Heat Exchanger Temperature Control (Simulink)

Model-based temperature control design for a heat exchanger using:

• Open-loop FOPDT + dead time modelling
• PI feedback control (tuned vs untuned comparison)
• Feedforward disturbance compensation (delay sensitivity study)
• Combined Feedforward + Feedback architecture (industry-style solution)

Built and simulated in MATLAB/Simulink R2025b.

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1) System Model

The process is modelled as first-order plus dead time (FOPDT) for both the plant and disturbance path.

• Plant (temperature path): Gp(s) = 1 / (21.3 s + 1) with delay
• Disturbance path: Gd(s) = 1 / (25 s + 1) with delay

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2) Control Architectures Implemented

A) PI Feedback Control

PI controller tuned to improve setpoint tracking and reduce steady-state error. Includes ITAE performance index computation for objective comparison.

B) Feedforward Disturbance Compensation

Feedforward designed to cancel measured disturbance influence through model inversion/ratio and delay alignment.

C) Combined Feedforward + Feedback

Feedforward handles predictable disturbance effects; feedback corrects model mismatch and unmeasured disturbances.

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3) Key Results (Plots)

Open-loop response

Tuned vs Untuned PI

Feedforward delay sensitivity (20.3s vs 25.3s)

Combined control response

Comparison: plant vs feedback vs feedforward vs combined

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4) How to Run

1. Open the Simulink models in /sim
2. Run simulations and view scopes/plots

Requirements

• MATLAB R2025b
• Simulink
• Control System Toolbox (recommended)

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5) Documentation

• Model details: docs/model.md
• Control design notes: docs/control_design.md
• Results and discussion: docs/results.md
• Full report PDF: report/IPC_assignment_Hakeem.pdf