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ocrdu
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Reflow Oven Control Techniqueoven control technique

I am developing a DIY Reflow Ovenreflow oven using a 10L common electric oven with quartz heating elements. Below it's shownis a graph that represents the oven's step response (open loop response):

enter image description here

In blue: oven's step response in open-loop.

In
In orange: theorical model using a first order with dead time (aproximationapproximation). The transfer funcionfunction of this orange curve is H:

enter image description here$$H=e^{-20s}\cdot\frac{1020}{150s+1}$$

Note the Simulink PID graph ploted as a response to the plant:   

enter image description here   

enter image description here

PID constants are (taken byfrom Simulink tunnertuner):   

enter image description here

The problem: 
In theory, the oven tunnedtuned with these PID values shoudshould converge the plant to follow the setpoint, which doesn't occursoccur in reality. The

The main reason this method doesn't work efficiently is probably because my plant havehas no other action to reduce the temperature than wait it to go below the setpoint (the oven is composed byof heating elements only, with nothing to cool it down). So

So, when the temperature overshoots the control enters in a state of "no return", because it's expected to have a correction, but it doesn't take place.

About the above, I have some questions for all of you guys thatwho understand much more about control thechniques:

  1. What method of control should be more suitable for this kind of problem (Itit seems a simple PID is not the best solution...)?
  2. How should I threattreat the overshooting in my PID (if it's the best technique to utilizeuse). Should I zero the integration and zero the proportional thermsterms when it overshoots?
  3. As shown above, my plant has a delay between the moment the heating elements are turned on and the moment the thermocoupler feelthermocouple feels the heat. Is the modeling of a "first order with dead time" suitable for this application? If so, is the delay already been countedaccounted for in the matlabMATLAB PID solution?

Thanks you all, hope I find some experienced people to help!

Reflow Oven Control Technique

I am developing a DIY Reflow Oven using a 10L common electric oven with quartz heating elements. Below it's shown a graph that represents the oven's step response (open loop response):

enter image description here

In blue: oven's step response in open-loop.

In orange: theorical model using a first order with dead time (aproximation). The transfer funcion of this orange curve is H:

enter image description here

Note the Simulink PID graph ploted as a response to the plant:  enter image description here  enter image description here

PID constants are (taken by Simulink tunner):  enter image description here

The problem: In theory, the oven tunned with these PID values shoud converge the plant to follow the setpoint, which doesn't occurs in reality. The main reason this method doesn't work efficiently is probably because my plant have no other action to reduce the temperature than wait it to go below the setpoint (the oven is composed by heating elements only, with nothing to cool it down). So, when the temperature overshoots the control enters in a state of "no return", because it's expected to have a correction, but it doesn't take place.

About the above, I have some questions for all of you guys that understand much more about control thechniques:

  1. What method of control should be more suitable for this kind of problem (It seems a simple PID is not the best solution...)?
  2. How should I threat the overshooting in my PID (if it's the best technique to utilize). Should I zero the integration and zero the proportional therms when it overshoots?
  3. As shown above, my plant has a delay between the moment the heating elements are turned on and the moment the thermocoupler feel the heat. Is the modeling of a "first order with dead time" suitable for this application? If so, is the delay already been counted in the matlab PID solution?

Thanks you all, hope I find some experienced people to help!

Reflow oven control technique

I am developing a DIY reflow oven using a 10L common electric oven with quartz heating elements. Below is a graph that represents the oven's step response (open loop response):

enter image description here

In blue: oven's step response in open-loop.
In orange: theorical model using a first order with dead time (approximation). The transfer function of this orange curve is H:

$$H=e^{-20s}\cdot\frac{1020}{150s+1}$$

Note the Simulink PID graph as a response to the plant: 

enter image description here 

enter image description here

PID constants are (taken from Simulink tuner): 

enter image description here

The problem: 
In theory, the oven tuned with these PID values should converge the plant to follow the setpoint, which doesn't occur in reality.

The main reason this method doesn't work efficiently is probably because my plant has no other action to reduce the temperature than wait it to go below the setpoint (the oven is composed of heating elements only, with nothing to cool it down).

So, when the temperature overshoots the control enters in a state of "no return", because it's expected to have a correction, but it doesn't take place.

About the above, I have some questions for all of you guys who understand much more about control thechniques:

  1. What method of control should be more suitable for this kind of problem (it seems a simple PID is not the best solution)?
  2. How should I treat the overshooting in my PID (if it's the best technique to use). Should I zero the integration and zero the proportional terms when it overshoots?
  3. As shown above, my plant has a delay between the moment the heating elements are turned on and the moment the thermocouple feels the heat. Is the modeling of a "first order with dead time" suitable for this application? If so, is the delay already accounted for in the MATLAB PID solution?
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Emanuel M
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Reflow Oven Control Technique

I am developing a DIY Reflow Oven using a 10L common electric oven with quartz heating elements. Below it's shown a graph that represents the oven's step response (open loop response):

enter image description here

In blue: oven's step response in open-loop.

In orange: theorical model using a first order with dead time (aproximation). The transfer funcion of this orange curve is H:

enter image description here

Note the Simulink PID graph ploted as a response to the plant: enter image description here enter image description here

PID constants are (taken by Simulink tunner): enter image description here

The problem: In theory, the oven tunned with these PID values shoud converge the plant to follow the setpoint, which doesn't occurs in reality. The main reason this method doesn't work efficiently is probably because my plant have no other action to reduce the temperature than wait it to go below the setpoint (the oven is composed by heating elements only, with nothing to cool it down). So, when the temperature overshoots the control enters in a state of "no return", because it's expected to have a correction, but it doesn't take place.

About the above, I have some questions for all of you guys that understand much more about control thechniques:

  1. What method of control should be more suitable for this kind of problem (It seems a simple PID is not the best solution...)?
  2. How should I threat the overshooting in my PID (if it's the best technique to utilize). Should I zero the integration and zero the proportional therms when it overshoots?
  3. As shown above, my plant has a delay between the moment the heating elements are turned on and the moment the thermocoupler feel the heat. Is the modeling of a "first order with dead time" suitable for this application? If so, is the delay already been counted in the matlab PID solution?

Thanks you all, hope I find some experienced people to help!