Precise Temperature Control through Thermoelectric Cooler with PID Controller
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1 Precise Temperature Control through Thermoelectric Cooler with PID Controller Mayursinh D. Thakor, S. K. Hadia, and Ashok Kumar Abstract Avalanche Photo Diode (APD) has wide applications in remote sensing electro optical payloads. APD s gain is highly sensitive to temperature. Hence, temperature of the APD needs to be controlled to get accurate & steady results. This paper proposes a Peltier element based Thermoelectric Cooler (TEC) system for precise temperature control. The design electronics system provides precise control by using PID based close loop system. A commercial available integrated TEC controller MAX1978 is considered for this purpose. This controller provides heating or cooling based on error between set temperature and measured temperature. A negative temperature coefficient (NTC) based Thermistor element is used for temperature measurement. This element is used in a bridge network and provides continuous feedback to controller. Developed electronics is evaluated with simulated load. With hardware test results, short term stability of 70mK is achieved. Peak power drawn by Peltier element is measured nearly 4W. Keywords Thermoelectric Cooler, Peltier element, PID controller, Thermistor. I. INTRODUCTION An Avalanche Photo Diode (APD) has wide applications in remote sensing electro optical satellite payloads like LASER based ranging systems, photon counting receivers. Its avalanche multiplication effect is highly sensitive to temperature. Hence, its temperature needs to be maintained to get accurate and steady results. An ambient temperature and thermal load used to vary with time; Peltier based Thermoelectric Cooler (TEC) is generally used for this purpose. Peltier element can perform heating and cooling both. For higher accuracy, PID (Proportional, Integral and Derivative) based close loop temperature control is considered. PID system has four corner points (2 poles and 2 zeros). Thermistor with negative temperature coefficient (NTC) is used as temperature sensing element. An error signal, which is difference of sensed temperature and set point temperature, is considered for driving PID controller. PID controller has been implemented on MAX1978 module, which can operate anywhere from -40 C to +85 C. Final design achieves temperature stability of 70mK and maintains the same for long time. Mayursinh D. Thakor is pursuing his Masters of Technology (M.Tech) in the department of Electronics & Communication, CSPIT, Charotar University of Science and Technology (CHARUSAT University), Changa, Anand, India. As a part of his M.Tech dissertation, he is currently working at Space Applications Centre (SAC), Indian Space Research Organization (ISRO). ( mayursinh7877@gmail.com, mayursinh@sac.isro.gov.in) S. K. Hadia is an associate professor in the department of Electronics & Communication, CSPIT, Charotar University of Science and Technology, Changa, Anand, India. ( skhadia.ec@charusat.ac.in) Ashok Kumar is a Scientist in SFED/SEG/SEDA department at SAC-ISRO, Ahmedabad, India. ( ashokkumar@sac.isro.gov.in) Section-II provides brief details of design elements like APD, TEC, PID controller and thermistor. Section-III provides design details. Section-IV provides implementation and hardware test results. II. DESIGN ELEMENTS A. Avalanche photo diode An avalanche photo diode (APD) is a highly sensitive semiconductor electronic device that exploits the photoelectric effect to convert light to electricity. APD gain i.e. avalanche multiplication effect varies strongly with the applied reverse bias and temperature, it is always necessary to control the reverse voltage and temperature to keep a stable gain. APDs therefore are more sensitive as compared to other semiconductor photo diodes [1]. Dependency of APD on temperature is described below by equation [2], ( ) (1) I APD is the APD output current, I d is the detected photo-current, I s is the saturation dark current, q is the electron charge, V is the device bias voltage (negative for reverse bias), k is Boltzmann's constant, and T is the Temperature in degree Celsius ( C). B. Thermoelectric Cooler(TEC) TECs have several advantages for regulate the temperature like high precision and stability, quick response time, a decent set-point temperature range, and simplicity of structural design with no moving parts. TECs are small in size and very low weight, reliable, independent from noise and friendly nature to environment. However, when comparing with temperature regulation approaches based on heat sinks for applications requiring specially for high thermal power output, TECs have many challenges like low thermal power, low efficiency, and high cost of TEC controllers. Hence, all characteristic values of TECs have been carefully chosen [3]. TEC stabilizes the temperature of various passive components in various equipments like various photo diodes. Peltier effect based TECs are generally used. TEC has two ceramic plates with the Peltier elements sandwich in between. Junctions of dissimilar metal are heated or cooled depending upon the direction in which an electric current passing through them. This effect is called as Peltier effect [4].
