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Procedia Computer Science 107 (2017) 196 201

International Congress of Information and Communication Technology (ICICT 2017)

Modeling and Simulation of Temperature Control System of

Coating Plant Air Conditioner
Dong Jie
Shandong Youth University of Political ScienceKey Laboratory of Information Security and Intelligent Control in Universities of Shandong
JingShi Road 31699 of Jinan, Jinan 250103, China
* Corresponding author: dj@sdyu.edu.cn Tel.: 86-0531-58997383

Abstract

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The air conditioning system is an important external condition for coating production. Effectively controlling the air conditioning
system temperature could ensure the external conditions required during the production process of the coating line, thus to ensure
product quality. Due to the large temperature difference change rate of outdoor fresh air at some areas, the traditional PID control
method can't meet the temperature control requirements of the air conditioning system. In order to solve above problem, an actual
plant air conditioning model was built based on the structure features of the truck coating plant air conditioning. An intelligent
adaptive control algorithm was designed, then we performed matlab simulation on this model. Through the simulation, the
experimental results show that the adaptive algorithm can meet the control requirements.

Keywords: Plant air conditioner; Adaptive; Temperature control

1. Introduction

Coating material, coating process, coating equipment and coating management are the four main elements of
coating production, which complement each other. it improves the progress and development of coating process and
technology together. Coating quality directly influences the product quality, considering current fierce international
competition, how to improve the products' coating quality is a challenge for the major manufacturers. For solving
this problem, cluster control automation of the air conditioning unit is an important condition to ensure coating
quality. If the temperature of the coating plant air conditioning system could be effectively controlled, the external
conditions required during the production process of the coating line could be guaranteed, thus ensure the product
quality and improve international competitiveness.
In order to effectively control the temperature system of the air conditioner, firstly it's necessary to execute
modeling for the control system of the air conditioner. Maxwell and other persons established the empirical model of

1877-0509 2017 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of the 7th International Congress of Information and Communication Technology
doi:10.1016/j.procs.2017.03.078
 Dong Jie / Procedia Computer Science 107 (2017) 196 201 197

chilled water coil, which is used to predict the response of every control algorithm under different gain values1.
While Clark and other persons given the dynamic model of pipe and hot water coil 2. Professor w.J.cai3 and his
students of Nanyang Technological University also studied modeling of HVAC system, they established a simple
and accurate engineering model for cooling coil based on energy balance and heat transfer principle, which is helpful
for the real-time control and optimization of HVAC system. Comparing with the cooling coil module established in
Braun4 and Rabehl5, its simpler and no iterative operation is required. Many domestic scholars have made much
contribution in this field, Zhang Huajun established a steady-state distribution model of the heat exchanger, this
model considered the existence of metastable liquid area in the capillary, and the influence on heat exchange of fins
shape, bank of tubes and other elements, and proven by experiment, the result is reasonable 6. Wang Kangdi and
Wang Huaixin established dynamic distribution parameter models for the refrigerant at the single-phase and gas-
liquid two-phase areas of the heat exchanger respectively7.
Generally the plant air conditioner is combined air conditioner, which has one-level or multi-level heater.
Typically the control of heater of the plant air conditioner is traditional PID control. Also, there are other control
methods. For example, Zhang Qianru et al. studied the characteristics of the air temperature distribution in a large
space with stratified air conditioning system8. Li Gaojian, Nie Jianbin designed PID mathematical model and
algorithm of the central air condihoning temperature control based on genetic algorithm 9. Rehrl Jakob. and Dobbs
Justin. R. presented an predicting control algorithm for heating, ventilation, and air conditioning (HVAC) systems 10.
Due to different air conditioners, many people explored different control methods for the heater of the air
conditioning system.
Although many people have studied the models and control methods of air conditioning components and system,
because the plants are different, the detailed requirements on equipment are different and the actual operating
conditions are different for the plant air conditioning system, it's impossible to get a general model of the control
system, the specified conditions must be analyzed particularly.

2. Structure and working principles of air conditioning system

2.1. A brief introduction of the coating plant air conditioner

There are 2 floors in the car coating plant, its length and width are 260 and 50 respectively. The total
construction area of the plant is about 26000m. The first floor are machines and offices, the air conditioning system
consisting of 5 big assembled air conditioning machines is on the second floor. The air is sucked into the assembled
air conditioning machines, ater heating it is sended into the workshops every parts. Normally, Air demand of the
car coating plant is 280000m3/h.

