Temperature Control in a Plastic Extruder Control System

  • Janko Petrovčič
  • Damir Vrančić
Part of the Advances in Industrial Control book series (AIC)


The chapter presents the development of a new control system for plastic extruders. The extrusion machine consists of a hopper (where the raw plastic material is stored), a large screw (within a barrel) that transports the plastic material up to the die, and heating and cooling zones distributed along the barrel. In order to satisfy all the requirements four control blocks had to be developed: temperature control, parison control, hydraulic control, and sequence control. The chapter concentrates on temperature-control problems, since a precise temperature profile along the barrel is very important for maintaining high quality plastic. The problem is addressed using auto-tuning and adaptation algorithms for each of the 17 PID controllers activating the heating/cooling zones along the barrel. The auto-tuner uses an original PID tuning method, referred to as the “Magnitude Optimum Multiple Integration (MOMI)” method, which is based on a process step response and multiple integrations of the time response. The adaptation algorithm is based on assessing the behaviour of the process. It relies on four detectors: an overshoot detector, an oscillation/decay detector, a long-tail detector, and a noise detector. The control blocks have been realised on standard modular programmable logic controllers (PLC) and tested on an industrial plastic extruder. The chapter concludes with a discussion of problems and limitations in applying theory to solve this control problem.


Control Loop Controller Parameter Adaptation Algorithm Temperature Control System Process Gain 
These keywords were added by machine and not by the authors. This process is experimental and the keywords may be updated as the learning algorithm improves.



The authors would like to thank to the engineers from the companies INEA, d.o.o., Mitsubishi Europe, and Techne for their contributions to the project. The authors would also like to thank the Slovenian Research Agency for its support under Grant No. P2-0001.


  1. 1.
    Åström KJ, Hägglund T (1995) PID Controllers: Theory, Design, and Tuning, 2nd edn. Instrument Society of America, Research, Triangle Park Google Scholar
  2. 2.
    Barber-Colman (2012) Invensys Eurotherm. Google Scholar
  3. 3.
    Cipet (2012) Plastics industry—Statistics. Google Scholar
  4. 4.
  5. 5.
    Plastics (2012) Injection molding machine manufacturers. Google Scholar
  6. 6.
  7. 7.
    Rake H (1987) Identification: transient- and frequency-response methods. In: Singh MG (ed) Systems and control encyclopedia; theory, technology, applications. Pergamon Press, Oxford Google Scholar
  8. 8.
    Rauwendaal C (2001) Polymer Extrusion, 4th edn. Hanser Gardner, Munich Google Scholar
  9. 9.
    Ravi S, Balakrishnan PA (2011) Stable self tuning genetic fuzzy temperature controller for plastic extrusion system. International Journal of Reviews in Computing 5:21–28 Google Scholar
  10. 10.
    Rockwell Automation (2012).
  11. 11.
  12. 12.
    Strejc V (1960) Auswertung der dynamischen Eigenschaften von Regelstrecken bei gemessenen Ein- und Ausgangssignalen allgemainer Art. Zeitschrift für Messen, Steuern, Regeln 3(1):7–10 MathSciNetGoogle Scholar
  13. 13.
    Taur JS, Tao CW, Tsai CC (1995) Temperature control of a plastic extrusion barrel using PID fuzzy controllers. In: Proceedings of the 1995 International IEEE/IAS Conference on Industrial Automation and Control, Taipei, pp 370–375 Google Scholar
  14. 14.
    Vrančić D (1995) A new PI(D) tuning method based on the process reaction curve, report no DP-7298, Jožef Stefan Institute, Ljubljana Google Scholar
  15. 15.
    Vrančić D, Strmčnik S, Juričić Ð(2001) A magnitude optimum multiple integration tuning method for filtered PID controller. Automatica 37:1473–1479 zbMATHCrossRefGoogle Scholar
  16. 16.
    Vrančić D, Juričić Ð, Strmčnik S, Hanus R (1999) Closed-Loop Tuning of the PID Controller by Using MOMI Method. In: Proceedings of the 1999 American Control Conference, San Diego, pp 3352–3356 Google Scholar
  17. 17.
    Yusuf I, Iksan N, Herman NS (2010) A Temperature Control for Plastic Extruder Used Fuzzy Genetic Algorithms. In: Proceedings of the 2010 International MultiConference of Engineers and Computer Scientists, Hong Kong, pp 1075–1080 Google Scholar

Copyright information

© Springer-Verlag London 2013

Authors and Affiliations

  • Janko Petrovčič
    • 1
  • Damir Vrančić
    • 1
  1. 1.Department of Systems and ControlJožef Stefan InstituteLjubljanaSlovenia

Personalised recommendations