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Modeling and control of 3D filament extruder

Article in Procedia Structural Integrity · January 2021

DOI: 10.1016/j.prostr.2021.10.109

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Structural Integrity Procedia 00 (2019) 000–000
www.elsevier.com/locate/procedia
ScienceDirect
Procedia Structural Integrity 33 (2021) 989–995

IGF26 - 26th International Conference on Fracture and Structural Integrity

Modeling and control of 3D filament extruder

Nassima Naboulsia*, Taoufik Hachimia, Fatima Majida, Rajae Rhanimb , Najat Zekritia,
Hassan Rhanima
a
Laboratory of Nuclear, Atomic, Molecular, Mechanical and Energetic Physics, Chouaib Doukkali University, El jadida, Morocco
b
Laboratory Study of Advanced Materials and Application, University Moulay Ismail, Meknes, Morocco

Abstract

This article allows a study of the electrical and control parts of a pilot extruder in order to transform polymers in
the form of filaments used by the 3D printer. The input materials used are often thermoplastics in the form of granules
or plastic waste. This paper aims are to design and manufacture the control part of a filament extruder in order to avoid
many existing problems such as a longer settling time, large time constants, and undesirable overshoot. The proposed
solution combined with a digital PID corrector, will have improvements in terms of time domain specification, set
point tracking and eliminating static error by ensuring optimal system stability.
The control method will be simulated and visualized using MATLAB\Simulink software. In order to proceed with
an analysis of the structural integrity of a high voltage electrical cable since the placement of the insulation part in a
HV electrical cable is made by an extrusion directly around the conductive core.
©
© 2021
2021TheTheAuthors.
Authors.Published by Elsevier
Published B.V.
by ELSEVIER B.V.
This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0)
This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0)
Peer-review under responsibility of the scientific committee of the IGF ExCo
Peer-review Statement: Peer-review under responsibility of the scientific committee of the IGF ExCo
Keywords: Extruder, PID corrector, stability, electrical cable;

*
Corresponding author. Tel.: ++212 633 26 26 08.
E-mail address: [email protected]

2452-3216 © 2021 The Authors. Published by ELSEVIER B.V.

This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0)
Peer-review Statement: Peer-review under responsibility of the scientific committee of the IGF ExCo

2452-3216 © 2021 The Authors. Published by Elsevier B.V.

This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0)
Peer-review under responsibility of the scientific committee of the IGF ExCo
10.1016/j.prostr.2021.10.109
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1. Introduction

The number of 3D printer users continues to grow, and between failed print waste and print media waste, plastic
recycling is emerging as an absolute necessity (Zhong & Pearce, 2018) . 3D printing technologies are widely used for
the production of polymer components using fused deposition modeling (FDM) (Mwema & Akinlabi, 2020). This
process allows to form a 3D print by depositing successive layers of extruded thermoplastic filament (Carneiro et al.,
2015). This is why we had the idea of designing a pilot-scale extruder to ensure the immediate availability of filament
spools to produce experimental specimens for our research and to satisfy the laboratory's equipment needs and to free
ourselves from the constraints related to the purchase of filament spools. In this context, various studies have been
conducted to satisfy this need (Nassar et al., 2019) (Nithya Priya et al., 2021).
In fact, the effect of temperature control of the heating system on the plastic pellets during the filament production
cycle is very important to maintain the reliability and conformity of the filaments to ensure that the raw material is
melted at a precisely controlled temperature to extract good quality filaments. In this paper, the temperature control is
achieved using a proportional-integral-derivative (PID) controller (Ang et al., 2005).
Therefore, temperature control must be performed in such a way that the static error tends to zero and to have a
system that responds as quickly as possible with the least amount of overshoot.
In this paper, we have identified and modeled the process of the extruder heating system that describes the most
representative behavior of the process in the form of a transfer function using the classical Broïda method (Ribeiro et
al., 2017). Then we have controlled the control loop by choosing the structure of the controller the most adapted to the
heating system and by calculating the parameters of this controller (Septiani et al., 2017) (Dehghani & Khodadadi,
2017) (Oo et al., 2018) in order to meet the greatest number of required constraints. The different simulations will be
established in the form of block diagrams using the SIMULINK software. And finally, by choosing the actions (P, I
and D) of the controller and by tuning the values to be applied to the parameters (kp, Ti and Td), we were able to
obtain the most comfortable response to the specifications.

Nomenclature

Kp is the proportional gain

KI is the integral gain
KD is the derivative gain
TI is the integral time constant
TD is the derivative time constant
K is the Static gain
τ is the delay
T is the time constant

2. Methods and Materials

The extruder of plastic filaments, as shown in Fig. 1, consists of a worm screw which turns inside a cylindrical
barrel. The screw allows to transmit the material to be extruded, often thermoplastic in the form of pellets or plastic
waste which are initially introduced in a hopper located at the end of the machine towards the head of the extruder
which is composed of another copper tube in the form of a chamber in which the material is collected and melted in
temperature by a heating system in order to pass in the nozzle to give the final form of the filament.
The extruder has two main functions: The first is to transport the material to be extruded and the second is to melt the
material from a temperature control process is performed by the controller PID which constitute three different control
factors; Proportional, Integral and Derivative; the Fig. 2 illustrates the block diagram of the extruder's thermal control
system.
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Fig. 1. Filament extruder.

