PERFORMANCE ANALYSIS ON MODEL BASED

CONTROL FOR DRYER IN PAPER MAKING PROCESS

PHASE-II PROJECT REPORT
Submitted by

SURESH.K (9912106006)

in partial fulfillment for the award of the degree

of

MASTER OF TECHNOLOGY
in

CONTROL AND INSTRUMENTATION ENGINEERING

KALASALINGAM UNIVERSITY
(Kalasalingam Academy of Research and Education)
KRISHNANKOIL - 626 126

MAY 2014

CERTIFICATE OF BONAFIDE RECORD

Certified that this Thesis report PERFORMANCE ANALYSIS ON MODEL BASED

CONTROL FOR MOISTURE IN PAPER MAKING PROCESS is the bonafide work of
K.SURESH who carried out the project work under my supervision. Certified further
that to the best of my knowledge, this report does not form part of any other project
report of dissertation on the basis of which a degree or award was conferred on an earlier
occastion on this or any other candidate

Dr.B.KANNAPIRAN, M.E., Ph.D.,

C.KARTHIK,M.Tech.,(Ph.D).,

PROFESSOR & HEAD

SUPERVISOR

DEPARTMENT OF ICE

ASSISTANT PROFESSOR
DEPARTMENT OF ICE

Date: ..
Station: KRISHNANKOIL

Submitted for the Viva Voce Examination in M.Tech (degree) Project Phase II held on
. at Kalasalingam University during the academic year 2013 2014 and
valued by

Internal Examiner

External Examiner

ACKNOWLEDGEMENT

This gives me immense pleasure to thank and acknowledge profusely the

following personalities who helped me to successfully complete this project.
I thank immense pleasure to Kalvivallal,Thiru.T.Kalasalingam,B.Com.,
founder of institution who had been guiding light for me in activities I had in our
university premises.
I would like to express my humble thanks to my beloved Chancellor
IllayavallalThiru.k.Sridharan,M.Com.,

and

Vice-Chancellor

Dr.S.Saravana

shankar,M.E.,Ph.D., for the permission to carry out the project work successfully.
I express my profound thanks to our beloved Dr.B.Kannapiran,M.E,Ph.D., Head
of department of Instrumentation and Control engineering for his co-operation throughout
this work and efforts for arranging this dissertation work.
I

would

like

to

thank

our

project

co-ordinator

Mr.R.P.Surya

Shankar,M.E.,(Ph.D)., Assistant Professor, Department of Instrumentation and Control

Engineering for his support.
Its my privilege to work under the guidance of Mr.C.Karthik,M.Tech.,(Ph.D).,
Assistant Professor in Instrumentation and Control Engineering Department who has
always motivated me to think with audacity and to create humbly perseverance.
I wish to extend my sincere thanks to My friends and All teaching and Nonteaching staff member in the Instrumentation and Control Engineering Department who
helped me to learn and utilize the facilities available in Labs during the project works

iii

ABSTRACT
This project deals with simulation of the dryer section in paper making process.The
moisture in the paper is controlled by adjusting the set point of the stream pressure
controller to the cylinders.There existing several incentives to focus on the performance
of the moisture control. This project deals with the performance evaluation on the
comparison of model based control for drying process of paper industry.In the design of
model reference adaptive control schme is used,in which the adaptive law have been
developed by MIT rule. Similarly design of PID and MPC and MRAC controller and
FUZZY MRAC controller used.
This paper presents a nonlinear dynamic control, based on heat and mass balance for
steam, cylinder and paper.The control was performed to the combined drying process
system using both the adaptive control algorithm and MPC controller method and its
results were analyzed. A simulation is carried out using MATLAB.Simulation results
reveal clear benefits of these Fuzzy MRAC over traditional controller and MPC and
MRAC controller methods.Thus by controlling this process prove real incentives for
industrial implementation.

Keywords: Model predictive control, Model Reference Adaptive control, PID controller,
Fuzzy Model Reference Adaptive controller, dryer section, MATLAB.

iv

LIST OF CONTENTS
CHAPTER.

TITLE

NO

PAGE.
NO

ACKNOWLEDGEMENT

iii

ABSTRACT

iv

LIST OF FIGURES

vii

LIST OF TABLES

ix

INTRODUCTION

1.1 General

1.2 Dryer section variables

1.3 Flow chart of paper making process

1.3.1 Head Box section

1.3.2 Wire section

1.3.3 Press section

1.3.4 Dryer section

1.4 Objectives of the project

LITERATURE REVIEW

SYSTEM IDENTIFICATION

14

3.1 Introduction of system identification

14

3.2 Identification Methods

14

3.2.1 Non Parametric approach

14

3.2.2 Parametric approach

14

3.3.1 Model identification

14

3.3.2 Experiment design

15

3.3.3 Model structure

15

3.3.4 Model validation

16

3.4 System Identification flow chart

16

METHODOLOGY
4.1 Introduction to pid controller
4.1.1 Tuning methods

17
17
18

4.1.1.1 Ziegler-Nigols tuning

18

4.1.1.2 Cohan Coon Tuning

19

4.2 Introduction to model predictive controller

20

4.2.1 MPC Motivation

20

4.2.2 MPC Design and simulation

22

4.2.2.1 Starting the design tool

22

4.2.2.2 Loading a plant model

22

4.2.2.3 Signal property specifications

22

4.2.2.4 Controller design

24

4.3 Introduction to model reference adaptive controller

25

4.3.2 Gradient method-MIT rule

26

4.3.3 References Model

28

4.4 fuzzy model reference adaptive control

29

4.4.1 Fuzzy control

32

4.4.2 performance objectives and design constraints

33

4.4.3 Fuzzy logic architecture

33

4.4.4 Fuzzy proposition

35

4.4.5 Membership functions

36

4.4.6 Procedure for fuzzy logic

40

RESULTS AND DISCUSSIONS

41

CONCULUSION AND FUTURE ENHANCEMENT

48

REFERENCES

49

LIST OF FIGURES

FIGURE.NO

TITLE

PAGE.NO

Paper making flow chart

Data Collection

15

System identification flow chart

16

Block diagram of PID Controller

18

Block diagram of MPC

21

MPC Control and Estimation Tools Manager

23

Block diagram of MRAC

25

The structure of the FUZZY MRAC control system

29

The structure of the Adaptive control system

32

10

Block diagram for fuzzy controller

33

11

FL system with triangular MFS

34

12

FL system with gaussion MFS

34

13

Membership function for linguistic value

36

14

Mamdani type fuzzy logic toolbox

37

15

Input membership function plots

38

16

Output membership function plots

38

17

Fuzzy rule base system

39

18

Fuzzy surface view diagram

39

19

Process model validation fitness output

41

20

PID simulation scenario

42

21

MPC simulation scenario

43

22

MRAC Simulink diagram

44

23

MRAC simulation scenario

44

24

FUZZY-MRAC Simulink diagram

46

25

FUZZY-MRAC simulation scenario

46

viii

LIST OF TABLES

TABLE.NO

TITLE

PAGE.NO

1.1

Technical specification of paper mechine

4.1

Ziegler Nichols tuning standard

18

4.2

Cohen-coon tuning standard

19

4.3

Comparison of process models

41

5.2

FAM Table

45

5.3

Comparison between PID vs MPC vs MRAC vs FUZZY

47

MRAC Controller Response

ix