2.2. Structure of air conditioning machines

Fig. 1. Structure diagram of the assembled air conditioning

back air

air in first heat Seco- air

gate filtra- mac- nd out
tion hine Filtra- spout gate
tion water

fan

In Fig.1, we know that when the air conditioning system is working, the two fans are running, fresh air from
outside enters the air conditioning system by the air in gate. First filtration system is able to clean air, then the air
198 Dong Jie / Procedia Computer Science 107 (2017) 196 201

enters into the heat machine, after that the air is filtrated again, then it enters spouting water system which can make
air wet to reach a certain humidity, at last the air enters the workshop through air out gate.

2.3 Principles of heat machine

The workshop is in north-east China, it is very cold in winter, usually under 30 degrees below zero. The hot water
owing high temperature and high pressure is used to heat the cold air. The hot-water valve position is adjusted to
control the quantity of the water, so, we are able to control the airs temperature. The system does not work in
summer. The temperature of the air conditioner is mainly controlled through regulating the feed water volume of the
hot water valve.

3. Modeling of air conditioning control system

At present, there are three methods to get process mathematical model. The first method is to get the process
mathematical model with mathematical derivation through the relation of static and dynamic material balance and
energy balance according to the internal mechanism of the process. The second method is to establish the
mathematical model of the controlled process through process identification and parameter estimation according to
the experimental data of process inputs and outputs. The third method is to combine the above two methods, that is
to say, determine the structure type of the model through mechanism analysis firstly, and then determine the
coefficients of the model through experimental data.
Because there are many uncertain factors within the room, it's impossible to correctly determine the mathematical
model of the air conditioning room temperature through process identification. The mathematical model of the
controlled process could be established through analyzing its mechanism according to the relation of material
balance and energy balance with mathematical description, this method has much universality. Because the space of
the controlled air conditioning room is typically large, the change of temperature and humidity is unreactive, there is
strong anti-interference capability by itself, and therefore we decided to establish the mathematical model of the
controlled process through mathematical derivation. At the same time, we know that the temperature and humidity
of the room are determined by many factors, such as the temperature and humidity of the outdoor atmosphere, the
structure and material of the external wall, the orientation of the room, the power of the heating equipment within
the room, the quantity of people and the working nature of the people, and these factors have their own uncertainties,
so it's difficult to get the accurate mathematical model of the air conditioning room temperature.

3.1 Flow characteristic of the regulating valve

The flow characteristic of the regulating valve is the relation between the relative flow of the regulating valve
and the relative opening of the regulating valve, and its function expression is:
Q l (1)
f( )
Qmax L
Relative flow Q/Qmax is the ratio of the flow under certain opening Q to the flow under full opening Q max of the
control valve. Relative opening l/L is the ratio of the travel under certain opening l to the travel under full opening L
of the control valve. The electric regulating valve selected in this project has equal percentage (logarithm) flow
characteristic, the function expression of the regulating valve is:
l
Q (
L
-1)
(2)
R
Qmax
According to the model of the electric valve we selected, R=30. In this project, the opening of the electric valve
is controlled by the voltage of 0-10V, the control voltage is expressed as U, so expression (2) is changed to:
 Dong Jie / Procedia Computer Science 107 (2017) 196 201 199

'U
Qmax * 30 1 0 (3)
Q(t )
30
DN25 electric regulating valve is used in this unit, the heating capacity of the valve under full opening is
150KW, and the vapor volume flowing through the valve is 0.15m 3/s, which is substituted into the above expression
(3), the result is
'U
Q(t ) 0.004 * 30 10 (4)

3.2 Characteristic of the heater

In this air conditioning system, 0.2Mpa vapor is used as the heat source of the heating air of the heating coil. Just
like the ordinary heat exchanger, it's considered that the heat dissipated from the heater is approximately equal to the
heat absorbed by air flowing through the heater, thus we establish the following equation:
1.2CPQK 't rCQS (5)
Where, Cp is specific heat at constant pressure of air; Cp=1.01KJ/kg*; Qk is the air volume flowing through
the heater m3/s; in this design, the combined air conditioning system is constant air volume air supply system,
Qk=6.5m3/s; r is the latent heat of vaporization of 0.2Mpa vapor, r=2164 kg; C is the specific gravity of 0.2Mpa
vapor, C=1.651kg/m3; t is the temperature rise of the air after flowing through the heater, in ; Qs is the vapor
flow entered into the heater, in m3/s
Substitute the above known quantities into the above expression (5), the result is:t = 450 Qs, the result after
Laplace transform is :
't ( s ) (6)
450
QS ( s )

