstanding performance in terms of achieving the desired value with very small values for the delay, rise, peak, settling time both in hardware and in simulation.

CONCLUSION
This research work demonstrates the design, analysis and suitability of neuro fuzzy controller for plastic extrusion

by neuro fuzzy control. Different type of controller like PID, Neural, Fuzzy, Fuzzy tuned PID, Neuro Fuzzy controller are simulated. From the simulation results it is found that the Neuro Fuzzy controller is suitable for plastic extrusion system. The neuro fuzzy controller is suitable for set points changes and for stability with the aid of the supervisory technique. The proposed controller identifies the process variations quickly.
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 Provides good control for the set point changes and for sudden disturbances. This temperature controller can provide accurate temperature control over a wide range of temperature variations; can also perform accurately at different operating conditions and avoiding disturbances. Earlier works on the temperature control for plastic extruder have not paid much emphasis on more number of set point temperatures. The main advantage of the proposed temperature controller is considering the coupling properties and real time implementation and it is achieved through the PIC controller.
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 The neuro fuzzy controller performs better than conventional and other intelligent controllers when the controllers are subjected to the same operating conditions. The simulation and experimental results show that the proposed controller takes less time to eliminate sudden disturbances and tracking the set point and more robust to load variations. The simulation results and the performance of the hardware implementation show that the optimal neuro fuzzy controller functions better than other controllers in terms of time domain specification, set point tracking, and disturbance rejection with optimum stability. The neuro fuzzy controller will prove especially efficacious in the case temperature control in plastic extrusion system.
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FUTURE SCOPE
The neuro fuzzy temperature controller can be implemented using ARM processor. The developed embedded based neuro fuzzy controller can be implemented for Aluminum extrusion process with required modifications. The graphical user interface developed using LabVIEW can transfer information to the networked clients through web server and monitoring of the set points may be achieved. The tuning of neuro fuzzy controller done through the genetic algorithm.

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List of publications Paper Publication International Journals

1. S.Ravi, M.Sudha and P.A.Balakrishnan, Design of Intelligent Self Tuning GA ANFIS Temperature Controller for Plastic Extrusion System, Modelling and Simulation in Engineering Journal, Vol.2011, Article ID 101437, DOI. 10.1155/2011/101437. S.Ravi and P.A.Balakrishnan, Design of Synthetic Optimizing Neuro Fuzzy Temperature Controller for Dual Screw Profile Plastic Extruder Using LabVIEW, Journal of Computer Science, Vol.7, No.5, pp.671677, May 2011.

2.

3. S.Ravi and P.A.Balakrishnan, Modelling and Control of an ANFIS Temperature Controller for Plastic Extrusion Process, Proceedings of the IEEE Xplore on Communication Control and Computing Technologies (ICCCCT), 2010, Ramanathapuram, India ,October 2010, pp.314-320.
4. S.Ravi and P.A.Balakrishnan, Temperature Response Control of Multistage Process Plant Using Matlab/Simulink, Journal of Instrument Society of India, Vol.40, No.3, pp177-178, September 2010.

5. S.Ravi and P.A.Balakrishnan, Genetic Algorithm Based Temperature Controller For Plastic Extrusion System, International Journal on Automatic Control and System Engineering, Vol.11, No.1, pp1-8, June 2011. 6. S.Ravi and P.A.Balakrishnan, Dual Screw Profile Extruder Temperature Control Using LabVIEW Enhanced Genetic Fuzzy Algorithm, European Journal of Scientific Research, Vol.50, No.1, pp.35-47, April 2011. 7. S.Ravi and P.A.Balakrishnan, Intelligent Self Tuning ANFIS Temperature Regulator for Plastic Extrusion System, CiiT International Journal of Artificial Intelligent Systems and Machine Learning, Vol.2, No.11, pp.333-339, November 2010. 8. S.Ravi and P.A.Balakrishnan, Stable Self Tuning Genetic Fuzzy Temperature Controller for Plastic Extrusion System, International Journal of Reviews in Computing, Vol.5, No.4, pp.21-28, January 2011. 9. S.Ravi and P.A.Balakrishnan, Temperature Response Control of Plastic Extrusion Plant Using Matlab/Simulink, International Journal of Recent Trends in Electrical Engineering, Vol.3, No.4, pp.135-140, May 2010.

Paper Accepted for Publication in International Journals

1. S.Ravi, M.Sudha and P.A.Balakrishnan, Modelling of Embedded Based Neuro Fuzzy Temperature Controller For Plastic Extrusion System accepted for the publication in Intelligent Automation and Soft Computing Journal.

Paper Presented in International Conferences

1. S.Ravi and P.A.Balakrishnan, Temperature Response Control of Plastic Extrusion Plant Using Matlab/Simulink, International

Conference on Instrumentation (ICI-2009), 2010, 21-23 January 2010,

pp.116-117.
2. S.Ravi and P.A.Balakrishnan, Modelling and Control of an ANFIS Temperature Controller for Plastic Extrusion Process, Technologies, ICCCCT10, 7-9 October 2010, pp.473-479. 2010 IEEE

International Conference on Communication Control and Computing

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