2 specified over the -40 C to +85 C temperature range. The thermally enhanced QFN-EP package with exposed metal pad used to minimize operating junction temperature for fiber optic laser modules. It is generally used for Laser-Diode Temperature Control, Fiber Optic Laser Modules etc. [11]. Fig. 1. Block diagram of Thermoelectric Cooler [7] There are two possible options for selecting the proper TEC configuration. One is with Low voltage and High current output and other is with High voltage and Low current. Choosing the right flavor is the primary deciding factor. It is usually easier to use high voltage, low current systems because most power supplies can source higher voltages rather than higher currents [5] [6]. The block diagram of TEC is shown in Fig. 1. The second important factor in selecting a TEC is its power rating. Without a proper selection of power rating for the TEC, the entire system will struggle to alter the temperature of the given object. It may also become very sluggish and take a long time to produce significant and desire changes in temperature rating. The system may even become less responsive and fail completely. It is also very important to choose a TEC that will provide the necessary power dissipation. Driving the TEC at its limit puts strain on the TEC and can even be less efficient then driving at a lower current [7]. C. PID controller Proportional, Integral and Derivative controller (PID controller) has wide applications in modern industry, controlling more than 95% of closed loop systems. This basic control loop feedback system can be implemented with hardware using various amplifiers or can be implemented through software tool. For the hardware implementation of PID controller, TEC controller MAX1978 is being used [8]. P element is for proportional to error signal at instant t, which is called present error. I element, is for proportional to the integral of error signal up to the instant t, which can be also interpreted as the accumulation of the past error. D element is for proportional to the derivative of error signal up to time instant t, which is called future error [9]. Various tuning methods would be used for automated tuning of PID like Ziegler Nichols Method and Cohen-Coon Method [10]. One commercial off the shelf PID controller MAX1978 (Maxim made) is considered for implementation. The MAX1978 is the small, very accurate, complete single-chip temperature controller for Peltier Thermoelectric Cooler (TEC) modules. This is an integrated TEC controller, which provides driving along with PID control. The MAX1978 is D. Thermistor The popularity of thermistor is mainly due to their sensitivity, size, and cost. Thermistors change several hundreds of ohms per degree Celsius. Most thermistor beads are the size of match heads, or smaller, allowing them to be precisely mounted to the device being cooled. The resistance value of a thermistor decreases in nonlinear manner with increasing temperature. However, this property and the narrow temperature sensing range (typically 50 C maximum) are limitations. The temperature-resistance relationship can be approximated using the equation given below [5]. (2) T =Temperature (in C), R = Resistance (Ω), C 0, C 1, C 2, C 3, C 4, C 5, and C 6 are temperature coefficients. C 0 = , C 1 = , C 2 = , C 3 = , C 4 = 4.524, C 5 = , C 6 = III. DESIGN DETAILS The block diagram of design is given in Fig. 2. For Highly sensitive APD temperature measurement, Thermistor is used. Thermistor has negative temperature coefficient (NTC). Reference temperature or set point temperature can be given by potentiometer or digital-to-analog converter (DAC) [6]. Both values are applied to the integrated temperature controller MAX1978. Difference between Actual sensed temperature and set-point temperature is called as the error signal. Fig. 2. Design Block diagram
3 There are many predefine functions in MAX1978 which are Chopper-Stabilized Instrumentation Amplifier, Integrator Amplifier, and Undedicated Chopper-Stabilized Amplifier. They are useful for achievement of constant and steady temperature. Peltier element is connected with MAX1978 for heating and cooling of APD. Thermistor continuously senses current temperature of APD and gives it as a feedback to MAX1978 with reference temperature. TECs can be crudely modeled as a two-zero, two-pole system. From the two poles, the second pole potentially creates an oscillatory condition because of the associated having 180 phase shift. PID controller has two additional zeros, which are used to cancel the TEC and integrator poles. Adequate phase margin can be achieved near the frequency of the TEC s second pole when using a PID controller [11].Equation for PID controller is described below, Fig. 3. Functional block diagram of PID Controller ( ) * ( ) ( ) ( )+ (3) e(t) = the error signal, c(t) = the output signal, K p = the proportional gain, K i = 1/T i = the integral gain, K d = T d = the derivative gain. The functional block diagram of PID controller is shown in Fig. 3[9]. The Proportional action in a PID controller is to improve response time and reject disturbance of error signal. Proportional controller can stabilize only 1 st order unstable process. It cannot stabilize higher order processes. The main limitation of plain proportional control is that it cannot keep the controlled variable on set point. The integral action in a PID controller is the sum of the instantaneous error over time and gives the accumulated offset that should have been corrected previously. The integral term accelerates the movement of the process towards set point and eliminates the residual steadystate error that occurs with a pure proportional controller. Hence, it is less responsive. The Derivative action in a PID controller predicts system behavior and thus improves settling time and stability of the system by preventing overshoot and eliminating oscillations [10]. Fig. 4. Functional details of MAX1978 [11]