3.3 Temperature characteristic description of the plant area

The volume of the plant air conditioning area is V (m3), the indoor temperature is tn ( ), the outdoor
temperature is tw (), the air supply temperature is ti (), the heat supplied into the room by the unit is Qi (kJ/h),
the air exchange rate of the air conditioning room is n(1/h); the heat generated by the machines and persons within
the plant is Qm (kJ/h); the specific heat at constant volume is Cv ( kJ/ m3*k), the parameter regulated is the indoor
air temperature tn ().
The heat dissipated from the air conditioning room is Qout, the heat taken by the return air is Qout,a, and the heat
permeated through the enclosure is Qout,b, i.e.:
Qout Qout,a  Qout,b nCvVt n  Qout,b (7)
The heat input into the air conditioning room Qin is the heat input through air supply Qin,n and the heat generated
by the machines and persons within the room Qp,
Qin Qin ,n  Q p nC vVt i  Q p (8)
The heat storage capacity of the indoor air W is:
W CvVt n (9)
Assuming that the enclosure and equipment don't store heat, then the equation of heat storage capacity change of
the air conditioning room is
dW (10)
Qin  Qout
dt
Substitute (7), (8), (9) into (10), the result is
dt n
CvV nCvVt i  Q p  nCvVt n  Qout,b (11)
dt
200 Dong Jie / Procedia Computer Science 107 (2017) 196 201

For simplifying calculation, assuming the enclosure doesn't transfer heat, ignoring the heat generated by persons
and equipment, then Qout ,b 0 , Q p 0 substitute it into (11), then the result is
dt n
nti  nt n (12)
dt
After Laplace transform, the equation (12) is:
t n ( s) 1 (13)
t i ( s) s
1
n
In the plant, the volume of the area controlled by one air conditioner is 2800m 3, the air supply volume of the
combined air conditioner is 50000m3/h, the air exchange rate per second of the room is: n 0.00496 , substitute it
to (13), the result is:
1 (14)
t n ( s) ti ( s)
202s  1
The distance between the air conditioning area and the unit is 50m, which are connected via air duct, the air
speed of the air supplied by the air conditioner is 7m/s, then there is about 7s delay of the room's air conditioner,
therefore the transfer function of the area to be conditioned is
1
t ( s) e 7 s t ( s ) (15)
202s  1
n i

3.4 Characteristic description of air conditioning unit

Substitute (4) into (6), then the temperature rise of the unit is: 't 1.8*30'U /10 , derive
'U /10
ti  tw 1.8*30 (16)
For simplifying calculation, assuming the outdoor temperature varies linearly with time tw 13sin((t  6)S /12)  7 , the
original point of t is 0.

4. Algorithm simulation of air conditioning system temperature control Structure

According to the transfer function (15), we established the simulation model as Fig. 2. If disturbance signal is
considered, the system will become unstable, tradditional PID control can not meet the requirements. In order to
stabilize the system, we designed a fuzzy pid adaptive control. An intelligent adaptive control algorithm is designed
in matlab to see Fig. 3.

Fig. 2. Simulation model Fig. 3. Fuzzy PID adaptive control simulation algorithm

According to the actual running state of the air conditioning, we use matlab to establish the fuzzy rules in Fig.4.
The Fuzzy PID adaptive control simulation result chart is in Fig. 5.
 Dong Jie / Procedia Computer Science 107 (2017) 196 201 201

Fig. 4. Fuzzy rules Fig. 5. Fuzzy PID adaptive control simulation char

5. Conclusions
In Northeast China, when people do actual engineering projects of factory air conditiong, due to the influence of
input temperature change and other disturbance, regular pid control method can not meet the demand of temperature
control system. So, in order to slove the temperature control problem, this paper explored the model of the
temperature control system and established the model of the coating plant air conditioner.
Also, we designed the fuzzy pid adaptive algorithm and carried out simulation on the model in matlab, through
the simulation result in Fig. 5., it could be seen that the control temperature value could reach the set temperature
value stably.
We have applied the algorithm to the actual control system, the actual temperature control system of the air
conditioning has been running for more than 3 years and it is in a good condition. Practice shows that the fuzzy
adaptive PID controller has been completely met the systems control demands. Obviously, the air conditioning
model established in this paper is very important and useful to study the temperature control of the clean plant air
conditioner.

Acknowledgements

This study is supported by A Project of Shandong Province Higher Educational Science and Technology Program
(12LN15).

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