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Development of Dental Autoclave Control

System Using Fuzzy Logic and Optimized PID
Algorithm
Article August 2013

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Ahmed Farag Seddik

Helwan University

Nahda University in Benisuef

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International Journal of Engineering Research & Technology (IJERT)

ISSN: 2278-0181
Vol. 2 Issue 8, August - 2013

Development of Dental Autoclave Control System Using Fuzzy Logic

and Optimized PID Algorithm
A. Elgarhy 1, M. T. Alwaked 2, S. Aboelkheir 2, A. F. Seddik * 2
1: Electronics and Communication Department, 2: Biomedical Engineering
Department, Faculty of Engineering, Helwan University, Egypt,
*: Guide
Abstract

Figure1. Dental autoclave.

Water steam heating process is not immediate in any
case, and needs time to reach thermal equilibrium; this
time varies according to the size of the autoclave, the
quantity and quality of the material to be sterilized. So the
time of sterilization is important and must be considered
in the treatment cycle.
Scientific European and American community have
fixed and defined three temperatures [3] 115C, 120C
and 134C relative exposures for different materials and
their resistance to temperature. Cycles at 125C for 15
minutes of sterilization is a middle cycle for sterilization
of any metal instruments. This is the used sterilization
cycle in this study.Steam [4] is an effective sterling for two
reasons. First, saturated steam is an extremely effective
carrier of thermal energy. It is many times more
effective in conveying this type of energy to the item than
is hot (dry) air. Steam, especially under pressure, carries
their thermal energy very quickly, while hot air does so
very slowly.
The second reason is that the steam is an effective sterling
because any resistant, protective outer layer of the
microorganisms can be softened by the steam, allowing
coagulation of the sensitive inner portions of the
microorganism.
Steam sterilization requires four conditions:
adequate contact, sufficiently high temperature, correct
time and sufficient moisture. Although all are necessary
for sterilization to take place, sterilization failures in
clinics and hospitals are most often caused by lack of
steam contact or failure to attain adequate temperature. It
also fails because it requires strict adherence to time,
temperature and pressure settings. Many temperature
control systems were used in order to improve sterilization

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Sterilization process is widely used in the medical

field.Dental autoclave is the most popular devicethat is used
in sterilizing process. The heat control system of the
sterilization process suffers from problems related to
undesirable overshoots and longer settling time and
oscillations. The purpose of this work is to obtain the best
control system to solve these heat control problems through
building a model for the dental autoclave heat control system
and a simulation of different control systems, different control
systems were applied to the model and evaluated to select the
best system to improve the performance of a dental autoclave.
Our experimental results have shown that the fuzzy-PID
control system reached the desired temperature of
sterilization faster and more accurate than other systems,
also the average error of the desired temperature is 0.05 C
which is very small compared to average errors of other
control systems.
Keywords:Dental autoclave modeling, Sterilization heat
control, Fuzzy logic application, Particle swarm optimization.

1. Introduction
Sterilization process [1] through saturated water vapor
(steam) is widely used in pharmaceutical, food industries
and medical fields. The sterilization process purpose is to
eliminate micro-organisms of any nature. Dental autoclave
[2] has one sterilizing cycle for a perfect and quick
sterilization of different materials used in hospital and/or
dental surgery. It is made of a boiler, a door, a gasket and
a timer to count sterilizing time, a sensor to check
temperature, and a safety valve for steam exhaust in case
of over-heating as shown in figure 1.

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2. PROPOSED METHOD

The heater system block simulation model depends

upon the fact that the transfer of energy as heat can take
place via conduction processes. Conductionis the transport
of thermal energy through an object by a series of
collisions between adjacent atoms, molecules, or
electrons. Heat flow [11] is represented by equation (2.1).
[ K heater (t ) * Qh (t ) K sys (t )Tsys (t )] * A / L
Heat flow = (2.1)

Where K heateris the thermal conductivity of heater

substance [m o C/ (J /s)], K sys is the thermal conductivity
of water inside autoclave [m o C/ ( J/s) ], Ais the cross
sectional area of the autoclave (meters2 or feet2),Tis
temperature ( o C or o F), Lis thickness (meters or inches),
Q h is the heat transferred to the water by the heater.
So heat transfer depends upon thermal conductivity of
the heater material, the equation could be re-written as:
Energy transferred=heat flow*time

