Thermal response simulation for tuning PID controllers in a 1016 mm guarded hot plate apparatus

A mathematical model has been developed and used to simulate the controlled thermal performance of a large guarded hot-plate apparatus. This highly specialized apparatus comprises three interdependent components whose temperatures are closely controlled in order to measure the thermal conductivity of insulation materials. The simulation model was used to investigate control strategies and derive controller gain parameters that are directly transferable to the actual instrument. The simulations take orders-of-magnitude less time to carry out when compared to traditional tuning methods based on operating the actual apparatus. The control system consists primarily of a PC-based PID control algorithm that regulates the output voltage of programmable power amplifiers. Feedback parameters in the form of controller gains are required for the three heating circuits. An objective is to determine an improved set of gains that meet temperature control criteria for testing insulation materials of interest. The analytical model is based on aggregated thermal capacity representations of the primary components and includes the same control algorithm as used in the actual hot-plate apparatus. The model, accounting for both thermal characteristics and temperature control, was validated by comparisons with test data. The tuning methodology used with the simulation model is described and results are presented. The resulting control algorithm and gain parameters have been used in the actual apparatus without modification during several years of testing materials over wide ranges of thermal conductivity, thickness, and insulation resistance values.