Fig. 2. Heating system control block diagram.

2.1. PID corrector

The PID corrector controls the power supply and regulates the power delivered to the heating collars by comparing
the setpoint with the values measured by the sensor in order to maintain that the setpoint value is always reached. The
objective is to develop an optimal control and to determine the best control structure for the heating process by
improving performance in terms of stability, precision and speed.

1
C ( p) K p  KI  KD p (1)
p
 1 
C ( p) K p 1 
  Td p  (2)
 TI p 

where Kp is the proportional gain, KI the integral gain, KD the derivative gain, TI the integral time constant and, TD
the derivative time constant. The three terms have respectively the following roles on the system performance: The
first one ' The proportional term ' acts on the response time, the second one ' The integral term ' affects the static error
and the third one ' The derivative term ' ensures the speed of the system.
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2.2. Identification system

Since the transfer function of the heating collar is unknown in our case, there is a classical method for system
identification which consists in obtaining a mathematical representation of the real system based on the response
curve. However, the heating system is a linear system with an aperiodic index response, so we used Broïda's method
to assimilate the transfer function of the system to first order affected by a pure delay from the experimental index
response. The Broïda model is represented by a first order function as shown in (3).

Ke  p
H ( p)  (3)
1  Tp

With The key parameters K is the Static gain, τ is the delay and T is the time constant.

The ideal transfer function of a process is practically impossible to determine. It is then necessary to use a model
as representative as possible of this process. To identify a process, it is necessary to find, from experimental data, the
parameters that characterize this model.
For this reason, we made an experiment, as shown in Fig. 3, of measurement of the temperature of the heating
collar with a multimeter as a function of time supplied by a stabilized voltage of 220V. Then we presented these results
by a curve of the real system showing the variations of the temperature every 30s until the maximum temperature of
370°C in the Fig. 5. Then from the Table 1 of the parameters of the model.

Table 1. Model parameters.

Parameters Values
��
�� (E = 220V) 1,68
�
� � ���𝑡𝑡� � ���𝑡𝑡� 0,028 min
� � ����𝑡𝑡� � 𝑡𝑡� � 2,79 min

The resulting transfer function of the Broïda model is then of the form (4).

1, 68e 0,028 p
H ( p)  (4)
1  2,97 p

Fig. 3. Experiment to measure the temperature as a function of time.

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2.3. Experimental validation

The principle is to adjust the parameters τ and T so that the response curve of the model and the real curve of the
system have two common points judiciously chosen. The points usually used correspond respectively to 28% and 40%
of the final value of the temperature. After doing the block diagram of the open loop system on SIMULINK software,
as shown in Fig. 4, the response of the real system compared to the response of the system generated by the
identification method by Broïda model.
For the system in question, the identification using Broïda method got the best response, as shown in the Fig. 5,
the agreement of the two points of intersection (t1 and t2) is well verified.

Fig. 4. The block diagram of the open loop system.

Fig. 5. Real curve approximated by the Broïda model.

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3. Results

The PID controller is one of the most popular and widely used control techniques in industry. The main objectives
of this controller are to reach the temperature at a desired set point, to anticipate the control and limit overshoot in the
transient state, to cancel the position error in steady state and to increase the response time. So, to achieve these
objectives, we have realized as you can see on Fig. 6 the block diagram of the closed loop system on Simulink. In this
article, we have made the adjustment or setting of the parameters of the PID controller from the "Tune" option of the
PID block of the Simulink software, which allows to calculate the parameters Kp, Ki, Kd in Table 2. Thus, we adjusted
on the graph to have the desired response of the system in closed loop.

Fig. 6. The block diagram of the closed loop system.

Table 2. Control parameters of the heating system of the extruder (PID Controller).
PID Parameters Values

P 1,25947
I 0,42996
D 0,21164

Fig. 7. Corrected heating system response.

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Fig. 7 illustrates the simulation of the response curve for a temperature set point of 170°C after adjusting the
parameters Kp, Ki, Kd of the graphical corrector. As shown in Table 3 the heating system had a response time or rise
time of 2.72 minutes, which the temperature stabilizes and reaches the set point value after 4.13 minutes and with a
minimum overshoot of 1.95%. For these results, the system must reach the maximum temperature and must stabilize
as quickly as possible to produce reliable and conformable filament in the shortest possible time.

Table 3. Control parameters of the heating system of the extruder (PID Controller).
PID Parameters PID controller

Rise Time 2,72

Settling Time 4,13
Overshoot 1,95

4. Conclusion

This paper aims to adjust the temperature of the extruder heating collars. For this purpose, during the studied
heating period, first we identified the dynamics of the system in the form of a transfer function, then we regulated the
parameters of the PID temperature controller using SIMULINK software to have a better thermal comfort condition
in the extruder. The simulation results verified the remarkable accuracy of the proposed method to control the heating
system.
The goal of this study is to ensure the integrity and conformity of the filaments in order to have experimental
samples to study the behavior and damage of the insulating part of high voltage electrical cables.

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