The overall dental autoclave temperature control

system model is represented in figure 2. The model
consists mainly of the temperature controller system block
and the heater system of dental autoclave block which
controls the temperature inside the dental autoclave and
(2.6)
the safety valve to prevent explosion in case of
overheating. The inputs to the temperature controlled
system block are the sterilization temperature and the
temperature error (except ON/OFF it is forward system);
and the inputs to the heater system block are energy
supplied to the heater as a function of time and a constant
representing the desired temperature (sterilization
temperature).The output of the overall system is actual
internal temperatures inside the autoclave with time. (2.7)

(2.2)

Energy transferred/time=heat flow (2.3)

Energy transferred to water / time=
(2.4)

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efficiency PID temperature control system, fuzzy

temperature control system, and fuzzy PID temperature
control system. But evaluation of these systems is very
difficult, as it needs a simulation model, this work
introduces that model.
The system model simulation [5][6] aims to
predict the autoclave inner temperature behavior [7],
mainly the time period when the system reaches the
desired temperature. This is the period when there is no
more commonly losses occur by overheating. Modeling
[8] should pursue simplicity and accuracy, but in general
they are conflicting characteristics. Our first attempt led to
complex models that treated the problem with distributed
heat transfer [9][10] ruled by partial differential equations
and thermodynamics basics [12][13][14]. But those
models were unsuited to use with regular control theory.
Searching for a simpler model, it was decided to use a
model ruled by ordinary differential equations, depending
upon quantity of energy transferred from the heater to the
liquid per unit time. Microsoft excel software is used to
import data from MATLAB/Simulink [15] to analyze the
controller by studying the response generated from the
modeling and simulation of the controller, The difference
between the desired temperature and output feedback [16]
temperature is passed as input into the controller
subsystem.

( K hQh KW TW )

Where K h is a constant that depends on the material the

heater is built and other factors, K wis a constant depends
on the specific heat of water and other factors, Twiswater
temperature, K wis a constant that is directly proportional
to specific heat difference between heater and water(K hw).
(2.5)
K K (T T )
W

hW

dE / dt K h (t ) * Qh (t ) KW (t )TW (t )
C h (t) and C w(t) are time dependent because the closer the
water
temperature
gets
to
the
desired
temperature(temperature of sterilization), the less
influence the heater has over the water, So C h approaches
zero and it is exactly zero if water temperature is the same
as heater temperature.

dE K h (t )Qh (t )dt KW (t )TW (t )dt

Using first law of thermodynamics:

+-

E =E system +E surroundings= 0

Sterilization
temp.
Temperature
controller
system block

Heater
systemblock

By integration

Output

T(t)
control

Figure 2.The overall dental autoclave model.

E (t ) E0 K h (t )Qh (t )dt KW (t )TW (t )dt

(2.9)
Safety valve

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(2.8)

Where E0 is the initial energy contained in the water.

Considering outside surface effect K out (surroundings), so
the heater simulation model is implemented using

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International Journal of Engineering Research & Technology (IJERT)

ISSN: 2278-0181
Vol. 2 Issue 8, August - 2013

The heater system of dental autoclave needs a

controller to achieve best autoclave efficiency by reaching
the desiered sterilization temperature faster and continue
at this temperature till the end of the sterilization cycle (15
minutes),Next subsections will discuss in details each of
controller systems used.

3.1 ON/OFF controller system

3.2 PID controller system

A PID controller incorporates a mix of proportional,

integral and derivative control action [21]. In this case the
control output is a function of the size of the error (e (t)),
the rate of change of the error with time Td
integral of the error over time

1
Ti

de(t )
dt

and the

e(t )dt ,as shown in

0

equation(3.1).

de(t ) 1
Q o K e(t ) Td

dt
Ti

Setpoint

r (t)

Inference
Mechani
sm

Rule
Base

Command

System

Output

u (t)

y (t)

Figure3. Fuzzy controller system block diagram.

Fuzzy techniques to control systems[22] consists of
two very different stages, first stage must be completed
before the control algorithm is executed and it consists of
establishing the controllers input and output variables
(linguistic variables), then defining each variables fuzzy
set, thendefining the sets membership functions, after that
establishing the rule base, defining the fuzzification,
inference and defuzzification mechanisms. Second stage,
to be completed with each step of the control algorithm,
and consists of obtaining the precise input values, then
fuzzification takes place by assigning the precise values to
the fuzzy input sets and calculating the degree of
membership for each of those sets, then Inference by
applying the rule base and calculating the output fuzzy
sets inferred from the input sets, finally defuzzification
takes place by calculating the precise output values from
the inferred fuzzy sets.These precise values will be the
controllers outputs (commands) and is applied to the
system to be controlled (heating system of dental
autoclave).
Fuzzy controller for a dental autoclave considers
temperature error e(t) and temperature error
variationsde(t)/dt as inputs and energy supplied to
the system as output.
Rule base of controlling temperatur is represented
in table1.Consider, LN: Large Negative ,MN:Medium
Negative, SN:Small Negative, ZE:Zero,SP :Small
Positive,MP :Medium Positiv,LP: Large Positive

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This is the simplest type of control [18] used, if the

input is below the set-point then the system is fully ON
and if the input rises above the set-point then the system is
fully OFF. In practice the use of ON/OFF control can
cause problems [19] such as that the system rapidly
switches ON and OFF leading to inefficient system
operation and increased mechanical wear.No feedback
process (only feedforward process) takes place in this
controller system.

