Stability analysis of paper machine headbox using a new PI(D) tuning technique

  • Authors

    • Parvesh Saini
    • Rajesh Kumar
    2018-03-11
    https://doi.org/10.14419/ijet.v7i2.6.10064
  • Paper Machine Headbox, Level, Pressure, PID/PI Controller, Ultimate Point.
  • Paper, today, has made an important place in human’s life. Being an important commodity, paper has different qualities throughout the globe. As the technology is advancing, paper is being used for numerous applications and need of good quality paper is increasing daily. To have papers of desirable quality, paper machines with latest technology are developed. However, the quality of paper principally depends on the prime element of paper machine i.e. Headbox. Headbox is a highly non-linear Multi-input Multi-output (MIMO) component of paper machine and requires a precise control of its major parameters to get good quality papers which eventually responsible for sustained economy of pulp and paper industry. In past few decades, headbox has been a key element for research. Researchers have developed different control algorithms for headbox. This paper presents stability analysis of paper machine headbox using a new technique of Proportional – Integral – Derivative (PID) controller design namely Extended Forced Oscillation method (EFO). Also, the paper presents a comparative analysis of EFO method of PID tuning with the conventional Ziegler - Nichols(ZN) tuning technique based on transient characteristics and performance indices of headbox.

  • References

    1. [1]. M.B. Kothari, “Effect of Headbox Operational Variables on Paper Formulationâ€, IPPTA Journal, Vol. 10, No. 1, (1973), pp. 42.

      [2]. TorstenCegrell, TorbjörnHedqvist, “Successful adaptive control of paper machinesâ€, Automatica, Vol. 11, No. 1, (1975), pp. 53-59.https://doi.org/10.1016/0005-1098(75)90008-4.

      [3]. A.K. Sinha, D.A. Rutherford, “Computer-aided controller design for paper Machineâ€, Proceedings of the Institution of Electrical Engineers, Vol. 123, No. 10, (1976) pp. 1021-1025.https://doi.org/10.1049/piee.1976.0229.

      [4]. S. K. Sud, K. K. Biswas and A. K. Sinha, "Stochastic state-variable model for a paper-machine headbox," Proceedings of the Institution of Electrical Engineers, Vol. 124, No. 12, (1977), pp. 1249-1254.https://doi.org/10.1049/piee.1977.0263.

      [5]. Qijun Xia, MingRao, “Fault-tolerant control of paper machine headboxesâ€, Journal of Process Control, Vol. 2, No. 4, (1992), pp. 171-178.https://doi.org/10.1016/0959-1524(92)80006-J.

      [6]. Ying Y., Rao M. and Sun Y. “Bilinear control strategy for paper-making processâ€, Chemical Engineering Communications, Vol. 8, (1992), pp. 13–28.https://doi.org/10.1080/00986449208935978.

      [7]. Q. Xia, M. Rao, X. Shen, Y. Ying and J. Zurcher, "Systematic modeling and decoupling control of a pressurized headbox", Canadian Conference on Electrical and Computer Engineering, Vol. 2, (1993), pp. 962-965.https://doi.org/10.1109/CCECE.1993.332454.

      [8]. D. G. Sbarbaro and R. W. Jones, "Multivariable nonlinear control of a paper machine headbox", Proceedings of the Third IEEE Conference on Control Applications, Vol. 2, (1994), pp. 769-774.https://doi.org/10.1109/CCA.1994.381223.

      [9]. M. E. Elkadiri, S. Tarasiewicz, M. Berrada and P. Radziszewski, "Study of a digital controller by its application to a head-box in pulp and paper industry", 20th International Conference on Industrial Electronics, Control and Instrumentation, Vol. 3, (1994), pp. 1907-1913.

      [10]. J.F. Whidborne, I. Postlethwaite, D.W. Gu, “Robust control of a paper machineâ€, Control Engineering Practice, Vol. 3, No. 10, (1995), pp. 1475-1478.https://doi.org/10.1016/0967-0661(95)00153-L.

      [11]. J. Bergstrom and G. Dumont, "An object oriented framework for developing dynamic models of a paper machine", Dynamic Modeling Control Applications for Industry Workshop, (1998), pp. 63-69.https://doi.org/10.1109/DMCA.1998.703488.

      [12]. J. J. Feeley, L. L. Edwards and R. W. Smith, "Optimal digital control of a laboratory-scale paper machine headbox," IEEE Transactions on Education, Vol. 42, No. 4, (1999), pp. 337-343.https://doi.org/10.1109/13.804542.

      [13]. J. Paattilammi and P. M. Makila, "Fragility and robustness: a case study on paper machine headbox control", IEEE Control Systems, Vol. 20, No. 1, (2000), pp. 13-22.https://doi.org/10.1109/37.823222.

