Model-based multivariable control of the drying of a thin sheet of fibres in a continuous infrared dryer

We developed an Internal Model Control (IMC) algorithm for drying a thin textile fabric, continuously passing through an electric infrared dryer, based on a reduced linear model of the drying dynamics. This model relates the controlled variables, the humidity and temperature of the web at the dryer outlet, to the manipulated variables, the electrical power supplied to the sources and the web speed through the dryer, and also to changes in the initial humidity of the web at the dryer inlet. The control algorithm was first tested by simulation using the model in regulation mode, and in set-point tracking mode, to vary the manipulated variables so as to maintain the controlled variables at their respective set-points when the inlet web temperature and humidity were changed. The performance under simulated operational conditions was compared to that of a conventional feedback proportional-integral (PI) controller coupled with a feedforward control. The IMC controller was then tested directly in regulation mode using a pilot scale infrared dryer, acting simultaneously on the manipulated variables, the emitter power and the web speed, to control the fabric temperature and humidity at the dryer outlet. The experimental results were compared with those from the above feedback-feedforward controller, on the pilot scale dryer. The results have indicated that the closed-loop stability of the process is assured simply by choosing a stable IMC controller. Also, such a controller does not require the design of specific compensators for the strong interactions between variables of the drying process.