Fuzzy
Controller

Defuzzification

3. Proposedtemperaturecontroller systems

3.3 Fuzzy controller system

Block diagram of fuzzy controller system is
shown in figure 3.

Fuzzification

equation 2.9. Where, E (t): quantity of energy transferred

from the heater to the liquid with time,E0:is the initial
energy contained in the water, Q (t): is the heat transferred
to the water by the heater, K h: constant depending upon
the material of the coil, Tw: iswater temperature, K w:
constant depending on the difference between actual
temperature and the desired temperature, Tout: outside
temperature.
The Simulink model of heater system block using
equation (2.9) is shown in section 4.

e(t )dt

(3.1)

Where, Td is the derivative action time (s), T i the integral

action time (s) and K the gain. PID control offers close
control system, the control action responds to the rate of
change of the error, while the integral control acts to
eliminate the set-point error experienced with proportional
control. The PID controller subsystem contains the
proportional gain scaling factor, The derivative gain
scaling factor and the integral gain scaling factor.

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Vol. 2 Issue 8, August - 2013

Table1 . representing rule base of controlling

temperature.
error/errorvariation
LP
MP
SP
ZE
SN
MN
LN

LN

MN

SN

ZE

SP

MP

LP

LN
LN
LN
LN
LN
LN
LN

LN
LN
LN
LN
LN
LN
LN

LN
LN
LN
LN
LN
LN
LN

LP
MP
SP
ZE
SN
MN
LN

LP
LP
SP
MP
ZE
SN
MN

LP
LP
LP
MP
SP
ZE
SN

LP
LP
LP
LP
MP
SP
ZE

3.4 PID/ fuzzycontrol system

It is a combination between PID control and fuzzy
[23]control in order to increase efficiency of dental
autoclave by increasing temperature stability inside the
autoclave and by reducing time taken to reach the desired
temperature this may also led to decrease time of
sterilization as shown in figure 4
.

Q (t)

T (t)

++

PID

4. Results
In this study results aresubdivided into: the heater
system model results, the temperature controller model
results and the output response of different controller
systems.

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Fuzzy

called particles, fly through the problem space by

following the current optimum particles. Each particle
keeps track of its coordinates in the problem space which
are associated with the best solution (fitness) it has
achieved so far (The fitness value is also stored) .This
value is called pbest. Another "best" value that is tracked
by the particle swarm optimizer is the best value, obtained
so far by any particle in the neighbours of the particle.
This location is called lbest. When a particle takes all the
population as its topological neighbours, the best value is
a global best and is called gbest. The particle swarm
optimization concept consists of, at each time step,
changing the velocity of (accelerating) each particle
toward its pbest and lbest locations (local version of PSO).
Acceleration is weighted by a random term, with separate
random numbers being generated for acceleration toward
pbest and lbest locations. MATLAB M-file where utilized
to run the PSO technique and apply it to the PID controller
system in order to improve the system performance , The
PID block calls the PID controller file, which in turn calls
the PSO technique .

Dental

4.1. Results of heater control system using

Simulink

Figure4. PID /Fuzzy control system scheme.

The simulink model of the PID/ fuzzy control
system of dental autoclave consists mainly of the fuzzy
logic controller block and the heating system in the dental
autoclave block. The fuzzy logic controller block contains
a reference to a fuzzy logic inference system. The
inference system has four linguistic variables which are
two inputs (error signal and error derivative) and two
output (energy supply control and safety valve control).
The fuzzy logic inference system for the fuzzy
proportional-integral-derivative controller contains a set of
fuzzy logic rules thatdefine thebehavior of the system in
relation between the error signal, error derivative signal
and the control signals (energy supplied to autoclave and
safety valve). A multiplexer is used to combine the two
inputs to the fuzzy logic controller
.
3.5 Optimized PID control system (using PSO

Using Simulink/ Matlab the simulation model of the

overall dental autoclave temperature control system is
shown in figure 5.

