Tuning of PID Controller

What is a PID Control?

PID control is based on feedback. The output of a device or
process, such as a heater, is measured and compared with the
target or set point. If a difference is detected a correction is
calculated and applied. The output is measured again and any
required correction recalculated.
PID stands for proportional-integral-derivative. Not every
controller uses all three of these mathematical functions. Many
processes can be handled to an acceptable level with just the
proportional-integral terms. However, fine control, and especially
overshoot avoidance, requires the addition of derivative control.
In proportional control the correction factor is determined by the
size of the difference between set point and the measured value.
The problem with this is that as the difference approaches zero,
so too does the correction, with the result that the error never
goes to zero.
The integral function addresses this by considering the cumulative
value of the error. The longer the set point-to-actual value
difference persists the greater the size of correction factor
calculated. However, when there is a delay in response to the
correction this leads to an overshoot and possibly oscillation
about the set point. Avoiding this is the purpose of the derivative
function. This looks at the rate of change being achieved,
progressively modifying the correction factor to lessen its effect
as the set point is approached.
Heat treatment processes example, the need for PID control. To
ensure consistent product quality the temperature inside an oven
or furnace must be kept within narrow limits. Any disturbance,
such as when a product is added or withdrawn or a ramp function
is applied, must be handled appropriately. Although simple in
concept, the mathematics underpinning PID control is complex
and achieving optimal performance entails selecting
processspecific values for a range of interacting parameters.
Defination:
The process of finding these values is referred to as
“tuning.” When a PID controller is tuned optimally, the
device minimizes deviation from the set point, and
responds to disturbances or set point changes quickly but
with minimal overshoot.
PID Tuning Methods:
Manual Tuning
Tuning Heuristics
Auto Tune
Manual tuning of PID controller
With enough information about the process being controlled, it
may be possible to calculate optimal values of gain, reset and rate
for the PID controller. Often the process is too complex, but with
some knowledge, particularly about the speed with which it
responds to error corrections, it is possible to achieve a
rudimentary level of tuning.
Manual PID tuning is done by setting the reset time to its
maximum value and the rate to zero and increasing the gain until
the loop oscillates at a constant amplitude. (When the response
to an error correction occurs quickly a larger gain can be used. If
response is slow a relatively small gain is desirable). Then set the
gain of the PID controller to half of that value and adjust the reset
time so it corrects for any offset within an acceptable period.
Finally, increase the rate of the PID loop until overshoot is
minimized.
Tuning Heuristics
Many rules have evolved over the years to address the question
of how to tune a PID loop. Probably the first, and certainly the
best known are the Zeigler-Nichols (ZN) rules.
First published in 1942, Zeigler and Nichols described two
methods of tuning a PID controller. These work by applying a step
change to the system and observing the resulting response. The
first method entails measuring the lag or delay in response and
then the time is taken to reach the new output value. The second
depends on establishing the period of a steady-state oscillation. In
both methods, these values are then entered into a table to
derive the values for gain, reset time and rate for the control
system.
ZN is not without issues. In some applications it produces a
response considered too aggressive in terms of overshoot and
oscillation. Another drawback is that it can be time-consuming in
processes that react only slowly. For these reasons, some control
practitioners prefer other rules such as Tyreus-Luyben or Rivera,
Morari and Skogestad.
Auto Tune
Most process controllers sold today incorporate auto-tuning
functions. Operating details vary between manufacturers but all
follow rules similar to those described above. Essentially, the PID
controller “learns” how the process responds to a disturbance or
change in set point, and calculates appropriate PID settings. In the
case of a temperature controller like OMEGA’s Platinum series,
when “Auto Tune” is selected the controller activates an output.
By observing both the delay and rate with which the change is
made it calculates optimal P, I and D settings, which can then be
fine-tuned manually if needed. (Note that this controller requires
the set point to be at least 10°C above the current process value
for auto tuning to be performed).
Newer and more sophisticated PID controllers, such as OMEGA’s
Platinum series of temperature and process controllers,
incorporate fuzzy logic with their auto tune capabilities. This
provides a way of dealing with imprecision and nonlinearity in
complex control situations, such as are often encountered in
manufacturing and process industries, and helps with tuning
optimization.
Applications of PID Controller:
Ovens and furnaces used in industrial heat treatment are required to achieve
consistent results regardless of how the mass and humidity of material being
heated may vary. This makes such equipment ideal for PID temperature
control.
Pumps used for moving fluids are a similar application, where variation in
media properties could change system outputs unless an effective feedback
loop is implemented.
Motion control systems also use a form of PID control. However, as the
response is orders of magnitude faster than the systems described above
these require a different form of controller to that discussed here.
References:
1) Handbook “Chemical Process Control An introduction to theory and Practice
by George Stephanopoulos” Chapter # 16 , Article # 16.5, Page # 310
2) Google website” https://www.omega.co.uk/technical-learning/tuning-a-
pidcontroller.html” served as a helping hand to me.
3) Online research PDF
https://canteach.candu.org/Content%20Library/20041603.pdf was also a
helping hand.