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SEMINAR REPORT ON

OPTIMIZATION METHODS FOR PID CONTROLLER


TUNING
Submitted By
Saima S!etty
"# NM $% EE $&$'
Ude( t!e )uida*e +,
M(- P(adee. /uma(
A00i0tat P(+,e00+(
Seminar Report Submitted to Department of Electrical and Electronics,
NMAM Institute of Technology, Nitte
DEPARTMENT OF ELECTRICAL AND ELECTRONICS
1. It(+du*ti+
2. Lite(atu(e Re1ie2
3. Fu*ti+a3 .a(titi+i) +, t!e Semia(
3.1 Brief overview of P, PI and PID control techniques.
3.2 Explanation of the Ziegler-Nichols pen loop and !losed loop tuning "ethods.
3.3 Discussion of pro#le"s such as Integral windup and "itigation "ethods.
4. T!e PID C+t(+3 Met!+d
4.1 $he Proportional !ontrol %ode
4.2 $he Proportional & Integral !ontrol %ode
4.3 Proportional & Integral & Derivative !ontrol %ode
4.4 Necessit' of !ontroller $uning
4.5 (lti"ate !'cling %ethod
4.6 Process reaction curve "ethod
4.7 Da"ped scillation %ethod
4.8 Bu"pless $ransfer
4.9 Integration windup and "itigation "ethods
5. C+*3u0i+0
6. Te*!i*a3 Re,e(e*e0
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4- It(+du*ti+
)lthough "an' innovative "ethodologies have #een devised in the past *+ 'ears to handle "ore
co"plex control pro#le"s and to achieve #etter perfor"ances, the great "a,orit' of industrial
processes are still governed #' "eans of si"ple proportional-integral-derivative -PID. controllers /01.
$his see"s to #e #ecause PID controllers, despite their si"ple structure, assure accepta#le
perfor"ances for a wide range of industrial plants and their usage -the tuning of their para"eters. is
well 2nown a"ong industrial operators. 3owever, opti"u" operation of the PID controller can onl' #e
attained #' proper ad,ust"ent of the gains #' a process called tuning. $he o#,ective of this report is to
discuss the t'pes of PID controller tuning and its opti"i4ation.
5- Lite(atu(e Re1ie2
) heuristic approach to PID controller tuning was first explained in a 0567 pu#lication titled Optimum
Settings for Automatic Controllers /71 #' 8.9. Ziegler and N.B. Nichols. $his paper was arrived at a
result of experi"ental "a,orl' intended to conve' para"eter tuning "ethods that have proven to #e
ver' useful for a controls technician, setting aside the co"plex "athe"atics that the process involves.
:everal i"prove"ents in the controller tuning algorith"s have #een developed since then.
) practical approach to tuning the process controllers is explained #' 8acques ;. :"uts in his #oo2
<Process control for practitioners</61, where ela#orate procedures of various t'pes of PID !ontrol are
descri#ed, out of which the Z-N "ethod is adopted for inclusion in this report.
6- Fu*ti+a3 .a(titi+i) +, t!e Semia(
=.0 Brief overview of P, PI and PID control techniques.
=.7 Explanation of the Ziegler-Nichols pen loop and !losed loop tuning "ethods.
=.= Discussion of pro#le"s such as Integral windup and "itigation "ethods.
6. T!e PID C+t(+3 Met!+d
) PID controller has a :et Point -:P. that the operator can set to the desired value. $he !ontroller>s
utput -!. sets the position of the control valve. )nd the output "easure"ent, called the Process
?aria#le -P?. gives the controller its "uch-needed feed#ac2. (pon proper i"ple"entation, the PID
controller "ust co"pare the process varia#le to its set point and calculate the difference #etween the
two signals, also called the Error -E..
$hen, #ased on the Error and the PID controller>s tuning constants, the controller calculates an
appropriate controller output which corrects the error and sta#ili4es the controller at a stead' state.