125

+-

Sterilization
temp.

Temp(t)
Heat Control
system

Heater
systemof
dentalautocla
Safety valve
ve

controller

autoclave control
cintroller

Figure5. The overall of dental autoclave temperature

control system simulation.
Dental autoclave heater model simulation using
equation (2.9) is shown in figure 6.

technique)
The system is initialized with a population of
random solutions and searches for optima by updating
generations. In PSO [25] [26], the potential solutions,

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International Journal of Engineering Research & Technology (IJERT)

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Vol. 2 Issue 8, August - 2013

PID fuzzy
Kh(t)

-1

Qa

125
Constant

1
s

Qh(t
)

Produ
ct

1/
E(t) m (1/m)E
-k-

+
+
-

+
Add
1+

20

1
s

+
1

T0
2
Th(t)

Sterilizati
on
temp.

1
s

0.1

Kw(
t)

0.1

actual

To
ut

Add
4

Fuzzy
System

Out
1

PID Fuzzy
controlled
autoclave

Safetyvalve
1

Temp(t)

In3

PID System

Safety
valve
control

E0

Figure 9.Simulink model of dental autoclave controlled

by PID/fuzzy controller.
The output of the each controller system is discussed
in details in the next section.

Figure 6. Heating system of dental autoclave

simulation

4.2. Results of temperature controlled systems

using Simulink/ Matlab.

4.3. Output block results

4.3.1.

ON/OFF temperature controller output

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ON/OFF temperature control system simulation is

shown in figure 7.
ON
To
Off
Workspace
Ti

Ta1

Temp(t)

125
Sterilization

SafetyValve

Safety
valvecontrol

On/OFF
autoclave

temp. 1
Figure 7.Simulink model of dental autoclave control by
ON/OFF controller.
PID temperature control system simulation is shown in
figure 8.
1
Safet
valve
y
1
in1

In1

Kh
w

Terr

Ta
set
Out
temp
1

Out
2

10

Ko
ut

Product
1

Tw(t
)

Ti
Switch

s+
15
Pl
s

+- T err
+-

s+
15
PD
s
2
In2

Qa

Gai
n
1

Gai
n1

Ta

Figure 10.Output response of the conventional

ON/OFF controller.
It is clear from curve in figure 10 that the ON/OFF
control system there are many oscillations for about
368 second while the sterilization cycle takes about
900 sec. (15 minutes), so it reduces both efficiency of
sterilization in dental autoclave and also affects the
power unit efficiency with time.
TError= Settimg temperature - T avg
= 125 119.79 = 5.21C

Ta

Temp(
t)
PID
Controlle
d
dental
autoclave
autoclave

Figure 8.Simulink model of

controlled by PID controller.
The Simulink model of the PID/fuzzy control system
of dental autoclave heater is shown in figure 9.

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4.3.2.

4.3.4.

PID temperature controller output

Figure 11. Output response of the PID controller.

It is clear from curve above in figure 11 that PID
control system reached the set point (125c) very fast
(after about 86 seconds), but there are a lot of oscillations
which affects efficiency of sterilization in dental autoclave
and affects the power unit efficiency with time as it goes
up & down.

TError=Settimg temperature - T avg

= 125 124.4=0.6C
Fuzzy temperature controller output

Figure 14.Output response of Optimized PID

control system.

This system reached the desired temperature only

in 59 seconds then after that time this temperature
remained till the end of the sterilization cycle as
shown in figure14.
TError= Settimg temperature - T average
= 125 124.9 = 0.1C

5. CONCLUSION

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4.3.3.

Optimized PID control system results: (using

PSO technique)

The most desirable heat control system performance

requires that the controllers to have the smallest possible
value for rise time, overshoot, and settling time. It also
requires the final value to be as close as possible to the
desired value which is 125 C as soon as possible; also the
system temperature must be without oscillations as long as
possible. From the output results it is clear that the PID
controller systemhas good performance but it has a lot of
oscillations till the end of sterilization cycle so it is not the
best controller system. PID/FUZZY controller system has
the bestperformance also it reaches accurately the desired
temperature (125C).

Figure 12. Surface view of fuzzy controlled

autoclave.

6. References

Figure 13.Output response of the fuzzy

controller.
It is clear from curve in figure 18 that the fuzzy control
system reached
(124.6 c) while the desired
temperature is (125 c) but it is more stable than (PID
control system) and (ON/OFF control system) as no
oscillations occur, also it reaches this temperature with no
oscillations in about 40 seconds only.
TError= Settimg temperature - T avg
= 125 124.5= 0.5C

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