      [14]. Jari P. H¨amalainen and PasiTarvainen, "Numerical Control of Paper Machine Headboxes", European Congress on Computational Methods in Applied Sciences and Engineering, (2000), pp. 1 – 14.

      [15]. Hämäläinen, J., Mäkinen, R. A. E. and Tarvainen, P., “Optimal design of paper machine Headboxesâ€, International Journal for Numerical Methods in Fluids, Vol. 34, (2000), pp. 685–700.https://doi.org/10.1002/1097-0363(20001230)34:8<685::AID-FLD75>3.0.CO;2-O.

      [16]. R. Whalley, M. Ebrahimi, “Optimum control of a paper making machine headboxâ€, Applied Mathematical Modelling, Vol. 26, No. 6, (2002), pp. 665-679.https://doi.org/10.1016/S0307-904X(01)00076-2.

      [17]. G. E. Stewart, D. M. Gorinevsky and G. A. Dumont, "Feedback controller design for a spatially distributed system: the paper machine problem", IEEE Transactions on Control Systems Technology, Vol. 11, No. 5, (2003), pp. 612-628.https://doi.org/10.1109/TCST.2003.816420.

      [18]. JariToivanen, Jari P. Hamalainen, KaisaMiettinen and PasiTarvainen, "Designing Paper Machine Headbox Using GA", Materials and Manufacturing Processes, Vol. 18, No. 3, (2003), pp. 533–541.https://doi.org/10.1081/AMP-120022027.

      [19]. J.P. Hämäläinen, K. Miettinen, P. Tarvainen, J. Toivanen, "Interactive Solution Approach to a Multi-objective Optimization Problem in a Paper Machine Headbox Design", Journal of Optimization Theory and Applications, Vol. 116, No. 2, (2003), pp. 265–281.https://doi.org/10.1023/A:1022453820000.

      [20]. Tang, Wei, Wang, Mengxiao& Li, Minghui., “The Summarize about the Control of Headbox of Paper Machineâ€, Journal of Shaanxi University of Science and Technology (Natural Science Edition). Vol. 23, No. 6, (2005), pp. 129-134.

      [21]. Tang, Wei, Wang, Mengxiao, Li, Minghui&Xue, Huijian., “The Advanced Control Strategies and Decoupling Algorithms of Headboxâ€, Transactions of China Pulp and Paper, Vol. 21, No. 1, (2006), pp. 107-114.

      [22]. Zhongjun Xiao, "Study on the NN Decoupling Control System of Air-cushioned Headbox", Computer and Information Science, Vol. 2, No. 3, (2009), pp. 87 - 93.https://doi.org/10.5539/cis.v2n3p87.

      [23]. Kumar Rajesh, A.K.Ray, "Artificial Neural Network Modeling and Control of Retention Process in the wet end", International Journal of Information Technology and Knowledge Management, Vol. 2, No. 2, (2010), pp. 259-264.

      [24]. Yan Zhao and Qingyu Dai, "Design of adaptive fuzzy controller in air-cushioned headbox," 2nd International Asia Conference on Informatics in Control, Automation and Robotics, (2010), pp. 9-12.

      [25]. Pradeep Kumar Juneja, A K Ray & R Mitra, "Various Controller Design and Tuning Methods for a First Order Plus Dead Time Process", International Journal of Computer Science & Communication, Vol. 1, No. 2, (2010), pp. 161-165.

      [26]. Zhongjun Xiao, "Application of neural network decoupler in air-cushioned headbox control system," Chinese Control and Decision Conference, (2010), pp. 2738-2742.

      [27]. Pradeep Kumar Juneja, A.K. Ray & R. Mitra, "Model Predictive Control of Important Parameters in a Paper Machine Headbox", Indian Chemical Engineer, Vol. 53, No. 3, (2011), pp. 170-181.https://doi.org/10.1080/00194506.2011.696369.

      [28]. Keliang Zhou, Pengzhen Chen, "Neural PID decoupling control of air cushion headbox based on genetic algorithms", 2nd International Conference on Artificial Intelligence, Management Science and Electronic Commerce (AIMSEC) , (2011), pp. 4099 – 4102.

      [29]. Juneja Pradeep Kumar, Ray A.K., Mitra R., "Advanced Prediction Based Control Strategy Application on A paper machine Headbox", IPPTA Journal, Vol.23, No. 2, (2011), pp. 149.

      [30]. Y. J. Meng, B. Zhou, Y. Y. Liu, "The Design of Decoupling Control System for Air-Cushioned Head Box of Paper Machine Based on Siemens S7-PLC300", Advanced Materials Research, Vol. 457-458, (2012), pp. 1105-1110 (DOI: 10.4028/www.scientific.net/AMR.457-458.1105).

      [31]. M. Hamdy, I. Hamdan and M. Ibrahim, "Non-fragile bilinear state feedback controller for a class of MIMO bilinear systems," 8th International Conference on Computer Engineering & Systems, (2013), pp. 146-151.

