Maintaining the barrel temperature leads to desired shape and structure in the plastic injection molding industry. The ON/OFF controllers used in industries for control of the barrel heating system; are not giving satisfactory performance. It consumes more power, and chattering which lead to wear out the relay quickly. These problems are overcome by introducing a model based PID controller. The mathematical model is obtained from the barrel heating system and ZN tuned PID controller and fuzzy tuned PID controller are simulated on the barrel heating system. The results show that fuzzy tuned PID gives good transient and regulatory performances compared to ZN tuned PID controller.
Most of the processes in process industries are non-linear and injection molding system is an example of such non-linear process. Maintaining proper barrel temperature is the key control action required for accurate shape and structure of the products. The mathematical model of each zone of the barrel can be used to analyze the characteristics of the plastic injection. Traditional Proportional Integral and Derivative (PID) and I-PD controllers are selected for analyzing performance of different zones of barrel heating system. The simulation results show that I-PD controllers outperform the conventional PID controller with improved set point tracking and load disturbance rejection.
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