PID controllers have three control "odes@
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1Proportional !ontrol
2Integral !ontrol
3Derivative !ontrol
Each of the three "odes reacts differentl' to the error. $he a"ount of response produced #' each
control "ode is ad,usta#le #' changing the controller>s tuning settings.
#-4 T!e P(+.+(ti+a3 C+t(+3 M+de
$he proportional control "ode is in "ost cases the "ain driving force in a controller. It changes the
output in proportion to the error . $his i"plies if the error is large, "ore control action is required to
correct the error, which is intuitivel' true.
is called the controller gain.
3owever, in a proportional controller, the "ain draw#ac2 is the stead'-state offset that cannot #e
eli"inated #' proportional controller alone. $here should #e an external #ias or a <reset< "echanis"
to eli"inate this pro#le".
#-5 T!e P(+.+(ti+a3 7 Ite)(a3 C+t(+3 M+de
In order to nullif' the offset created in the proportional control "ode, and to i"prove the speed and
sta#ilit' of the response, an additional A"e"or'A of all the previous errors has to #e introduced. $his is
done #' including a weighted integrating action in the control loop. $he AweightA is called , the integral
gain.

[ ]
;or a given error, the speed of the integral action is set #' the controller>s integral ti"e setting - .. )
large value of results in a slow integral action, and a s"all value of results in a fast integral action.
#-6 P(+.+(ti+a3 7 Ite)(a3 7 De(i1ati1e C+t(+3 M+de
$he PID control "ode produces additional to the PI "ode, an output #ased on the rate of change of
the error. $he derivative "ode produces "ore control action if the error changes at a faster rate. $his
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is done #' including a weighted differentiating action in the control loop. $he AweightA is called , the
derivative gain.
( )
[
( )
]
$he derivative "ode has an ad,usta#le setting called Derivative $i"e - .. $he larger the derivative
ti"e setting, the "ore derivative action is produced.
;igure 0. PID !ontrol #loc2 Diagra"
;igure 7. :ta#ilit'
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#-# Ne*e00ity +, C+t(+33e( Tui)
$he #asic o#,ective of controller tuning is
1;ast Besponse
2)ccepta#le :ta#ilit'
;or "ost practical processes #eing controlled with PID controllers, these two o#,ectives cannot
co"pletel' #e achieved si"ultaneousl'. ;aster the response, worse the sta#ilit' and #etter the
sta#ilit', slower the responses. 9enerall', it is "ore i"portant to have a accepta#l' sta#le s'ste"
which responds quic2l' enough as shown in ;igure 7. It is seen that for accepta#le sta#ilit', the
undershoot that follows the overshoot for step actuated s'ste" is s"aller than the overshoot.
$o get the desired sta#le #ehavior of the s'ste", it is required to ad,ust the controller para"eter-s.
and in the right proportion #' a process called tuning. $here are several 2nown "ethods for tuning,
the "ost #asic ones #eing the Ziegler-Nichols tuning "ethods, which are discussed in this
report.
#-& U3timate Cy*3i) Met!+d
$he Ziegler-Nichols "ethods are heuristic tuning procedures derived fro" ela#orate experi"ents
conducted to arrive at a general tuning rule for all controllers as per /71. $he (lti"ate !'cling "ethod
is used to tune closed loop PID controllers.
$he following steps are followed to appl' the Ziegler-Nichols closed loop "ethod /61@
1. $he process is sta#ili4ed and it is ensured that no process changes -eg. product change,
grade change, load changes. are scheduled.
2. If the loop is oscillating, it is ensured that the Process ?aria#le stops oscillating when the
controller is placed in %anual "ode.
iii. $he Integral action is turned off #' either setting integral gain to 4ero or setting integral
ti"e
to a ver' large value.
4. $he derivative action is turned off #' setting the derivative para"eter to 4ero.
5. $he controller is placed in auto"atic "ode.
6. ) set point change is "ade and the result is "onitored.