4 Undedicated Chopper stabilized amplifier in MAX1978 is intended to provide a proportionally temperature analog output with respect to input given. The thermistor voltage is typically connected to the undedicated chopper amplifier through the included buffers. It can be used as thermistor voltage monitor. The output monitor voltage is not showing precisely linear, because of non-linearity of thermistor [11]. TEC generally has stronger heating capacity than cooling capacity because of the effects of wasted heat [5]. Frequencies of poles and zeros are set to be at 0.16 Hz, 0.3 Hz and 15Hz, 30Hz respectively with respect to resistors and capacitors [11]. IV. IMPLEMENTATION AND RESULTS Fig. 5. Application Circuit diagram of MAX1978 [11] The functional block details of MAX1978 are shown in Fig. 4. Application circuit diagram is shown in Fig. 5. The power stage of the MAX1978 TEC temperature controllers consists of two switching buck regulators which are operated together for control TEC current directly. This configuration provides a differential voltage across the TEC, which used is allow bidirectional TEC current for controlled heating and cooling. Chopper stabilized instrumentation amplifier in MAX1978 has two inputs. One input is an external thermal sensor, typically a thermistor, which is connected to one of the amplifier s inputs. The other input is connected to a reference voltage that represents the temperature set point. This temperature set point can be derived from a resistor-divider network. The included instrumentation amplifier provides low offset drift needed to prevent drift of the temperature set-point with ambient temperature changes. The instrumentation amplifier output is proportional to 50 times the difference between the set-point temperature and the current TEC temperature. This difference is commonly referred to as the error signal as we discussed earlier. For getting best temperature stability purpose, derive the set-point voltage from the same reference that drives the thermistor. This configuration is called a ratiometric or bridge connection. The function of bridge connection is to optimize temperature stability by eliminating reference drift as an error source. Errors at reference are nullified or neglected because they affect the thermistor and set point equally. An integrator amplifier in MAX1978 generally controls the thermal-control-loop dynamics. They are set by the integrator amplifier input and feedback components. The major hardware parts in the system are Thermoelectric Cooler Assembly and TEC Controller MAX1978. Input DC supply of 5.6 V, 1A is applied to MAX1978. Most of the power is consumed by TEC. Fig. 6 shows photograph of test system. Peak power drawn by Peltier element is measured around 4W. Thermoelectric Cooler is stuck with Aluminum (Al) plate with the help of thermal material. Cooling fan is connected the other side of Al plate for removing heat. This acts as a heat sink. Thermistor is fitted on cooling side of Peltier element. Physically assembled connection set of entire system is show in Fig.6. Cooling fan Peltier Element TEC Fig.6. Photograph of entire Assembled System For measurement purpose, set temperature is kept near to 25 C. Lab temperature is measured around 30 C to 31 C. Fig. 7 shows time wise profile of measured temperature. Fig. 8 shows steady state temperature profile (zoomed part of Fig. 7). Kindly note that achieved short term stability is 70mK. System became stable after around 178 seconds and steady temperature value is nearly C which is our stable point temperature. We can change the set point temperature by changing the value of resistors in ratiometric connection or Thermistor Bridge.
5 thermistor as feedback element is used. This is evaluated with simulated load. Short term temperature stability of 70mK is achieved. In future, same design will be evaluated with APD in application conditions. ACKNOWLEDGMENT Fig. 7. Measured Temperature of Peltier System The authors are thankful to J. Ravishankar, Head, HRDD, SAC-ISRO for the opportunity. The authors are thankful to Sanjeev Mehta, head, SFED, SEDA for his valuable support. The authors are also thankful to Shri Saji Kuriakose, Dy. Director, SEDA and Shri Arup Roy Choudhury, GD, SEG for their constant encouragement and keen support during the work. The authors are also thankful to CHARUSAT University for their constant support. REFERENCES Fig. 8. Measured steady state temperature of Peltier System (zoomed part of Fig. 7) Given result has been taken at air-conditioning (AC) lab environment in absence of APD. APD is simulated with thermal load of ambient environment (room temperature AC condition with good speed air flow). Measurement with APD requires precise ambient condition. Variation in surrounding temperature condition may affect performance. Hence, in future, APD will be tested with same setup in clean room condition. V. CONCLUSION [1] Online: [2] Characterization of Advanced Avalanche Photodiodes for Water Vapor Lidar Receviers. Tamer F. Refaat, Gary E. Halama, and Russell J. De Young. National Aeronautics and Space Administration, Washington, DC : Technical Publication, NASA CASI (301) , July [3] Li, G. L. Thermoelectric cooler details, Analog technologies, online: [4] Thermoelectric Coolers Basics. TEC Microsystems. Retrieved 16 March [5] Application Note #14: Optimizing TEC Current, ILX Lightwave Photonic Test and Measurement, PO Box 6310, Bozeman, MT 59771, [6] Optimizing Thermoelectric Temperature Control Systems, Wavelength Electronics, PO Box 865, Bozeman, MT 59771, [7] Frequently asked questions about our product,tellurex. Retrieved 16 March [8] Intriduction: PID controller design, University of michigan. [9] Araki, M. PID control. Japan : Kyoto universiy. [10] Westcott Tim, PID without PhD, Embedded Systems Programming, pp , October [11] Integrated Temperature Controllers for Peltier Modules, Sunnyvale, CA: Maxim Integrated Products, 120 San Gabriel Drive, Close loop based precise temperature control electronics is design for APD system. Integrated PID controller with
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