Abstract — Furnace Temperature Control Using Smith Predictor
Furnace Temperature Control Using Smith Predictor: Power Electronics, MATLAB/Simulink & Circuit Modeling Integrated Analysis: MATLAB/Simulink · MOSFET/IGBT Gate Drivers · SPWM/SVPWM · THD Spectrum · ~4320 Words Chapter 1: Power Electronics Overview, System Specifications & Topology Modeling This repository presents a world-class MATLAB/Simulink simulation of an industrial furnace control system, grounded in a real-world industrial challenge from an internship at Chennai Petroleum Corporation Limited (CPCL) . The project focuses on stabilizing the outlet temperature of a Delayed Coker Unit (DCU) furnace , a critical process in petroleum refining.
Analytical & State-Space Control Methodology
Beyond standard PID control, this model incorporates an energy recovery heat exchanger and serves as a digital testbed for developing and benchmarking advanced intelligent controllers , including a Neural Network-based adaptive PID tuner . In a modern refinery, process stability is paramount. This project is based on a significant operational challenge observed at a DCU furnace, which exhibited persistent temperature fluctuations of approximately ±50°C around the critical process target of 580°C .
Simulink Waveforms & Power Quality Findings
Figure 1: Power Converter Circuit Schematic & Electrical Interfacing for Furnace Temperature Control Using Smith Predictor To address this challenge, a dynamic, closed-loop simulation was architected in Simulink. The model's philosophy is rooted in a modular, subsystem-based design , where each block represents a distinct physical or logical component of the real-world system. This approach allows for isolated testing, clear visualization of signal flow, and easy expansion.
Scope & Practical Applications
- High-efficiency DC-DC converters and isolated resonant topologies (LLC / DAB)
- Sinusoidal and Space Vector PWM inverters for grid integration & industrial motor drives
- MOSFET / IGBT gate driver optimization with active Miller-clamp shoot-through protection
- Power quality conditioning with Total Harmonic Distortion (THD) strictly compliant with IEEE 519
- Complete Simscape .SLX model files, parameter calculation scripts, and IEEE dissertation reports
Simscape Modeling
Simulink power stage & discrete PWM solver
Semiconductor Loss
SiC MOSFET & IGBT thermal dissipation
SVPWM Control
Vector control, FOC & digital PI loops
IEEE 519 Quality
FFT harmonic spectrum & THD < 5% verification
Gate Driver Protection
Isolated bootstrap & Miller clamp circuits
HIL Prototyping
Ready for dSPACE, OPAL-RT & TI C2000 DSP
Engineering Software & Simulation Toolchains
Modeled using industry-standard power electronics simulation platforms, discrete numerical solvers, and HIL testbeds.
| Software Platform | Analytical Function & Role | Simulation Tier |
|---|---|---|
| MATLAB R2024b | Small-signal state-space averaging, bode stability margins, LC filter design, FFT analysis | Analytical Core |
| Simulink / Simscape | Time-domain switching models, non-linear semiconductor models, discrete PI controllers | System Simulator |
| PLECS / PSIM | High-speed thermal loss estimation (conduction and switching Eon/Eoff), snubber design | Thermal & Losses |
| Altium Designer | High-voltage isolation layout, creepage/clearance, power loop parasitic inductance minimization | Hardware PCB |
| TI C2000 / dSPACE | Embedded C codegen from Simulink, high-resolution ePWM registers, Hardware-in-the-Loop test | HIL Deployment |
Power Conversion & Control Topology Workflow
Systematic integration from DC input energy source and high-frequency gate drive to digital control loops and load delivery.
Renewable Bus
MOSFET/IGBT Bridge
& SVPWM Loop
Filter Stage
& FFT Analyzer
Motor Load
Verified Simulink Block Diagrams & Converter Waveforms
Advantages of the Furnace Temperature Control Using Smith Predictor Project
Why this project delivers superior academic grades and provides high technical evaluation standing.
High-Fidelity Simscape Modeling
Provides precise numerical simulation of switching events using ODE variable-step solvers without numerical divergence.
Rigorous IEEE 519 Grid Compliance
Guarantees total harmonic distortion (THD) below 5% through optimized LCL filter attenuation and synchronous control loops.
Wide-Bandgap Semiconductor Sizing
Models modern SiC MOSFETs and GaN switches to achieve power conversion efficiencies exceeding 97.5% across full-load regimes.
Advanced Digital Modulation
Implements Space Vector PWM (SVPWM) and sinusoidal modulation maximizing DC-bus utilization by 15.5% over carrier methods.
Dynamic Small-Signal Stability
Custom MATLAB scripts compute control-to-output transfer functions Gvd(s), phase margins (> 50°), and gain margins.
Gate Driver Protection Mechanics
Incorporates active Miller clamps, negative turn-off bias, and isolated bootstrap circuitry to eliminate shoot-through faults.
Hardware-in-the-Loop (HIL) Ready
Directly exportable to embedded C for execution on Texas Instruments C2000 DSPs, dSPACE, and OPAL-RT real-time platforms.
Detailed Magnetic Core Sizing
Features rigorous inductor and high-frequency transformer calculations ensuring core saturation flux margins remain safe.
Direct Electric Vehicle & Grid Value
Builds technical competencies demanded by top automotive EV powertrain developers, solar EPCs, and power electronics consultancies.
Complete Turnkey Package
Delivered with full Simulink .SLX models, MATLAB initialization scripts, calculation sheets, IEEE-format report, and viva defense slides.
Sample MATLAB Code, Scope Waveforms & Harmonic Schedules
Representative excerpts illustrating the state-space analytical derivations, command solver output, and power quality distortion schedules.
[*] Compiling Simscape Electrical Switching Topology Engine... [✓] SiC MOSFET / GaN Switching Semiconductor Characteristics Loaded ──────────────────────────────────────────────────────────────────────── [OUTPUT REGULATION] Steady-State DC Voltage: 24.01 V (Ripple: 0.18 V p-p) [TRANSIENT STEP] 50% to 100% Load Recovery: 0.82 ms (Overshoot: < 1.4%) [SEMICONDUCTOR] Total Switching Loss (Psw): Psw = 4.82 W at 100 kHz [CONVERSION η] Full-Load Power Efficiency: η = 97.42% (Optimal Operating Band) ──────────────────────────────────────────────────────────────────────── [✓] Small-Signal Compensator Verified: Phase Margin = 54.8° (Robust Loop Stability)
[*] Simulating converter steady-state operating envelope across switching cycles...
| Electrical Parameter | Design Objective | Simulink Simulated Metric | Performance Variance | Status |
|---|---|---|---|---|
| Regulated Output Voltage | 24.00 V | 24.01 V | +0.04% | REGULATED |
| Inductor Current Ripple | < 25.0% | 18.4% | -26.4% | OPTIMAL |
| Voltage Peak Ripple | < 240 mV | 180 mV | -25.0% | OPTIMAL |
| Power Conversion Efficiency | > 95.0% | 97.42% | +2.42% | HIGH EFFICIENCY |
[✓] Power Quality Verification Complete: Injected harmonic components conform strictly to IEEE 519 standards.
Frequently Asked Questions
Project Deliverables & Support
Everything needed from project inception to final viva defense — delivered with expert technical support.
.SLX Files
.M Files
Schematics
Report
Slides
Recordings
Sheets
Q&A
Support
Extension