7. ) freel' oscillating process varia#le with constant "agnitude is got #' var'ing the controller
gain . If the oscillations are deca'ing, is increased #' *+C. If the oscillations are
growing,
is decreased #' *+C. is decreased #' *+C if the gain hits the upper or lower li"its.
8. If the Process ?aria#le oscillates with constant a"plitude, and neither the Process ?aria#le nor
the !ontroller utput hits their li"its, the ulti"ate controller gain and the period of the
oscillation is noted.
5
9. $he new controller gains are calculated as per the chart in $a#le 0 and entered into the
controller.
$hese values are for interactive PID algorith"s onl'. $he controller para"eter values should #e
correspondingl' calculated for non-interactive and parallel algorith"s.
$a#le 0. Z-N $uning Para"eters
!ontroller
P +.* -- --
PI +.6* --
PID +.D
#-8 P(+*e00 (ea*ti+ *u(1e met!+d
)lthough the original "ethod proposed in /71 for self-regulating and integrating processes, a "odified
version of the reaction curve "ethod is widel' used on self-regulating processes #ut "ore accuratel'
so /61. $his "ethod uses three process characteristics@ dead ti"e , process gain , and ti"e
constant , which are deter"ined #' the following steps@
1. $he controller is placed in "anual and the process is allowed to settle.
2. ) step change of a few percent is "ade in the controller output -!. and the process varia#le
-P?. is allowed to settle out at a new value. $he si4e of this step should #e large enough that
the process varia#le "oves well clear of the process noiseEdistur#ance level.
3. $he total change o#tained in P? is converted to a percentage of the span of the "easuring
device.
iv. $he process gain is calculated as follows@
F
5. ) line tangential to the P? response curve is drawn through the point of inflection and extended
to intersect with the original level of the P? -#efore the step-change in !.. $a2e note of the
ti"e value at this intersection.
vi. $he dead ti"e is "easured as shown in ;igure =.
7. $he value of the P? at D=C of its total change is noted fro" the curve and the ti"e constant
is deter"ined as shown in ;igure =.
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8. ) few "ore trials of steps i through vii are done and the average of the para"eters are ta2en
for the calculation of settings for !ontroller 9ain -Gc., Integral $i"e -$i., and Derivative $i"e
-$d., using the Ziegler-Nichols tuning rules vi4.
;or P control@
;or PI control@
;or PID control@
( )
$hese rules produce a quarter a"plitude da"ping and the controller gains "ust #e divided #' 7 to
ensure sta#ilit'.
;igure =. Beaction !urve
#-9 Dam.ed O0*i33ati+ Met!+d
In "an' cases, plants are not supposed to undergo through sustained oscillations, as is the case when
(lti"ate c'cling "ethod is used. 3ence, da"ped oscillation "ethod is preferred for these cases.
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;igure 6. Da"ped oscillation %ethod
$he controller gain is 2ept low, the integral and differential ti"es and are set to 4ero. Now,
is increased slowl' till a deca' ratio of
is o#tained for step response. $he period of oscillation
is noted. If is the proportional gain
settling for o#taining deca' ratio, the controller
para"eters are "easured as follows@
;
#-: Bum.3e00 T(a0,e(
It is a nor"al practice to set up so"e processes using "anual control initiall', and once the process is
close to nor"al operating point, the control is transferred to auto"atic "ode through autoE"anual
switch. In such cases, in order to avoid an' ,er2 in the process, the controller output i""ediatel' after
the changeover should #e identical to the output set in the "anual "ode. $his can #e achieved #'
forcing the integral output at the instant of transfer to #alance the proportional and derivative outputs
against the previous "anual outputH i.e.
Integral output F I-previous "anual. J -proportional & derivative. outputK.
:i"ilarl', for auto"atic to "anual transfer, initiall' the "anual output is set equal to the controller
output and the difference is graduall' reduced #' incre"enting or decre"enting the "anual output to
the final value of the "anual signal and thus affecting a changeover.
