An Introduction to Temperature Controls

Temperature control in manufacturing is a

quintessential part of proper product formation. If the
temperature slips above or below the ideal range needed
for a particular stage in a manufacturing process, the
results can be harmful—improperly adhered coatings, a
weakened base material, or an overall compromised
component—so it becomes increasingly important that
the manufacturer not only determine the proper temperature for each stage,
but also monitor the temperature inside the machine and receive appropriate
feedback.

Temperature controllers in manufacturing operations serve exactly this

function: they ensure that a machine is running properly by gauging the
temperature at different stages in the process and comparing the data to the
programmed temperature specifications. As a result, manufacturers can
quickly and easily discover temperature related machine malfunctions, and
treat them as necessary.

There are three general kinds of temperature controllers that are used to
monitor temperature during manufacturing processes: on-off, proportional,
and PID controls.

On/Off Temperature Controls

An on/off temperature control is the least expensive of the control types, and
also the most simple in terms of how it works. The control is either on or off—
if the temperature drops below a certain point, the control signals to the
machine to turn raise the temperature. Likewise, if a temperature goes above a
certain point, the control is triggered to tell the machine to lower the
temperature. A common example of on/off systems is a household thermostat.
When the temperature drops below a certain point, the controller triggers the
heater to raise the temperature back to the programmed value. With air-
conditioning it works the other way: if the temperature rises past a certain
point, the controller triggers the air-conditioner, dropping the temperature
back to the programmed norm.

On/off controls are often used in processes where the temperature change is
very slow, and precise control of temperature isn’t necessary.

Proportional Control
Unlike on/off controls, which only respond when a set limit is reached,
proportional controls are designed to respond to temperature change before it
slips out of the desired range. Essentially, proportional controls increase or
decrease the power supply as the temperature reaches its upper or lower limit,
or setpoint, which slows or speeds the heater and helps stabilize the
temperature.

The temperature range in which proportional controls either lessen or

increase the power supply to slow or speed heating is known as the
“proportional band.” If a temperature reaches the lower or upper setpoints,
the control then functions as a full on/off control—the temperature is either
turned fully on to increase the temperature, or fully off to drop the
temperature. When the temperature is within the proportional band, and the
power supply is decreased or increased, the heat is raised or lowered in
relation to how far the temperature is from the setpoint.

PID (proportional-integral-derivative) Control

This control combines proportional control with integral and derivative

control (PID). Operating within a proportional band in the same way a
proportional control does, a PID system has two added features that enhance
overall temperature regulation. The proportional feature allows the control to
react to the current circumstances and adjust accordingly. The integral value
takes into consideration the sum of recent events (in other words, past
proportional control rhythms) and the derivative value determines the
appropriate reaction based on the rate at which past rhythms have been
changing. Combined, the three use current data, past data, and the rate at
which data is changing to set a case-specific algorithm to control temperature.
By compensating for temperature error between the process variable and the
setpoint, a steady temperature can be maintained.

Considerations

When deciding which kind of control is best for a specific process, there are
several things to keep in mind. First of all, consider the kind of input sensor
(thermocouple or RTD) and the temperature range the process calls for.
Secondly, consider the form the ouput should be represented in:
electromechanical relay, SSR, or analog output. Thirdly, decide what kind of
control algorithm is necessary (on/off, proportional, PID). Lastly, consider the
number and type of outputs needed for the application, such as heat, cool,
alarm, and limit. Once these factors have been determined, it will be much
easier to determine which type of temperature controller is suited to a specific
application.