      [32]. D. Sharma, R. Kumar and V. Verma, "Fuzzy tuned proportional integral derivative control of paper machine headbox," Annual IEEE India Conference (INDICON), (2015), pp. 1-4.

      [33]. Rajesh Kumar,Minisha Moudgil, "Multiple-Input Multiple-Output Paper Machine System Control Using Fuzzy-PID Tuned Controller", Proceedings of Fifth International Conference on Soft Computing for Problem Solving, Advances in Intelligent Systems and Computing (Springer), Vol. 437, (2016), pp. 145-155.https://doi.org/10.1007/978-981-10-0451-3_15.

      [34]. A. S. Bazanella, L. F. A. Pereira and A. Parraga, "A New Method for PID Tuning Including Plants Without Ultimate Frequency," IEEE Transactions on Control Systems Technology, Vol. 25, No. 2, (2017), pp. 637-644.https://doi.org/10.1109/TCST.2016.2557723.

      [35]. A. Nissinen, H.N. Koivo, T. Huhtelin, “Multivariable PI Control of Industrial Paper Machine Headboxesâ€, IFAC Proceedings Volumes, Vol. 29, No. 1,(1996), pp. 6686-6691.https://doi.org/10.1016/S1474-6670(17)58756-X.

      [36]. Kikiewich Z., and Panday, R.S.D., “Theory and design of paper machineâ€, Tara book agency varanasi, Vol. I, (1983).

      [37]. Md. ShamsuzzohaMoonyong Lee, "PID controller design for integrating processes with time delay", Korean Journal of Chemical Engineering, Vol. 25, No. 4, (2008), pp. 637–645.https://doi.org/10.1007/s11814-008-0106-2.

      [38]. G.D. Pasgianos, K.G. Arvanitis and A.K. Boglou, “Introduction to PID Controllers - Theory, Tuning and Application to Frontier Areas,†InTech, (2012), pp. 51-74 (DOI: 10.5772/2422).https://doi.org/10.5772/2422.

      [39]. Li, Pingkang, Peng Wang, and Xiuxia Du. "An approach to optimal design of stabilizing PID controllers for time-delay systems," Control and Decision Conference, (2009), pp. 3465-3470.https://doi.org/10.1109/CCDC.2009.5192414.

      [40]. M. Chidambaram, R. Padma Sree, “A Simple method of tuning PID Controllers for integrator/dead time processesâ€, Computers & Chemical Engineering, Vol. 27, (2003), pp. 211-215. https://doi.org/10.1016/S0098-1354(02)00178-3.

      [41]. Wang Q.-G., Lee T.-H., Fung H.-W.,Qiang B., and Zhang Y., “PID Tuning for Improved Performanceâ€, IEEE Transactions on Control System Technology, Vol. 7, No. 4, (1999), pp. 457-465.https://doi.org/10.1109/87.772161.

      [42]. Wen Tan, Jizhen Liu, Tongwen Chen, Horacio J. Morquez, “Comparison of some well-known PID tuning formulasâ€, Computers and Chemical Engineering, Vol. 30, (2006), pp. 1416-1423. https://doi.org/10.1016/j.compchemeng.2006.04.001.

      [43]. M. Chidambaram, “Design of PI controllers for integrator/dead time processes,†Hungarian Journal of Industry and Chemistry, Vol. 22, (1994), pp. 37-43.

      [44]. A. O'Dwyer, “Handbook of PI and PID Controller Tuning Rules†London: Imperial College Press, (2003). https://doi.org/10.1142/p277.

      [45]. K. J. Åström and T. Hägglund, “Automatic tuning of simple regulators with specifications on phase and amplitude margins,†Automatica, Vol. 20, No. 5, (1984), pp. 645–651.https://doi.org/10.1016/0005-1098(84)90014-1.

      [46]. Ogunwusi, A.A. and H.D. Ibrahim, "Advances in Pulp and Paper Technology and the Implication for the Paper Industry in Nigeria", Industrial Engineering Letters, Vol.4, No.10, (2014), pp. 3 – 11.

      [47]. Y. Cao, P. Yan, S. Lin, Z. Zhou and W. Zhang, "KF-based MPC for the cascaded headbox system in papermaking process," 36th Chinese Control Conference, (2017), pp. 4369-4374.

      [48]. Z. Zhou, S. Guo, S. Lin and W. Zhang, "Internal model control on hybrid headbox system," 36th Chinese Control Conference, (2017), pp. 4397-4401.

  • Downloads

  • How to Cite

    Saini, P., & Kumar, R. (2018). Stability analysis of paper machine headbox using a new PI(D) tuning technique. International Journal of Engineering & Technology, 7(2.6), 39-45. https://doi.org/10.14419/ijet.v7i2.6.10064