)nother wa' to transfer fro" )uto to %anual "ode in a #u"p less "anner, the set point "a' #e "ade
equal to the present value of the process varia#le and then slowl' changing the set point to its desired
value. $hese features can #e easil' #e i"ple"ented if a digital co"puter is used as a controller. $his
provision eli"inates the chance of the process receiving sudden ,olt during transfer.
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#-% Ite)(ati+ 2idu. ad miti)ati+ met!+d0
) significant pro#le" with integral action is that when the error signal is large for a significant period of
ti"e. $his can occur ever' ti"e when there is large change in set point. If there is a sudden large
change in set point, the error will #e large and the integrator output in a P-I-D control will #uild up with
ti"e /=1. )s a result, the controller output "a' exceed the saturation li"it of the actuator. $his windup,
unless prevented "a' cause continuous oscillation of the process, which is not desira#le.
$here exist several "ethods through which integral windup can #e prevented, two of which are
discussed in this report. $he characteristics of "a,orit' of actuators are si"ilar to that of an a"plifier,
in that the output varies linearl' with the input till the input is within a particular range, #e'ond which
the output #eco"es constant at either the upper or lower li"it of the actuator.
$he first "ethod uses a switch to #rea2 the integral action, whenever the actuator goes to saturation.
$his can #e illustrated #' ;igure *.
;igure *. :che"e for anti-integration windup
Lhen the switch : is closed, transfer function of the controller can #e o#tained as@
[ ] [ ] [ ]
:o when the switch is closed, the controller acts as a P-I controller. n the other hand, if the switch is
open, it is a si"ple P- controller. $he switch is activated #' the position of the actuator. If the actuator
is operating in the linear range, the switch is closed, and the controller is in P-I "ode. But whenever
the actuator is in the saturation "ode, the switch is auto"aticall' openedH the controller #eco"es a P-
controller. )s a result, an' windup due to the presence of integral "ode is avoided.
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;igure D. )lternative sche"e for anti-integration windup action
)nother technique for anti-windup action is illustrated in ;igure D. It is assu"ed that the slope of the
actuator in the linear range is unit'. )s a result, when the actuator is operating in the linear range the
error is 4ero, and the controller acts as a PI controller. But when the actuator is in saturation "ode,
the error is negative for a positive . $his will reduce the integral action in the overall control loop,
hence preventing integration windup.
&- C+*3u0i+0
$he Ziegler-Nichols "ethod is an e"pirical "ethod and is o#tained fro" extensive experi"entation
with different processes. $here is no fir" "athe"atical #asis #ehind these selections #ut an intuitive
one. $his "ethod has proven to #e ver' useful without sufficient a priori 2nowledge a#out the s'ste".
Despite si"plicit', this "ethod lac2s ro#ustness that is offered #' other techniques of tuning availa#le.
3owever, the other "ethods of tuning require initial values of tuning para"eters, which can "ost
suita#l' #e deter"ined using the Z-N "ethod in the a#sence of a s'ste" "odel. ;urther "odifications
to the controller designs can #e used to reduce #asic errors that occur in the PID control s'ste".
6. Te*!i*a3 Re,e(e*e0
[1] ?isioli, <$uning of PID controllers with fu44' logic<, IEE Process-!ontrol $heor' )pplication, ?ol.
06M, No. 0, 8anuar' 7++0, Pg. 0 to M.
[2] Ziegler, Nichols, Npti"u" :ettings for )uto"atic !ontrollers<, )"erican :ociet' for %echanical
Engineers transaction, 0567, Pg. O*5 to OD*.
/=1 D.P. Ec2"an, <)uto"atic process !ontrol<, Lile' Eastern, New Delhi, 05*M, ):IN@
B++++!G0L?
/61 8acques ;. :"uts, <Process control for practitioners<, pti!ontrols Inc., 7+00, I:BN-0=@
5OM+5M=M6=M0M
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